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OPERATING, MAINTENANCE AND SERVICE MANUAL Prolyft

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1. _n Ret ae Figure 2c lug p Ret This is the standard multi purpose suspension lug available for Prolyft Dimensions are in mm This lug is made reversible for conversion trom single reeved to double reeved configurations Prolyte Products Group 2004 page 14 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com INSPECTION amp MAINTENANCE CHECKING amp INSPECTIONS A planned inspection routine should be established for this chain hoist based upon frequency of use severity of use and environmental conditions Some inspections should be made frequently daily to monthly and others periodically monthly to yearly Circumstances where chain hoists are used in the entertainment industry can vary as much as any other type of application Ranging from fixed installations in well protected conference centres to six months of continuous outdoor use in aggressive atmospheric conditions at beach stages Or from occasional use in TV studios to almost daily application in the touring industry or from less than one lift a day in a theatre to manifold lifting sequences is a smoke saturated an
2. IMPORTANT Always refer to the wiring diagram located on the inside of the electrical cover or Figures 7A and 7B when performing electrical repairs Make sure all terminals are securely fastened and check for damaged insulation It is also imperative that the power circuit has conductors of adequate size LUBRICATION Reter to Figure 9 Proper lubrication is necessary to ensure a long and reliable chain hoist life Refer to the following and the RECOMMENDED LUBRICATION SCHEDULE for lubrication points type of lubricant and frequency of lubrication GEARING The gearbox of this chain hoist is filled at assembly with 1153cc 390z US of SAE 90 EP gear oil To check oil level hang the unit by the suspension hook motor up position the unit and decals will be upside down and remove the oil level check plug With the chain hoist hanging level the gear oil should be even with the hole Prolyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST BEARINGS All bearings except hook bearing and 2 ton block idler sheave bearings are lubricated at the factory and should not require additional lubrication Noisy or worn bearings should be replaced IDLER SHEAVE BEARING BUSHING Disassemble the 2 ton load block and apply a light coat of NLGI 2 grease or equivalent inside of the bearing NOTE If the chain hoist is used in an atmosphere containing abrasive dust frequent clean
3. 12 Supporting frames or beams used as a chain hoist hanger must have a greater load capacity than the chain hoist 13 Do not attempt to operate chain hoist beyond normal maximum lift range 14 Align chain hoist for a straight vertical pull Avoid side pull or end pull 15 Do not operate chain hoist with twisted knotted damaged or corroded chain 16 Do not operate a damaged or malfunctioning chain hoist until necessary adjustments or repairs have been made 17 Do not use a chain hoist to lift people or to carry loads over people 18 Do not leave a load suspended in the air unattended 19 Always remove load before making repairs 20 Do not remove or obscure capacity or warning decals co N INSTALLATION POWER amp CONTROL SYSTEM REQUIREMENTS The Prolytt hoist comes in a direct control and a low voltage version They must be connected to a power and control system that is properly designed to operate the chain hoist and to handle the power consumption of the motor Prolytt hoists are standard wired tor 400V 3ph 50Hz operations For other voltages the chain hoist motor can be re wired internally for 415V 3ph 50Hz 380V 3ph 50Hz 208V 3ph 50z 200V 3ph 50Hz 460V 3ph 60Hz and 230V 3ph 60Hz page 5 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of t
4. 0 75kw 1 9amp 1Am 2m pending 50 300 68db 5 pocket 7 1 x 20 5mm 1 1kg 34kg direct CEE 16A 4p optional 115v standard PLE 12 001 1000kg 4 400v 3P 50Hz 460v 3p 60Hz optional IP 54 0 75kw 1 9amp 1Am 2m pending 50 300 68db 5 pocket 7 1 x 20 5mm 1 1 1kg 34kg direct CEE 16A 4p optional 115v standard PLE 13 001 2000kg 2 400v 3P 50Hz 460v 3p 60Hz optional IP 54 0 75kw 1 9amp 1Am 2m pending 50 300 68db 5 pocket 7 1 x 20 5mm 2 2 2kg 37kg direct CEE 16A 4p optional 115v standard Prolyte Products Group 2004 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com page 4 of 37 APPLICATION INFORMATION The Prolyft is intended for professional use in rigging applications to litt and support material loads within its rated capacity It is designed as a component to be integrated into a rigging system The user is responsible for ensuring the adequacy and reliability of their controller and power supply and the whole lifting system and operation as such Prolyft can not be held responsible for applications ot
5. 13 series CHAIN HOIST Figure 15 LIMIT SWITCH PARTS PARTS LIST FOR LIMIT SWITCH Part Ref Part No Description No Description IAO Qty No 2 Limit Switch Assembly 9441667 Tinas items 320 6 8 32UNCX 1 4 Screw 854823 a limit Switch Nut gold K6000 630 n 8 External tooth Lockwasher H4158 Frame and Guide Assembly 258JG7 Prolyte Products Group 2004 page 31 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST Figure 16 GEARBOX _ n S ee ee ee a e NOTE This stage of gearing is not required on 8 m min models NOTE Orient the output gear 33 with Long Boss towards the transmission cover 3 Prolyte Products Group 2004 page 32 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission
6. 500 KG 1000 Kg 2000 Kg PLE 11 PLE 12 PLE 13 APROLYFT OPERATING MAINTENANCE AND SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST Follow all instructions and warnings for inspecting maintaining and operating this chain hoist The use of any chain 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 chain 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 chain hoist operator Failure to operate the equipment as directed in the manual may cause injury Should you have any questions or have problems with this product please call Prolyft at 31 0 594 85 15 15 Before using the chain hoist fill in the information below Model No Serial No Purchase Date Service point TABLE OF CONTENTS Safety Precautions Chain Hoist Specifictions Application Information Adverse Environmental Conditions Lifting of Hazardous Loads Tandem Lifts and Multiple Lifts Suspending Loads over People Safety Information Installation Power amp Control System Requirements Preliminary Checks Rigging amp Motor Handling Instructions for Temporary Installations Rigging the Hoist in Motor Down Position Chain climber De Rigging the Hoist in
7. Motor o G S o Oo ee 7 2 Stator Assembly o E i OSO ao koorem OOOO S asea O G ShimWosher o Not available as an individual part Prolyte Products Group 2004 page 27 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST Figure 12 BRAKE amp SOLENOID PARTS NOTE Refer to wiring diagram inside electrical cover of lifting motor or Figures 7A 7B or 7C when connecting any wires PARTS LIST FOR BRAKE amp SOLENOID Part Ref Part No Description No Qty a 7 Plate amp Frame Assem JF857Z Zinc Plated 230v 853JL2 No Description No Brake Assembly Zinc 1 hp 230 Volt 854PL2BZ Brake Plate Zinc Plated JF291Z Plate amp Armature Zinc Plated JF858Z Qty ld 2 Plate amp Stud Assem 859JGIZ 1 E eae C Shading Coil Adhesive 782 1 Note 230 460V 3 Phase models use 230V brake coils Prolyte Products Group 2004 page 28 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserv
8. Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST PARTS LIST FOR GEARBOX Ref Part No Description No Qty 2 Fensmission Goshen Sse oO Trensmision Cover haudes OfSeal e o a Spring Wesker sgn i 6 Presse Relig Fiting SSS tw e oam SSS Sng s Tnput inion OOO S T tag a E S o emessa OO o 20 21 OGIAN o O E T E S a feen O o 2 23 overtoad Ciurh Assemsy Joo 2 B3 a a po tom 59S 24 Retaining Ring SOB 26 Bearing i Pz I 2B 2 3 3st 32 Bo o 2 a i 1 2ton 32fm NIA a 2 E 3 ME Sub Shoft Limit Swich De O wo C A QB etining O o s owce OOO a 9 2 3 4 5 6 27 28 m ho 0 2 3 3 3 3 3 Not Shown Prolyte Products Group 2004 page 33 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST Figure 17 CHAINING PARTS 1 Ton amp Under Models 2 Ton Models Prolyte Products Group 2004 page
9. 800 N mm e applicable standards DIN 8684 e type of marking see sample picture below Every 10 links e surface hardness 85 HRI5N 500Hv on Vickers scale 75HRA Rockwell A scale e max working load 1000kg 2206lbs single strand e minimum breaking strength 6448 kg 14 418lbs single strand e max elongation 10 e weight per meter 1 114 kg m 2 49 lbs m 0 76 lbs ft 3 4 lbs ft For replacement load chains use Prolyft chain only ss mamn T the ra T Fi n F e m p r Make sure the inspection frequency complies with the applicable regulations Prolyte Products Group 2004 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com page 15 of 37 A CAUTION O Max allowable wear is 2 of 11t as per DIN 685 T5 Chain to be measured over 11 links 11t YAY WZ Measure d1 and d2 gt d1 d2 2 lt 0 9d WARNING Chains of completely identical size and measurement still can be fully and totally different in steel alloy and characteristics like breakings strength ductility elongation and price Load chains for chain hoists are generally more
10. HOLE CODE DIA mokoa oa won ser 150 106 12 106 owe ea 1 06 aa ave 10a ova as0f 100 ove xraoe 500 en eobkg 9822 wero 692 30a 2692 va 9 77 ave ease ovas aera ew meal of esr Hook ners 1905 won 420 res 127 143 19 094 726l rre 2 00 ano me o 2a 100 one xra0s EE A ED ES EZ E SSeS CS AT AA A NSE CS SS EA A SN RR PE REVOLVING SIZE LATCH LATCH KIT HOOK HOLE CODE DIA Es A ON os aape e we i ee ar e a a a ee e a e e e e a a anal ee Se eo Standard hook mounted on PLE 11 12 13 XX 4 _ _ ja 1 i 4 i i O LO e yY f 4 j A X j f j p k i j gt N i Dy j 7 i i ISS i w r 5 l Figure 2b revolving hook Prolyte Products Group 2004 page 13 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST 147 2 74 6 106 4 a 53 2 16 3403 50 8 Typ 2 Places 25 4 7 9 x45 Typo EI 47 Ret B19 440 3 Typ 4 Places 7 15 9 100 0 l bee Ret 54 0
11. using clutch chains DE RIGGING THE HOIST IN MOTOR DOWN SITUATION A CAUTION Part of this procedure can involve working from an elevated platform scissors lift or cherry picker Before doing so make sure you are competent to work with those and take all safety precautions needed 1 Remove the secondary when present WARNING Do not let anyone stand under the suspended load when the secondary is removed 2 Check the direction of travel If the pre selection switch on the controller is in the down direction the chain hoist should run in down direction 3 Check if both the lifting directions work properly lifting and lowering 4 Remove all people from the area before you start lowering the load Do NOT allow any people to stand under the moving load 5 Make sure you have a full visual view on the complete travel path of the load 6 Bring the load down until within reach for further dismantling WARNING Do not use the control button in an intermittent switching manner This can lead to hazardous situations The chain hoist motor can get overheated or considerable increase of forces due to dynamic loading can be caused 7 Remove all parts of the load and any slings attached to the suspension hook 8 Remove the chain bag and when applicable put this in the chain bag compartment of the chain hoist flight case 9 Lower the chain hoist gently on the floor place the hoist horizontall
12. 11 12 13 series CHAIN HOIST SAFETY INFORMATION 1 Follow all local electrical and safety codes and applicable local standards 2 The chain hoist must be securely and adequately grounded The power pigtail includes a green yellow lead for grounding 3 Be careful when touching the exterior of an operating motor it may be hot enough to be paintul or cause injury With modern motors this condition is normal if operated at rated load and voltage modern motors are built to operate at higher temperatures J WARMING Always disconnect the power source before working on or near a chain hoist or its connected load If the power disconnect point is out of sight lock it in the open position and tag to prevent unexpected application of power 4 Protect the power and control cables from coming in contact with sharp objects 5 Do not kink the electrical cables and never allow them to come in contact with oil grease hot surfaces or chemicals 6 Make certain that the power source conforms to the require ments of your equipment Visually check the unit daily before operating chain hoist Cluttered areas and benches invite accidents 9 The operator should not engage in any practise that will divert his attention while operating the chain hoist 10 Before using the chain hoist the operator should be certain that all personnel are clear of the load 11 Do not operate chain hoist with loads exceeding its rated capacity
13. 34 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST PARTS LIST FOR REPLACEMENT PARTS Part Description N Qty O toad cran gcd a Boom BlockAssombly Mensos i 3 1 4 20UNC x 1 4 Socket T E E a Gemet OOO OOOO S Be OOOO O O o E Sd ood BlockPin SSS o SlotedHoxNut Sigg o Bearing gto lachkt aig S 20 Botom Hook Assembly with Lath for Ton amp Under azs 21 Bolom Block Assembly forzo mnes h E S CS lt S OMS 23 Loed BlockSerow eeo a E A 25 sheave Shatt Assembly Sir 26 Sheave shat SSS iz 27 Sheave amp Bearing sembly SSS o E SS 2 30 i x 2 2 1 1 1 1 1 1 2 2 2 1 1 1 ee ee l _ oo 0 O N aA o olajon 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 Prolyte Products Group 2004 page 35 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be acc
14. If the chain hoist develops either undesirable over travel after a push button is released this condition is most noticeable in the lowering direction or hesitates to litt the load promptly the brake should be adjusted BRAKE ADJUSTMENT Reter to Figure 4 1 DISCONNECT CHAIN HOIST FROM POWER SUPPLY and remove the electrical cover WARNING Failure to follow proper lockout tagout rocedures may present the danger of electrical shock TO AVOID INJURY Disconnect power and lockout tagout disconnecting means before removing cover or servicing this equipment 2 With reference to Figure 4 the gap between the brake armature A and the field B should be checked The correct gap is 0 38mm 0 015 Adjustment should not be necessary until gap reaches 1mm 0 040 3 Adjust gap by adjusting the 3 locknuts F and checking with a feeler gauge to be sure gap is the same on both ends of the solenoid 4 Check of the brake discs are properly aligned before re assembly page 18 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com 5 Adjustment is now complete and the b
15. Motor Down situation Rigging the Hoist in Motor Up Position De Rigging the Hoist in Motor Up situation Installing the chain hoist Overload Limiting Protection Limits of travel Chain bag Optional Accessory Converting a 1000kg hoist into a 2000kg model Operation Emergency procedure Lowering Without Power Optional features Sensors for positioning Speed controls Hooks Lug O On oo CO N 10 10 11 11 11 11 12 12 13 14 Inspection amp Maintenance Checking amp Inspections Chain Identification of Chain Chain Replacement with Chain in Lifting Motor Chain Replacement with no Chain in Chain hoist Load Chain Cleaning Chain End Stop Cutting Chains Limit Switch Adjustment Adjusting Upper Limit Gold Nut Adjusting Lower Limit Silver Nut Check Both Upper and Lower Limits Brake Brake Adjustment Wiring Lubrication Gearing Bearings Idler Sheave Bearing Bushing Hook Bearing Limit Switch Shaft Chain Hoist Repairs Chain hoist Repairs Bolts Electrical Parts and Brake Motor Gearing Suspension Power Cord Precautions Frequency of Inspection Frequent checks Periodic inspection Wiring Diagrams Trouble Shooting Inspection and Maintenance Check List Recommended Lubrication Schedule Parts list for replacement parts Warranty 23 24 25 35 36 SAFETY PRECAUTIONS Each Prolyft Chain hoist is built in accordance with the 18 specifications co
16. Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com save BAG OPTIONAL ACCESSORY lt is strongly recommended to use a chain bag with the Prolytt Chain bags like shown in Figure 1 are available from the manutacturer supplier The bags which are colored black fit closely to the chain hoist and are as inconspicuous as possible Be sure to follow the directions that come with Prolyft chain bags before installing 2 Any other chain bags used should be capable of safely supporting the weight of the full length of the load chain and preferable have a drainage hole at the bottom to prevent accumulation of rainwater in case of outdoor use A CAUTION Do not attempt to store more chain in a chain bag than outlined on its instruction sheet or serious damage to the chain hoist may result and hazardous conditions may be created ee E 2 2 F Figure 1 PLE serie with optional Chain Bag CONVERTING A 1000KG HOIST INTO A 2000KG VERSION A Prolytt PLE 12 model hoist can be converted into a 2000 kg version by means of a special kit article code PLS 13 002 This kit contains a 2 ton cha
17. Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com INSTALLING THE CHAIN HOIST General 1 Be certain that supporting structures and attachment points have the strength to satety absorb the weight of the intended loads 2 Hooks should be attached to appropriate points such that the load will be applied at the saddle of the hook only Never allow a load to rest on the tip of a hook Hook latches should always close completely 3 The Prolyft can be mounted upright as motor up in the traditional industry situation or motor down which has become standard in the entertainment touring industry Always make sure that it is clear whether the load chain shall move or whether the hoist housing shall move This does have effect on the way power and control cables should be run 4 Connect the controls to the chain hoist as shown in the Wiring Diagrams starting on page 21 When installing a three phase chain hoist check to make sure the chain hoist travels in the direction intended when operating the controls To correct improper motor travel reverse any two wires except the yellow green ground wire at the power source Do not change connections in the chain hoist Once the direction of travel is ve
18. The chain hoist must not be operated when chain is twisted or kinked An important phase of chain hoist maintenance is chain inspection Check individual links and check for chain elongation As oil needs to sit at the bearing surtace of each chain link it is advised to submerge the chain in oil for 30min Take it out and let the chain hang dripping for 24 hours before putting in the hoist Every hoist comes with a can of chain oil which should be used to drip oil at chain link bearing surfaces Prolyte has the experience that in the entertainment industry chain wear in general is only very limited and often even impossible to measure after 10 years of normal use On the other hand it is a well known fact that the load chains in the entertainment do tend to be misused or even abused and sometimes badly neglected in corrosion prevention Severely damaged deformed dented partly eaten or even broken chain links have been regularly reported by users in the entertainment sector and constant attention must be given that such chains are immediately taken out of service All this is typically the responsibility of the customer or user of the chain hoists IDENTIFICATION OF CHAIN Prolytt load chain can be recognised and determined original by the following marks on the chain Chain specifications e diameter 7 1mm 0 281 fractions e pitch 20 5mm 0 808 fractions e class DAT e grade Grade 80 8 minimum tensile strength
19. a j BLACK VHITE ao BL BLL Le ER BR BCE u n J B BLaLkK Figure 7B Low Voltage diagram Prolyte Products Group 2004 page 22 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com TROUBLE SHOOTING Always disconnect unit trom the power supply system before A WARNING Failure to follow proper lockout tagout procedures may present the danger of electrical shock TO AVOID INJURY Disconnect power and lockout tagout disconnecting means before removing cover or servicing this equipment removing chain hoist covers or the back cover of a control station Probable Cause Remedy Hook fails to stop at end of travel 1 Limit switch not operating Phase are reversed Brass limit switch nuts not moving on shaft Reversing contactor malfunctioning AON amp NY Check adjustment See LIMIT SWITCH ADJUSTMENT page 17 Check connections against wiring diagram Check phase and reverse if needed Check for stripped threads or bent nut guide Remove electrical cover and check reversing contactor Tighten loose connections or
20. allows for greater flexibility in mounting the unit as required by each application The light weight and high strength of the aluminium alloy housings are a plus when the chain hoist is moved from site to site The Prolyft oil filled gearbox provides smooth and reliable opera tion while its magnetic disc brake provides the sure stopping and secure holding of loads that is expected in rigging applications On the low voltage controlled hoist the lifting height is regulated by adjustable up and down limit switches As a standard all Prolytt Lifting speeds can vary 5 Speeds are measured with full load in an upward direction Dimensions are measured over the outmost exterior parts of the hoist excluding the chain hook Prolyft chain hoists come stand ard with handles to manoeuvre or guide the hoist in or out of a flight case or position it over the load Technical specifications Prolyft Performance hoist PLE series Load capacity Lifting Speed 50Hz standard m min Operating voltage Single phase operation Protection class Motor power at 50Hz Power consumption at operation FEM Classification FEM Duty factor Starts per hour Noice level Load wheel Load chain DIN 5684 Falls of chain Weight of chain per meter lift Weight of body Type of control Type of connector Low voltage control Suspension with swivelhook IP 55 available as option PLE 11 001 500kg 4 400v 3P 50Hz 460v 3p 60Hz optional IPoA
21. and remove the gearbox cover 6 Inspect gears tor broken or severely worn teeth and inspect all bearings Replace as necessary The overload slip clutch is factory calibrated and must not be disassembled or readjusted a Prolyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST A CAUTION Do not disassemble or readjust clutch or replace with a clutch assembly from another lifting motor Doing so will void the warranty and may create an unsafe condition If replacement is needed due to wear or loss of adjustment always use a new clutch assembly 7 Reassemble in reverse order of disassembly making sure the gasket is in place and in good condition Coat gasket with Permatex or other gasket cement Extreme care should be taken to avoid damage to oil seals 8 Make sure the oil is refreshed to its proper oil level as indicated on the hoist To much oil will cause the hoist to leak oil during operation 9 Check all wire terminals to be sure they are properly seated and in accordance with wiring diagram Before placing chain hoist back into service check brake adjustment Figure 6 Assembled Gearing SUSPENSION Use the Parts List for Basic Unit and Chaining Parts to help in repairs in this section See Figures 10 and 17 The chain hoist sections must be separated at the top hook line in order to inspect the load sheave and chain guides See CHAIN REPLACEM
22. be adjusted for the application to prevent dangerous conditions or incidents that could occur with over travel It is strongly advised to never run the chain hoist up to these limits They are additional satety teatures and should be kept as such Before transport run back the chain for approx 15cm to release the limit switch This prevents the micro switch from tripping at each bump in the road 2 Chain travel for the Prolytt direct control hoist is not limited except for the chain stop and chain hook mechanically It is strongly advised to always keep at least 15 cm 6 of chain free staying away from the chain hook and the chain stop A CAUTION Not doing so can cause additional wear on the overload protection and might result in hazardous situations J WARKENG When two or more chain hoists are used in combination lifting a single load the operation of just one might lead to a shift in the centre of gravity of the load and therefore a change in load per chain hoist Overloading one of them even when not moving at the time can result in extremely hazardous situations where a chain reaction of overload failures might happen A CAUTION Limit switches are electrical connected in such way that they are in direct conjunction with the two phases which determine the direction of the lift In case somehow the phases are exchanged with the third one limit switches are overridden and will damage page 10 of 37
23. find cracks use dye penetrant magnetic particle or other suitable detection methods Hook and Suspension Missing damaged or illegible NOTE Refer to Maintenance and Inspection Sections of the Lifting Motor Maintenance Manual for further details FREQUENCY OF INSPECTION Frequent 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 The exact period of inspection will depend on frequency and type of usage Determination of this period will be based on the user s experience It is recommended that the user begin with a monthly inspection and extend the periods to quarterly semi annual or annually based on user s semi annually experience Figure 8A Recommended Inspection and Maintenance Check List NOTE This inspection and maintenance check list is in accordance with our interpretation of the requirements of the Safety Standard for Overhead Hoists ASMEB30 16 It is however the ultimate responsibility of the employer user to interpret and adhere to the applicable requirements of this safety standard Prolyte Products Group 2004 page 24 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their p
24. replace Lifting motor does not respond to pushbutton Power failure in supply lines Wrong voltage or frequency Improper connections in chain hoist or pushbutton station Brake does not release E JONE 5 Faulty reversing contactor A w N Check circuit breakers switches and connections in power supply lines Check voltage and frequency of power supply against the rating on the nameplate of the motor Check all connections at line connectors and on terminal block Check terminal block on dual voltage chian Check connections to the solenoid coil Check for open or short circuit Check for proper adjustment Check coils for open or short circuit Check all connections in control circuit Check for burned contacts hoist for proper voltage connections See BRAKE ADJUSTMENT page 17 Replace as needed Hook does not stop promptly 1 Chain hoist overloaded 2 Brake not holding Reduce load to within rated capacity of chain hoist 2 Check brake adjustment See BRAKE ADJUSTMENT page 17 It may be necessary to replace discs Hook moves in wrong direction 1 Three phase reversal 2 Improper connections NO Reverse any two wires except the green ground wire at the power source See INSTALLATION page 5 Check all connections against wiring diagram Chain hoist hesitates to lift when energized single phase chain hoist only 1 Chain hoist overloaded 1 Reduce lo
25. the rails on the plate using a small screwdriver DO NOT SLIDE THE END CLAMPS The contactor can be slid off the rail but must be snapped on Where the contactor fits the rail one side has springs or pads that apply pressure against the edge of the rail By pressing against that side at the base of the contactor you can snap the part on or off using a rotating action Note the numbers that label the terminals on the contactor and orient the part as shown in Figures 7A 7B page 19 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com Silver Nut Down Gold Nut Ha EN Up a Plate Limit Switch Assembly Figure 5 Brake and Limit Switch Assembly 2 Remove the electrical panel by removing the stand off screws See Figures 13 amp 14 The limit switch and brake are now accessible as shown in Figure 5 3 Remove the transformer bolted to the back of the panel plate if it requires replacement 4 Refer to Figure 15 to disassemble the limit switch See LIMIT SWITCH ADJUSTMENT on page 17 to properly set the upper and lower limits of travel MOTOR Refer to Figure 11 The chai
26. ENT WITH NO CHAIN IN CHAIN HOIST page 16 While this section is apart check the following e Load sheave Chain Chain guides and plates e Chain support on 2 ton models e Bearings Replace parts as necessary including screws lock washers etc When reassembled recheck operation POWER CORD PRECAUTIONS Electric chain hoists require a sufficient power supply It is especially important with single phase voltage to ensure that the conductors running to the chain hoist from the power source are adequate in size to handle the power requirements of the chain hoist Inadequate power cables and branch circuits will cause low voltage high amperage damage to the chain hoist and potential fire hazards Such problems can be minimized by using 230V power on 115 230V chain hoists The following are recommendations for the conductor gauge size depending on the length horsepower and voltage for 3 phase 400V hoist MAINS POWER CABLE WIRE COLOR EU COLOR US PIN PE ground Yellow Green Yellow Green GND page 20 of 37 Zero Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com LOW VOLTAGE C
27. ONTROL CABLE WIRE COLOR EU FUNCTION PIN woo e e a e e o o ETa velon O oo BRAKE INS BRAKE OUTS COLOR EU oxo wlow Gren a moona ooo o fpe C moona FREQUENCY OF INSPECTION FREQUENT CHECKS Indicates items requiring inspection daily to monthly Daily inspections should be taken as visual checks prior to each time of use and may be performed by the operator if properly designated In general the items to be checked accordingly are chain hook amp latch suspension hook amp latch load chain power and control tails including the stress reliefes and connectors Furthermore the general state of the hoist body should be observed for missing parts or anything that might indicate a deterioration of the safe use of the chain hoist Checks like these do not legally require filling out any written document however in dry hire rental companies this still might be advised for liability reasons PERIODIC INSPECTION Indicates items requiring inspection monthly to yearly Inspections to be performed by or under the direction of a properly designated person The exact period of inspection will depend on frequency and type of usage as already stated on page 15 Determination of this period will be based on the user s experience In standard entertainment applications it is recommended that the user begins with a semi annually inspection and extends the periods to annually based on user s semi annually ex
28. ad within rated capacity of chain hoist 2 Motor brake requires adjustment 2 Check motor brake adjustment See BRAKE ADJUSTMENT page 17 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 lifting motor reversing contactor while lifting a load 5 Faulty SINPAC starting switch or start capacitor 5 Replace faulty component Hook raises but will not lower 1 DOWN circuit open 2 Broken conductor in pushbutton cable 3 Faulty reversing contactor wn Check circuit for loose connections Check DOWN limit switch for malfunction Check each conductor in the cable If one is broken replace entire cable Check coils for open or short circuit Check all connections in control circuit Check for burned contacts Replace as needed Hook lowers but will not raise 1 Lifting motor overloaded 1 Reduce load to within rated capacity of chain 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 chain 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 enti
29. any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST WIRING DIAGRAMS IMPORTANT MULTI VOLTAGE LIFTING MOTOR TO CONVERT VOLTAGE REDOMNECT LEADS MARKED WITH AHM i TO THE TERMINAL BLOCKS EXACTLY AS SHOWN BELOW TO COMMEC TOR TO CONNECTOR TO TERMINAL BLOCKS Ti T2 T3 T4 TS TH T Te T sj m 0 09 0 Q FO O O BRAKE SOLENOES EPO GIL GY GREEN VELLOW Bi BLACK WHITE 1 B 27 BLACK WHITE 2 Bele BLACK WH TE 4 BL BLUE BR BROW B BLACH CONTROLLER OPERATION ia up DOWN Li BLUE L3 BLUE L2 BROWN L2 BROWN L3 BLACK Li BLACK Figure 7A Direct Control Diagram IMPORTANT MULTI VOLTAGE LIFTING MOTOR TS GOMERT OL TRIE RESOSNHECT LEADS TO THe TERMIHAL BLOCKS EXACTLY AT HEH BELON FOR 10V THE Ta TS AHD Ti UOTOR LEACH ARE SRLECED TOGETHER QOHHECT THE APPROPRIATE TRANSFORMER LEAD H OR Hi TO THE GOHTACTOR As Soe TO TEARRAL BL OCRS aad tn n Ta T L ka ti POR UE a REONE C4 C5 AND CH APDR VARTS FR TE Pa BLEER AHD COA TALTER TOHE TKH EW Tii i Ta Th T cm i H2 2I ORANGE Fii o UA ie ALARE Dh UP LihiiT Ei LT CONTE CORMECTOR aiTcH aH ii OOM BLUE ELLERY 2 GOLONUT B3 SILVER NUT Fe he ee GY GARPEMTELLOW Bet BLACK VVHETE Fi LEa aes BS BLACKAWHITE 2 ed
30. as described on 15 16 Limit switch travel is changed also see page 17 Prolyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST OPERATION This chain hoist is designed for operation within the limits of its rated capacity It needs to be controlled by a special dedicated control system or a push button station Prolytt strongly advises to use control systems with thermal motor protectors for each controlled hoist The UP direction is controlled by closing the circuit between X1 and C20 DOWN is controlled by closing the circuit between X1 and C21 See Figures 7A 7B The operator should be aware of the location of the load at all times If the extreme limits are encountered the user should immediately stop the motor With properly set limits tandem units can be synchronized by easing each one to its corresponding limit Depending on the application you will use the UP or DOWN limit as your guide J WARKEING Do not use chain hoist to lift support or otherwise transport people OPERATING NOTES Points which must be observed at all times to maintain proper operation 1 Know the weight s of the load to be lifted Never overload the chain hoist 2 Use common sense at all times when operating a chain hoist 3 Do NOT operate if direction of travel is not the same as indi cated on button being pushed Make sure phases are corrected until direc
31. ase the brake 3 Use several quick releases instead of holding brake open continuously Do not exceed normal lowering speed page 11 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST OPTIONAL FEATURES SENSORS FOR POSITIONING Prolytt hoist can be equipped with internal sensors for positioning purposes Contact your dealer or Authorised Service station SPEED CONTROLS For reasons of smooth operation or variable lifting speeds chain hoists can be run through variable speed frequency controls Contact your dealer or Authorised Service station A CAUTION The overload limiting clutch is an emergency protective device and should not be used to measure the maximum load to be lifted or to sense the overload imposed by a constrained load While the overload limiting clutch will protect the lifting motor from damaging overloads it will not ensure that a load is within the rated capacity of the chain hoist J WARKING Do not purposely allow the overload limiting clutch to slip Excessive slippa
32. b the gold slotted nut if it has been set previously CHECK BOTH UPPER AND LOWER LIMITS 1 Connect the chain hoist to the power supply Be sure the green ground wire is properly grounded A CAUTION If the wires running to the limit switches are ever disconnected for any purpose be sure to replace wires in accordance with the correct wiring diagram See Figures 7A 7B 2 Check the direction of hook travel See INSTALLING THE CHAIN HOIST page 10 3 Carefully operate to upper limit and observe if it stops automatically at desired level Do not allow load block to run into the chain hoist housing this will damage the chain hoist Maintain a minimum clearance of 51mm 2 from the chain hoist housing and the load block on single fall models and 25mm 1 trom the chain support to the load block on double reeved models 4 Carefully operate to lower limit and observe if it stops automatically at the desired level Do not allow slack end loop of chain to become taut against chain hoist housing This will damage the chain hoist There should be a minimum clearance of 51mm 2 between the chain stop and the chain hoist 5 If upper and lower limits operate satisfactorily the chain hoist is ready for use If they are not as desired repeat adjustment BRAKE Properly adjusted this brake will release promptly when energized It is capable of both smoothly stopping and securely holding the rated capacity of the chain hoist
33. be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST Figure 14 ELECTRICAL PARTS 10 PARTS LIST FOR ELECTRICAL PARTS 1 PHASE Part Ref Part Qty No Description No Qty B i Panel Standoff Spacer 200J4Z 1 4 Internal tooth H4134 3 Lockwasher No Description No M34 Panel Plate 257UJ200 a Terminal eck oono Je a End Clamp 909313 opening plug JM761 6 Marking Strip 909J11 Power Pigtail 953PL1 Coil voltage of the contactor and the secondary voltage of the transformer are the same This is referred to as the control voltage Standard units are supplied with 115V Control Prolyte Products Group 2004 page 30 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12
34. cautions have been taken NOT allow the load chain or hook to be used as an electrical or welding ground NOT allow the load chain or hook to be touched by a live welding electrode NOT remove or obscure the warnings on the chain hoist decals are missing or illegible NOT operate a chain hoist unless load slings or other approved single attachments are properly sized and seated in the hook saddle NOT allow your attention to be diverted from operating the chain hoist NOT allow the chain hoist to be subjected to sharp contact with other chain hoists structures or objects through misuse NOT adjust or repair the chain hoist unless qualified to FEM classification 30 perform such adjustments or repairs NOT attempt to lengthen the load chain or repair damaged load chain NOT drag the load chain and or chain hook across dirty sandy of abrasive surtaces concrete floors NOT hold on to the load chain which is dangerous for obvious reasons and hold on to the motor housing which is dangerous as this can get very hot Holding onto the power or control pigtails is certainly not advised as well 1 performing chain hoist DO S 2 NOT operate the chain hoist until you have thoroughly read l and understood the manufacturer s Operating and Mainte nance Instructions or Manuals 3 NOT operate a chain hoist which has been modified 2 without the manufacturer s approval 4 NOT allow anyone under 18 yea
35. control cable and make sure these have proper stress relieves and sufficient slack in every direction of planned tilting of the load Use Velcro or cable strings to tie the cable to the hoist body or lifting suspension hook A CAUTION Tie wraps may eventually cut the cable or the conductors and gaffer tape might leave remains of the glue layer to cable or hoists gathering dirt and dust etc 5 Check the direction of travel If the pre selection switch on the controller is in the up direction the chain hoist should run in up direction 6 Check if both the lifting directions work properly lifting and lowering It is better to find a malfunction in a relay at ground level than at elevations that are out of reach 7 Guide the chain carefully into the chain guides when running it taut Prevent the chain from twisting knotting or piling upon the hoist body In a well designed flight case the chain motor can rest in the box until the chain has been run taut WARNING Always use gloves to protect your hands Keep your hands away from the chain hoist by at least 0 5m 1 5 ft Getting caught in between chain and chain guide can cause severe injuries or even loss of fingers Do not let your hair or clothes get caught in between chain and chain guide Prolyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST 8 Lift the chain hoist out of the flight ca
36. d hard to reach discotheque rig It is strongly recommended that an Inspection and Maintenance Check List and an Inspector s Report similar to those shown in Figures 8A and 8B on page 23 and 24 to be used and filed for reference All inspections should be performed or overseen by a designated inspector Special inspections should be made following any significant repairs or any operating occurrence leading one to suspect that the chain hoist s capability may have been impaired CHAIN 1 Inspect chain before each use for twisted links damage denting deformation cracking or corrosion Check the chain for overall wear or stretch by selecting an unworn un stretched length of chain at the slack end for example Let the chain hang vertically with a light load about 10 kg 22 Ibs on the chain to pull it taut Use a large calliper to measure the outside length of a convenient number of links about 150mm 6 Measure the same number of links in a used section of chain and calculate the percentage increase in length of the worn chain A CAUTION The chain used on this lifting motor has very carefully controlled dimensions and has been heat treated Do not attempt to substitute any other manufacturer s chain OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST 2 Chain is to be kept clean and lubricated See LUBRICATION page 18 Visually check chain every time chain hoist is used
37. e chain hoist suspension hook chain hook hook latches as well as the load chain itself prior to each time of use for any damage deformation or malfunction DO make sure that the structure from which the Prolyft chain hoist is suspended as well as the slinging equipment is able to safely absorb the force resulting from the weight of the load and the chain hoist itself multiplied by the dynamics of starting and stopping the lifting action For the Prolytt this is app 1 4 times the static load DO check brake function by tensioning the chain hoist prior to each lift operation DO shut down a chain hoist that malfunctions or performs unusually and report such malfunction DO make sure hook travel is in the same direction as shown on the controls DO maintain firm footing or be otherwise secured when operating the chain hoist DO guide the chain hoist to take up slack chain carefully without twisting or knotting DO make sure load is balanced and load holding action is secure before continuing lifting operation DO always keep your attention to the chain hoist and the load that it is supporting DO use hook latches Latches are to retain slings chains etc under slack conditions only page 3 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be rep
38. e installation area must provide safe operating conditions for the operator including sufficient room for the operator and other personnel to stand clear of the load at all times page 6 of 37 RIGGING amp MOTOR HANDLING INSTRUCTIONS FOR TEMPORARY INSTALLATIONS RIGGING THE HOIST IN MOTOR DOWN POSITION CHAIN CLIMBER A CAUTION Parts of this procedure can involve working from an elevated platform scissor lift or cherry picker Before doing so make sure you are competent to work with those and take all needed safety precautions 1 Before each use visually inspect the hoist and all load bearing parts of the hoist like hooks and load chain 2 Make sure the intended structural support component is able to sately absorb the chain hoist lifting capacity WARNING A fully loaded motor can put considerably higher forces to the support structure when dynamic forces are induced A similar thing happens when a lowering movement of other hoists on the same load e g truss structure causes the centre of gravity to slide towards the resting hoist which will get overloaded Overload protection in the chain hoist causes the structure to be overloaded as well 3 Attach the chain hook to the main structural support member either direct to an existing eyebolt or lug plate or using a bracket or beam clamp It is also possible to use a sling or bridle Avoid slinging on sharp edges 4 Connect the power and
39. educe load to within rated capacity of chain hoist Check for proper brake adjustment or other defects Ensure that the voltage at the reversing contactor is within 10 of the nominal voltage while lifting a load Replace overload clutch assembly Motor brake noise or chatter while starting chain hoist 1 See BRAKE ADJUSTMENT page 17 2 Ensure that the voltage at the reversing contactor is within 10 of the nominal voltage while lifting a load 1 Brake needs adjustment 2 Low voltage Motor brake buzz anytime chain hoist is running 1 See BRAKE ADJUSTMENT page 17 2 Replace shading coil or complete brake frame assembly 1 Brake needs adjustment 2 Broken shading coil on brake frame Prolyte Products Group 2004 page 23 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST INSPECTION AND MAINTENANCE CHECK LIST ELECTRIC POWERED OVERHEAD CHAIN CHAIN HOIST Type of chain hoist Capacity Tons Location Original Installation Date Manufacturer Manufacturer s S
40. ee ADJUSTING UPPER LIMIT page 1 7 Prolyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST CHAIN REPLACEMENT WITH NO CHAIN IN CHAIN HOIST 1 DISCONNECT CHAIN HOIST FROM POWER SUPPLY and move the chain hoist to a work table Remove the electrical cover electrical panel and the electric brake assembly WARNING Failure to follow proper lockout tagout procedures may present the danger of electrical shock TO AVOID INJURY Disconnect power and lockout tagout disconnecting means before removing cover or servicing this equipment NO Detach the chain stripper from the bottom of the chain hoist 3 Insert the new chain between the load sheave and the chain guide Feed the chain into the chain hoist by manually turning the brake hub Allow about 40cm 15 of chain below the chain hoist on the slack end Be sure the welds of the upstanding links are out away from the load sheave and that proper orientation is observed for attachment of the slack end Also be sure the load hook assembly if already attached to the chain is toward the centre of the chain hoist or to your right looking from the transmission end 4 Reinstall the chain stripper observing proper chain alignment and avoiding any twist in the chain 5 Follow steps 11 through 14 in previous section CHAIN REPACEMENT WITH CHAIN IN CHAIN HOIST to complete the chain replacement procedure NOTE In
41. epted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com Warranty LIFE TIME WARRANTY REGULATIONS If your hoist is inspected certified and if necessary repaired by a Prolytt Vendor authorised service point the warranty as described can extend for a technical lifetime If not a normal 2 year warranty is applicable See regulations The hoist should not exceed the FEM class of operating times in use The periodic inspection should be carried out at a minimum of once a year local or specific regulations can vary to this sequence Every hoist is thoroughly inspected and tested prior to shipment from the factory and service point Should any problem develop return the complete hoist prepaid to your nearest Prolyft Authorised Warranty Service point If inspection reveals that the problem is caused by defective work manship or material repairs will be made without charge and the hoist will be returned transportation prepaid This warranty does not apply where deterioration is caused by normal wear abuse improper or inadequate power supply eccentric or side loading over loading chemical or abrasive actions improper maintenance or excessive heat nor for lifting chains chain guide
42. erial No Item Frequency of Inspection Possible Deficiencies Action Required Periodic Daily semi annually 1 12 Mo Operating Controls Brake Mechanism Any deficiency causing improper operation 1 Any deficiency causing improper operation 2 Pitting or deterioration 1 Slippage or excessive drift 2 Glazing contamination or excessive wear Excessive throat opening 15 bent or twisted more than 10 degrees damaged hook latch wear chemical damage worn hook bearing To find cracks Use dye penetrant magnetic or other suitable detection methods Nuts Bolts Rivets Sh Distortion cracks and excessive wear rors Build up of foreign substances Cracks distortion Excessive wear internal build up of Housings Load Block foreign substances Wiring and Terminals E a i Fraying defective insulation Chain hoist Reversing Contactor other Electrical Loose connections burned or pitted contacts Apparatus Supporting Structure and Trolley Damage or wear which restricts ability to support if used imposed loads Nameplates Decals Warning Labels Pins Bearings Bushings Shafts Couplings Excessive wear corrosion cracks distortion Looseness stripped and damaged threads corrosion Chain Inadequate lubrication excessive wear or stretch cracked damaged or twisted links corrosion or foreign substance Cracks excessive wear or other damage which may impair Suspension Lug if used the strength of the lug To
43. es it is mandatory to reduce the allowable amount of load lifted to 75 or even 66 of the rated capacity of the chain hoist Prolyft considers the application of the chain hoists in any other than stand alone situations as being the responsibility of the operator or user Prolytt strongly advises operators to acquire sufficient knowledge of the local national or international rules and regulations when these types of lifting are applied SUSPENDING LOADS OVER PEOPLE The suspension of loads over people demands the highest level of rigging knowledge equipment and equipment maintenance The Prolyft must be installed and used in accordance to local and national standards and regulations when suspending loads over people These include the following important precautions 1 It is preferred that the load always be tied off with an auxiliary chain or cable secondary or safety before access to the area beneath the load is permitted 2 Asan alternative the system may be designed in such way that malfunction or failure of one chain hoists load bearing components does not cause load loss and or overloading of any other chain hoists in the system Note that in such a system chain hoist performance and function must be monitored visually or should be monitored using load cells 3 Never operate the chain hoist while people are under the load Prolyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE
44. es the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST Figure 13 ELECTRICAL PARTS 3 PHASE PARTS LIST FOR ELECTRICAL PARTS 3 PHASE Ref Part No Description No Description No Qty Panel Plate 257UJ200 _ 3 Phase 4 cond 953PL1 LT 10 Panel Standoff Spacer 200J4Z 3 Zinc Plated Pri 230 460V Sec 24V 821J432 1 4 Internal tooth H4134 Pri 230 460V Sec 115V 8214431 Lockwasher Pri 208V Sec 24V 821J472 1 4 20UNC X 4 Screw H1027P _ Pri 208V Sec 115V 821J471 8 32UNC X 5 16 Screw H2751 _ Pri 380V Sec 24V 821J482 8 External tooth H4158 _ Pri 380V Sec 115V 821J481 aaisa _ Pri 415V Sec 115V 8211491 ea ae _ Pri 575V Sec 24V 821J452 opening pug JM761 Pri 575V Sec 115V 6 End Piate 230 460v 9092 Coil voltage of the contactor and the secondary voltage of the transformer are the same This is referred to as the control voltage Standard units are supplied with 115V Control Pri 415V Sec 24V 821J492 1 4 Flatwasher H4002P Prolyte Products Group 2004 page 29 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will
45. expensive because of the characteristics needed for safe operation Regular slinging chains are certainly cheaper but in no way safe when used in a chain hoist Never leave even the slightest bit of doubt when safety is a major issue CHAIN REPLACEMENT WITH CHAIN IN LIFTING MOTOR 1 With the unit hanging by the suspension hook motor up position run the load hook to its UP limit 2 DISCONNECT CHAIN HOIST FROM POWER SUPPLY and remove the electrical cover 3 Using a screwdriver pry the spring guide plate out of the slots in the limit switch nuts See Figure 5 page 19 Turn the gold nut back to about the center of the threaded shaft Do not disconnect the wires from the limit switches 4 Remove the load block assembly from the old chain On double chained lifting motors detach the chain from the chain support and pull it through the load block assembly 5 Make a C shaped chain link by grinding through the end link on the load end of the old chain 6 Using the C link attach the new chain to the load end of the old chain Be sure that the welds of the upstanding links of the new chain will face outward from the load sheave The end links must be oriented for attachment to the dead end shackle and the chain support double chained only without any twist in the chain Note that the chain end is attached to the shackle with a split link 7 With the electrical cover off connect the chain hoist to the power
46. ge will damage the clutch and motor Hazardous conditions will be created Prolyte Products Group 2004 page 12 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST HOOKS amp LUGS Refer to Figure 2 3 The hook latches should be checked before use to ensure that 1 Visually inspect hooks before use for conditions for cracking they close the hook throat opening in a secure manner when a extreme wear deformation or spreading load is applied 2 Replace hooks showing any of these signs If the throat NOTE A latch opened in the wrong direction is an openings are spread wider than the maximum permissible indication tor an overloaded hook 15 increase listed here the hooks have been overstressed 4 Inspect the hook shank and nut for any stripping of the threads and must be replaced Any hook that is bent or twisted more or other damage The hook nut should be fully restrained by than 10 from the plane of an unbent hook must also be the retaining pin replaced J LESS LATCH Figure 2a fixed hook
47. h nuts 4 Turn the slotted gold nut toward its limit switch until the switch clicks then turn two slots farther Release the spring guide plate and be sure it slips back into the slots in both limit switch nuts Do not disturb the silver slotted nut if it has been set previously ADJUSTING LOWER LIMIT SILVER NUT 1 Suspend the chain hoist in the motor up position Operate DOWN to a point where the slack end loop of the chain hangs down 15cm 6 or more from the chain hoist housing or the limit desired in any particular application allowing the minimum 15cm 6 There should be a minimum clearance of 51mm 2 between the chain stop and the bottom of the chain hoist 2 DISCONNECT CHAIN HOIST FROM POWER SUPPLY and remove the electrical cover WARKING Failure to follow proper lockout tagout procedures may present the danger of electrical shock TO AVOID INJURY Disconnect power and lockout tagout disconnecting means before removing cover or servicing this equipment Prolyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST 3 With a screwdriver pry the spring guide plate out of the slots in the limit switch nuts 4 Turn the slotted silver nut toward its limit switch until the switch clicks then turn two slots farther Release the spring guide plate and be sure it slips back in the slots in both limit switch nuts Do not distur
48. he limit switch might malfunction IMPORTANT Before placing chain hoist in operation check the limit switch adjustment Limit switches are provided to protect the chain hoist against damage resulting from over travel or to allow setting the hook travel within the factory set limits of travel The standard Prolyft limit switch allows for the maximum amount of lift 43 meter 143 on the 500 1000kg models and 21 meter 71 on the 2000kg models The limit switch adjusting nuts are colour coded gold for the UP limit and silver for the DOWN limit Movement of the limit switch nuts toward or away from each other increases or decreases the hook travel respectively ADJUSTING UPPER LIMIT GOLD NUT 1 Suspend the chain hoist in the motor up position For single fall models operate UP until there is a minimum clearance of 51mm 2 from the chain hoist housing and the rear end of the block Double reeved models require a minimum clearance of 25mm 1 from the chain support to the chain guide side of the load block 2 DISCONNECT CHAIN HOIST FROM POWER SUPPLY and remove the electrical cover WARNING Failure to follow proper lockout tagout procedures may present the danger of electrical shock TO AVOID INJURY Disconnect power and lockout tagout disconnecting means before removing cover or servicing this equipment 3 With a screwdriver pry the spring guide plate out of the slots in the limit switc
49. her than those for which the Prolyft hoist is intended Prior to installation and operation we caution the user to review his application for abnormal environmental or handling conditions and to observe the applicable recommendations as follows ADVERSE ENVIRONMENTAL CONDITIONS Do not use the chain hoist in areas containing flammable vapours liquids gases or any combustible dusts or fibres Do not use this chain hoist in highly corrosive abrasive or wet environments Standard Prolyft hoists have an IP54 protection class For outdoor use in rainy conditions it is advised to use an IP55 protection class Do not use this chain hoist in applications involving extended exposure to ambient temperatures below 20 C 10 F or above 50 C 130 F LIFTING OF HAZARDOUS LOADS This chain hoist is not recommended for use in lifting or transport ing hazardous loads or materials which could cause widespread damage if dropped The lifting of loads which could explode or create chemical or radioactive contamination if dropped requires fail safe redundant supporting devices which are not incorporated into this chain hoist TANDEM LIFTS AND MULTIPLE LIFTS Chain hoists of any manufacturer unless otherwise stated are basically designed to operate as a stand alone type of machinery When two or more chain hoists are used to lift one single load the risks increase considerably Several countries around the world have legislation that in such cas
50. his manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com G Ades Adem Core Cond Onnschwripvang Beschreibung Descripaion Definition Insallatiedraad Aderleitung Building wire Fil d installation Noles PE Gbeschenmingskiding Schutzieier protedivg conduct faseleidingen Prasenieier phase conductors conduchturs de phase Mar Aan genummerd schwarz nurenerernt black numbered noir numero Laagapanningskabel zonder gre Niederspannungskabel ohne onge Low vonage cables without gye Cables basse tension sans hja Laagapanningskabel met gr g Niederspannungskabel mit onge Low vollage cables with qrye Cables basse avec veja iheharmoaniseerde buigzame leidingen Harmonisiene Schlauchleitungen Harmonised flexible cablas Cables souples harmonis s L Li L L3 PRELIMINARY CHECKS Before installing starting to use the chain hoist check the follow ing General 1 After unpacking the unit carefully inspect for any damage that may have occurred during transit Check for loose missing or damaged parts Shipping damage claims must be filed with the carrier Be sure that the voltage labelled on the unit matches your power supply 2 Make sure all supporting structures and attaching devices have the strength to safety absorb the weight of the intended loads If in doub
51. in block hook and an anchor point 1 Run the chain through the hoist in such way that 1 one meter of hoist chain is left This facilitates the conversion Disconnect the hoist form the power supply Take out bolt 11 to release the aluminium chain guide 6 Take off the chain hook 12 Feed the chain over the chain wheel of the 2 ton block 21 Note Be sure that the welds of the chain links are facing outwards and sideways only 6 Feed the chain through the chain guide 6 and connect the anchor point 4 amp 5 Note Be sure that both chain falls are free of twists Failure can cause severe damage to the hoist or other property and even result in personal injury or death 7 Place the chain guide back and fasten bolt 9 to a torque of 14Nm 8 Check again if the chain is lined up correctly and run the double reeved chain out to its required length Reverse the lifting hook at the body of the hoist see figure 10 10 Pass the serial number of the hoist through to Prolyft for guarantee reasons 11 Change the decals of the hoist to the proper WLL 2000 Kg a amet ade NOTE As the hoist is now changed into a double reeve two fall system the lifting speed and lifting height are reduced by factor 2 When litting height should be maintained another chain at least twice the length of the required height should be installed Make sure no other that the original Prolyft load chain is used Reset limit switches if necessary
52. ing and oiling may be necessary HOOK BEARING Apply a few drops of new SAE 30 gear or motor oil around the edge of the bearing LIMIT SWITCH SHAFT Remove any dirt accumulation and spray with a general purpose lubricant AWARNING Remove load and disconnect chain hoist from power supply before starting to do any repairs or to take any sections apart Chain Hoist Repairs CHAIN HOIST REPAIRS NOTE If you do not have an experienced mechanic to do your repair work we recommend that you send your chain hoist to an approved service station for repairs Use authorized repair parts only 1 For major repairs or when the chain hoist is to be sectioned in the suspension area it will be necessary to move the chain hoist to a workbench or table 2 For repairs which can be done by removing the electrical cover only the chain hoist need not be moved Lowering the chain hoist to a convenient working level is desirable The following repair instructions will help you in understanding repair procedures when related to the Replacement Parts List on page 34 For clarity these are broken down into areas BOLTS All bolts should be 8 8 grade minimum The bolts of the gearbox housing require a torque moment of 12 5 Nm The bolts should be tightened crosswise All critical bolts are sealed ELECTRICAL PARTS AND BRAKE 1 Refer to Figures 13 and 14 Remove the cover to access the controls The terminal blocks and end clamps snap off of
53. ir parts or accessories other than those supplied by Prolytt Authorised Warranty Service points are used on the hoist 5 failures caused by a lack of maintenance Equipment and accessories not of the seller s manufacture are to be warranted by their manufacturer Except as stated herein Prolyte makes no other warranties express or implied including warranties of merchantability and fitness for a particular purpose If for reasons outside the control of the vendor the delivery is delayed the time lag can not exceed 3 months If the use installation of the hoist is delayed the extension of the guarantee limited to 3 months must be requested and written conformation obtained The warranty only applies for original service point or factory installed spare parts including chain page 36 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com The guarantee excludes any other services or indemnities The repairs covered by the guarantee are carried out as a rule in JL WARK ERA k the workshop of the service point or vendor or authorised agent All replaced parts become the p
54. ith those and take all safety precautions needed 1 Before each use visually inspect the hoist and all load bearing parts of the hoist like hook and chain 2 Make sure the intended structural support component is able to safely absorb the chain hoist lifting capacity WARNING A fully loaded motor can put considerably higher forces to the support structure when dynamic forces are induced A similar thing happens when a lowering movement of other hoists on the same load e g truss structure causes the centre of gravity to slide towards the resting hoist which will get overloaded Overload protection in the chain hoist causes the structure to be overloaded as well 3 Attach the chain bag to the chain bag bracket with the hooks facing outward 4 Put the chain into the chain bag and make sure there are no twists or knots in the chain in the chain bag 5 Attach the chain hook to the main structural support member either direct to an existing eyebolt or lug plate or using a bracket or beam clamp It is also possible to use a sling or bridle Avoid slinging on sharp edges page 8 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Product
55. n hoist s motor is located on the opposite end to that of the electrical parts but the two are tied together with electrical leads running through the housing 1 If it is necessary to replace or repair the motor DISCONNECT THE CHAIN HOIST FROM THE POWER SUPPLY and remove the electrical cover 2 Loosen the screw clamps on the terminal blocks and reversing contactor to disconnect the motor leads See Figures 14 and 15 3 Remove the four motor mounting bolts attaching the motor to the housing It will come loose at the motor coupling WARNING Failure to follow proper lockout tagout procedures may present the danger of electrical shock TO AVOID INJURY Disconnect power and lockout tagout disconnecting means before removing cover or servicing this equipment 4 Inspect the motor coupling motor shaft and all the bearings Replace as necessary 5 Install new or repaired motor according to the wiring diagram located inside the electrical cover or Figures 7A and 7B GEARING Use the Replacement Parts List for Basic Unit and Gearbox Parts to help in repairs on gearing See Figures 10 and 16 As disassembly is extensive for gearing disconnect the chain hoist and move it to a workbench 1 DISCONNECT THE CHAIN HOIST FROM THE POWER SUPPLY and remove electrical cover Remove electrical panel Remove brake assembly Drain oil from the gearbox Remove the four screws attaching the gearbox cover to the gear housing
56. n hoists used in the touring sector often need their load chains to be run in and out This should be given thorough attention as jamming or knotting might seriously damage the load chain 3 It is necessary to have a thorough visual check of all major components before each operation 4 Any kind of damage has to be checked and must be within the limits of the rejection criteria mentioned in this operation manual Prolyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST OVERLOAD LIMITING PROTECTION This chain hoist is equipped with a factory calibrated overload limiting clutch that will permit the lifting of loads within its rated capacity but will prevent the lifting of damaging overloads while the chain hoist is being operated This is conceived through a mechanical slipping device as is the case in almost all chain hoists found in the entertainment industry If the load being lifted exceeds the lifting capability of the overload clutch the motor will continue to run causing overheating of both the clutch and motor This condition should be avoided by immediately releasing the UP button and reducing the load to within the rated capacity of the chain hoist See GEARING page 19 for additional instructions on this device LIMITS OF TRAVEL 1 Chain travel for the Prolytt low voltage control hoist is limited by UP and DOWN limit switches that should
57. ntained here in and at the time of manufacture complies with our interpretation of applicable sections of European 19 FEM or equivalent to American Society of Mechanical Engineers 20 Code ASME B30 16 Overhead Hoists the National Electrical Code ANSI NFPA 70 and the Occupational Safety and Health Act 21 OSHA Since OSHA states the National Electrical Code applies to all electric chain hoists installers are required to provide current 22 overload protection and grounding on the branch circuit section in keeping with the code Check each installation for compliance 23 with the application operation and maintenance sections of these articles 24 NOT operate a chain hoist on which the safety placards or FEM classification load spectrum average daily use in hours HE aa Medium duty 1Bm 1Am m m Intensive duty Am m Very intensive duty 1Am 2m lt 16 lt 16 p be oS cess fam an m om a1 The Prolyft has 1Am classification 2m pending DONT S 1 NOT operate a damaged malfunctioning or unusually OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST NOT apply load if bearing prevents equal loading on all load supporting chains NOT operate beyobeyond the limits of the load chain travel NOT use the chain hoist s overload limiting clutch to measure load NOT leave a load supported by the chain hoist unattended unless specitic pre
58. o NOT allow any people to stand under the moving load 14 Make sure you have a full visual view on the complete travel path of the load 15 Lift the load to the required height WARNING Do not use the control button in an intermittent switching manner This can lead to hazardous situations The chain hoist motor can get overheated or considerable increase of forces due to dynamic loading can be caused OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST DE RIGGING THE HOIST IN MOTOR UP SITUATION A CAUTION Part of this procedure can involve working from an elevated platform scissor lift or cherry picker Before doing so make sure you are competent to work with those and take all safety precautions needed 1 Remove the secondary when present WARNING Do not let anyone stand under the suspended load when the secondary is removed 2 Check the direction of travel If the pre selection switch on the controller is in the down direction the chain hoist should run in down direction 3 Check if both the lifting directions work properly lifting and lowering 4 Remove all people from the area before you start lowering the load Do NOT allow any people to stand under the moving load 5 Make sure you have a full visual view on the complete travel path of the load 6 Bring the load down until within reach for further dismantling WARKING Do not use the contr
59. o ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST Figure 10 Basic Unit PARTS LIST FOR BASIC UNIT Part Qty Description No Motor a Cover Screw Top Hook Assembly vin tan SS Capacity Decl O Socket head screw x 1 S49 77 Jam free chain guide JM254 Prolyte Products Group 2004 page 26 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST Figure 11 MOTOR 3 PHASE NS ia i Refer to the motor nameplate for part number voltage full load amperage horsepower and other motor information PARTS LIST FOR MOTOR 3 PHASE Ref Part Description No No Qty
60. ol button in an intermittent switching manner This can lead to hazardous situations The chain hoist motor can get overheated or considerable increase of forces due to dynamic loading can be caused 7 Remove all parts of the load and any slings attached to the chain hook 8 Run the load chain out depending on the specitic circumstances of use and storage 9 When running the load chain out make sure approx 0 5m 1 5 ft is remaining on the dead end A CAUTION Never run the chain all the way to the limit switch and leave it like that Run back the chain for approx 15cm to release the limit switch WARKING Do not let anyone stand under the suspended load until this is properly secured using a secondary suspension 16 Add a secondary in between support structure and the load when persons have to get under the load 17 Make sure this secondary is as tight as possible preferably using clutch chains Prolyte Products Group 2004 10 Disconnect the power and control cables 11 Remove the chain hoist from the suspension structure and bring it down 12 Put the chain hoist and the chain bag in their compartments of the flight case when applicable or other transport and or storage facility 13 Remove any bracket beam clamp or slinging from the main structure elements page 9 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors
61. perience It is advised however to check with local or national legal regulations or standards and stick to the mandatory frequency even if from a technical point of view this would not be required Prolyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST MAINS CABLE WIRE COLOR EU COLOR US PIN PICKLE FOR LOW VOLTAGE CONTROL WIRE COLOR EU FUNCTION PIN PET around ellowiGreen oo MULTI CABLES WIRE NO MAX CABLE LENGTH IN METERS LIFTING CAPACITY 1 5 MM2 CORDS 2 5MM2 CORDS PROLYFT HOIST 400V 50 hz 230v 50hz 400V 50 hz 230v 50hz 250g 200 zs 255 s Items to be inspected are those of the frequent inspection plus at least the following gear box lubricant level lifting capacity in static and dynamic response using a testing facility any screwed connection in power and control cords and connectors and resealing if needed wear measurement on load chain dead end fixation of load chain chain bag condition and chain bag suspension points and so on All of these items are to be documented and signed by the person having executed the inspections page 21 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in
62. rake properly set Replace the electrical cover reconnect the power supply and check chain hoist brake action Figure 4 Brake Assembly A CAUTION Be sure the bottom of the armature does not bear against the splined adapter H As adjustments are made the built in clearance will be reduced When this clearance is gone REPLACE BRAKE DISCS Minimum allowable disc thickness is 4 1 See Figure 12 for further illustration WIRING Refer to Figures 7A and 7B on page 21 Single phase units 115 230V are wired for 230V and 3 phase units 230 460V are wired tor 230V 460V unless otherwise specified when ordering Conversion of dual voltage units can be done simply and quickly as follows 1 DISCONNECT CHAIN HOIST FROM POWER SUPPLY and remove electrical cover 2 When converting a 380 460V 3 phase unit to 230 3phase add the C4 C5 and C6 jumper wires as shown in Figure 7A and 7B The T4 T5 and T6 motor leads are then spliced together one of the transformer leads H2 Low voltage and H4 High voltage is connected to the contactor as shown on the diagram depending on the voltage 3 Make sure that all of the screw clamps on the contactor and terminal blocks are tightened Tug on the connected wires to ensure they are securely connected and match the diagram to ensure proper wiring 4 Check the operation of the chain hoist ensuring that the direction of travel is correct See INSTALLING THE CHAIN HOIST page 10
63. re cable 5 Faulty 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 lifting motor 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 overheats 1 Excessive load Low voltage 3 Extreme external heating 4 Frequent starting or reversing 5 Brake dragging N Reduce load to within rated capacity of chain hoist Determine cause of low voltage and bring up to within plus or minus 10 of the voltage specified on the motor As the ambient temperature rises towards the 130 F limitation of the unit frequency of the chain hoist operation Excessive inching jogging or reversing should be avoided since this type of operation will drastically shorten the life Check brake adjustment See BRAKE ADJUSTMENT page 17 Measure voltage at the chain hoist reversing contactor while lifting a load must be limited to avoid overheating of the motor See ADVERSE ENVIRONMENTAL CONDITIONS page 5 of motor contactor and brake Lack of proper lifting speed 1 chain hoistr overloaded 2 Brake dragging 3 Low voltage 4 Overload limiting clutch intermittently slipping RON R
64. rified to be correct permanent connections can be made at the power source 5 Once the controls are properly connected run the motor in the down direction to allow enough length of chain to attach the load hook to its suspension point 6 Ensure that the load will bear on the saddle of the hook 7 The chain hoist should be permitted to align itself for a straight and plumb pull A CAUTION Do not attempt to pull around corners Chains that move can be hazardous in grinding action and eating itself into softer surfaces such as aluminium trusses 8 Reset the limit switches when present to allow for only the amount of travel required See LIMIT SWITCH ADJUSTMENT page 17 9 It is imperative that no twists exist in the chain especially on double reeved units Chain twists can create hazardous conditions Twists occur when the 2 ton load block is capsized or when the slack end of chain is not properly attached at the side of the chain hoist 10 If necessary lubricate the chain see LUBRICATION page 18 Touring 1 Chain hoists used in the touring sector are often moved from one venue to the next in repetitive use This might cause more than average wear and tear on the hoist Therefore a sturdy and protective transport facility flight case or road box is strongly advised This should give adequate support to the housing of the chain hoist in any direction and have a eparate compartment for the load chain 2 Chai
65. roduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com 13 14 15 16 17 18 17 20 21 22 23 DO make sure the hook latches are closed and not supporting any parts of the load DO make sure the load is free to move and will clear all obstructions DO make sure the power and control cables and connectors have proper stress relieves and are never fully tight during lifting or lowering movement DO warn personnel of an approaching load DO avoid swinging the load or hook DO inspect the chain hoist regularly replace damaged or worn parts and keep appropriate records of maintenance DO use a protective cover for the chain hoist to prevent exposure to rainfall when applied outdoors DO only use factory recommended parts when repairing the unit DO protect the load chain from weld splatter or other damaging contaminants DO lubricate load chain according to manufacturer s recommendations DO transport the chain hoist in a flight case or other sturdy amp protective facility hooks are equipped with sturdy hook latches OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST CHAIN HOIST SPECIFICATIONS The Prolyft is a rugged and portable chain hoist designed for the demands of rigging applications With its compact construction and ability to operate inverted the Prolytt
66. roducts or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST INSPECTOR S REPORT REMARKS LIST DEFICIENCIES AND RECOMMENDED ACTION Inspector s Date Signature Inspected Approved by Figure 8B Recommended Inspector s Report RECOMMENDED LUBRICATION SCHEDULE LIFTING MOTOR FIGURE amp COMPONENT TYPE OF LUBRICANT TYPE OF SERVICE AND REFERENCE NO USE ONLY NEW LUBRICANT FREQUENCY OF LUBRICATION HEAVY NORMAL INFREQUENT Figure 18 SAE 90 extreme pressure EP gear oil ini eras ear A a 8A a 8 amp 30 Load Hook Bearing SAE 30 gear or motor oil Weekly Monthly NLGI 2 multi purpose Ref No 27 Bushing Assembly lithium base grease At periodic inspection See Figure 8A Figure 19 Idler Sheave Bearing NOTE All bearings except hook and idler sheave bearings are prelubricated and sealed This lubrication schedule is based on a chain hoist operating in normal environment conditions Lifting motors operating in adverse atmospheres containing excessive heat corrosive fumes or vapors abrasive dust etc should be lubricated more frequently Figure 9 Recommended Lubrication Schedule Prolyte Products Group 2004 page 25 of 37 Prolyte has made every effort t
67. roperty of the vendor and must be Alterations or modifications of equipment and use of returned to the vendor at his prior approved expense AA EAA repair parts can lead to dangerous operation TO AVOID INJURY For components of relative particular importance that are not Do not alter or modify equipment manutactured by the vendor or his authorised service point and Do not use equipment to lift support or otherwise which carry the brand name of specialised manufactures the transport people i Do not suspend unattended loads over people manutacture s guarantee which can vary is applicable APROLYFT PROLYFT BV Industiepark 9 PO Box 41 Leek The Netherlands tel 31 0 594 85 15 15 e fax 31 0 594 85 15 16 www prolyft com 2004 PROLYFT The Netherlands
68. rs of age to operate the 3 chain hoist 5 NOT lift more than rated load for the chain hoist 6 NOT operate a chain hoist unless it has been securely 4 attached to a suitable support 7 NOT use chain hoists with load chains that are knotted twisted kinked damaged or worn 8 NOT use the chain hoist to lift support or otherwise transport people without additional or mandatory local or national safety precautions 3 9 NOT let anyone stand beneath a moving load 10 NOT move a load in any manner that can endanger persons 11 NOT operate unless all persons are and remain clear of the supported load 7 12 NOT operate unless load is centered under chain hoist 13 NOT use limit switches as routine operating stops 8 They are emergency devices only 14 NOT operate a chain hoist when it is restricted from forming a straight line from hook to hook in the direction of loading 15 NOT use load chain as a sling or wrap the load chain around 10 load 16 NOT apply the load to the tip of the hook or to the hook latch 11 17 NOT apply load unless load chain is properly seated in the chain sprocket s Prolyte Products Group 2004 12 DO make sure that the weight of the load to be suspended is known and in accordance to the lifting capacity of the chain hoist In multiple lifts make sure a rigging plot is present DO make sure that the hoist operator is in good physical and mental condition DO check th
69. s buffers sprockets chain buckets hooks and cabling problems resulted from repairs modifications or alterations made by persons other than factory or Prolyft Authorized Warranty service personnel the hoist has been abused or damaged as a result of an accident repair parts or accessories other than those supplied by Prolytt Authorised Warranty Service points have been used on the hoist failures caused by a lack of maintenance Equipment and accessories not of the seller s manufacture are to be warranted by their manufacturer Except as stated herein Prolyte makes no other warranties express or implied including warranties of merchantability and fitness for a particular purpose currently 1Am 2m pending Prolyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST If for reasons outside the control of the vendor the delivery is delayed the time lag can not exceed 3 months If the use installation of the hoist is delayed the extension of the guarantee limited to 3 months must be requested and written conformation obtained The warranty only applies for original service point or factory installed spare parts including chain The warranty excludes any other services or indemnities The repairs covered by the guarantee are carried out as a rule in the workshop of the service point All replaced parts become the property of the vendor and must be ret
70. s Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com 6 Connect the power and control cable and make sure these will have proper stress relieves and sufficient slack in every direction of planned tilting of the load Use Velcro or cable strings to tie the cable to the hoist body or lifting suspension hook A CAUTION Tie wraps may eventually cut the cable or the conductors and gaffer tape might leave remains of the glue layer to cable or hoists gathering dirt and dust etc 7 Lower the chain hook by letting the chain run out to the required height 8 Put the load under the chain hook WARNING Do NOT move the chain hook towards the load This will result in swaying or side pulling and can become hazardous when the load is lifted 9 Attach the load to the chain hook either to a lug plate eyebolt or using one or more slings 10 Run the chain up until the load chain just taut 11 Check all lifting and slinging connections and lift the load until it is freely floating of the ground 12 Visually check the whole lifting structure from chain hoist and cables through the load chain down to the load A CAUTION Any unusual or disruptive appearance of chain links along the stretch of load chain might indicate deformation of one or more links that should be inspected before the lifting operation starts 13 Remove all people from the area before you start lifting the load D
71. se to about 1 meter 3 ft above the floor A CAUTION Always guide the chain hoist using the handles Never use the chain to move the chain body around 9 Attach the chain bag to the chain bag mounting bracket with the chain bag hooks facing outwards 10 Take slack chain from the floor and put this into the chain bag with as less twisting as possible 11 Litt the dead end chain from the chain guides when possible to about 1m from the chain bag bottom to relieve possible twists Let it sink back in smoothly 12 Attach the load to the suspended hoist WARNING Do NOT move the suspended chain hoist towards the load This will result in swaying or side pulling and can be hazardous when the load is lifted 13 Attach the load to the chain hoist suspension hook Use an eyebolt or lashing eye fixed to the load or proper sling s that will not harm the load itself 14 Use a shackle when a basket hitch is used and connect this to the suspension hook A CAUTION Prevent slings to have a side force to the suspension hook Two wire rope thimbles might not fit the suspension hook saddle area and can cause hazardous situations 15 Make sure the chain bag is hanging free of the load and the inlet of chain is not obstructed 16 Run the load chain up until it is just taut 17 Visually check the whole lifting structure from chain hook down along the load chain to the load A CAUTION Any unusual or disrup
72. spect chain guides and load sheave for wear replace as needed LOAD CHAIN CLEANING Clean the load chain with acid free solvent and coat with new SAE 90 gear oil Wipe excess oil to prevent dripping Never apply grease to the chain CHAIN END STOP The end stop on the dead end chain should be mounted on the 11th link No less than 11 links should be in between the dead end and the chain stop CHAIN END The dead end of the chain needs to be connected to bolt which is used to connect the chain bag bracket to the jam free guide see page 33 pos 10 and fig 5 page 19 Prolytt load chain is hardened and therefore difficult to cut The following methods are recommended when cutting a length of new chain from stock or cutting a worn chain a Use a grinder and nick the link on both sides then secure the link in a vise and break of with a hammer b Use a bolt cutter with special cutter jaws for cutting hardened chain page 17 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com LIMIT SWITCH ADJUSTMENT Refer to Figure 5 WARNING If the phase are not connected properly t
73. supply Be sure that the green ground wire is properly grounded See INSTALLATION page 5 8 Carefully jog the UP button and run the joined pieces of chain into the lifting motor until about 15 of the new chain comes out the other side DISCONNECT CHAIN HOIST FROM POWER SUPPLY 10 Remove the C link and the old chain Remove the chain stop from the old chain by prying off its retaining ring with a flathead screwdriver If attached remove the old chain from the shackle on the side of the lifting motor by opening up the split link 11 Attach the chain stop to the slack end of the new chain by capturing the 12 link with the two stop halves positioned with their tapered ends pointing towards the lifting motor Slide the sleeve over the halves and attach the retaining ring If you are not using a chain container attach the slack end of the new chain to the shackle on the side of the unit using the split link DO NOT allow twists in the chain 12 Adjust the lower limit switch See ADJUSTING LOWER LIMIT page 17 13 Attach the load block on single chained chain hoist using a new load block screw or pin See Figure 17 On double chained chain hoist feed the chain through the load block welds of the upstanding links will be in towards the sheave and fasten the end of the chain to the chain support using a new chain support pin See Figure 17 Be sure there are no twists in the chain 14 Adjust the upper limit switch S
74. t consult a qualified structural engineer 3 Chain hoists should not experience voltage drops of more than 10 of the supply voltage It is critical to use adequate sized power cables On multiple voltage chain hoists the installer must ensure that the chain hoist is correctly wired for the intended voltage See WIRING page 21 Prolyte Products Group 2004 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com oud alt old ancien excl UK Gondiucheur che protection N nulleiceng Meuran nieubral conductor OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST nieuw meu new nouveau imel UK L L1 L l 8 6L3 Sa G nd meung J WARKEING ALWAYS DISCONNECT CHAIN HOISTS FROM POWER SUPPLY before removing electrical cover or when making any electrical connection in the chain hoist The user s control board must be grounded in accordance with the electrical codes that are applicable in the local area Power cables to chain hoists must include a ground conductor The power pigtail includes a yellow green ground conductor Th
75. tion of travel is coherent with push button operation Do NOT make side pulls with the chain hoist 5 Do NOT sling the chain hoist load chain around an attachment point Use a separate and proper sling 6 Run the motor until the load chain is as good as taut 7 Check the load being held securely in the hook or sling chains before it is raised 8 Never stand or allow people beneath a moving load 9 Do NOT move a load in such a manner as to endanger personnel 10 Do NOT move the load by intermitent use of the control button 11 Do NOT lower into areas where visibility is obscured unless a specific person is guiding the operation 12 Do NOT operate unless limit switch devices function Test without load prior to each time of use 13 Do NOT operate when chain hoist is not over the centre of gravity of the load 14 Do NOT operate a damaged or malfunctioning chain hoist EMERGENCY PROCEDURE LOWERING WITHOUT POWER If the power fails with a load suspended the chain hoist will automatically stop In an emergency and in an emergency only the load can be lowered without power as follows 1 DISCONNECT CHAIN HOIST FROM POWER SUPPLY AND REMOVE ELECTRICAL COVER 2 Open disc brake manually by using two screwdriver blades one on each side of the brake at a point close to the brake spring posts Apply pressure to the underside of the armature plate points X Figure 4 page 17 to close the solenoid and rele
76. tive appearance of chain links along the stretch of load chain might indicate deformation of one or more links This should be inspected before the lifting operation starts 18 Check all suspension connections as well as the power and control cable s 19 Remove all people from the area before you start lifting the load Do NOT allow any people to stand under the moving load 20 Make sure you have a full visual view on the complete travel path of the load 21 Litt the load to the required height page 7 of 37 Prolyte has made every effort to ensure the accuracy of this manual No liability will be accepted for errors Prolyte reserves the right to change or alter their products or manuals without prior notice No part of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 851515 Fax 31 0 594 851516 www prolyte com WARNING Do not use the control button in an intermittent switching manner This can lead to hazardous situations The chain hoist motor can get overheated and considerable increase of forces due to dynamic loading can be caused WARNING Do not let anyone stand under the suspended load until this is properly secured using a secondary suspension 23 Add a secondary in between support structure and the load when persons have to get under the load 24 Make sure this secondary is as tight as possible preferably
77. urned to the vendor at his prior approved expense For components of relative particular importance that are not manutactured by the vendor or his authorised service point and which carry the brand name of specialised manufactures the manutacture s guarantee which can vary is applicable TWO YEAR WARRANTY The hoist should not exceed the FEM class of operating times an use The inspection should be carried out at a minimum of once a year local or specific regulations can vary to this sequence Every hoist is thoroughly inspected and tested prior to shipment from the factory and service point Should any problem develop return the complete hoist prepaid to your nearest Prolyft Authorised Warranty Service point If inspection reveals that the problem is caused by defective workmanship or material repairs will be made without charge and the hoist will be returned transportation prepaid This warranty does not apply where 1 deterioration is caused by normal wear abuse improper or inadequate power supply eccentric or side loading overloading chemical or abrasive actions improper maintenance or excessive heat nor for lifting chains chain guides buffers sprockets chain buckets hooks and cabling 2 problems resulted from repairs modifications or alterations made by persons other than factory or Prolytt Authorized Warranty service personnel 3 the hoist has been abused or damaged as a result of an accident 4 repa
78. y and not vertically or place the hoist into a designated flight case Prolyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL Prolyft PLE 11 12 13 series CHAIN HOIST 10 Run the chain out until approx 0 5m 1 5 ft is remaining on the dead end A CAUTION When running out the chain make sure the incoming chain part is free of loops twists etc and the outgoing part is not piling up on top of the motor housing This might result in jamming or catching chains parts and can cause severe damage to individual chain links thus resulting in hazardous lifting thereafter A CAUTION Never run the chain all the way to the limit switch and leave it like that Run back the chain for approx 15cm to release the limit switch 11 Disconnect power and control cables and store them into a safe area in the flight case 12 Take the chain hook from the supporting structure bring the chain down gently and guide it into the chain compartment of the flight case 13 Hook the chain hook onto the U bracket in the flight case to prevent it from twisting around and knotting with the chain during transport 14 Remove beam clamp bracket and sling or bridle materials from the supporting structure RIGGING THE HOIST IN MOTOR UP POSITION A CAUTION Parts of this procedure can involve working from an elevated platform scissors lift or cherry picker Before doing so make sure you are competent to work w

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