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Operating, maintenance and service manual Prolyft PLE-10

1. LJ Em EC XC 7 r c aan i DURO Gn Fai E LS A a A i e E o X 2 X aS Dal Bas 8 es APROLYFT Operating maintenance and service manual Prolyft PLE 10 250 Kg Follow all instructions and warnings for inspecting maintaining and operating this hoist The use of any hoist presents some risk of personal injury or property damage That risk is greatly increased if proper instructions and warnings are not followed Before using this hoist each operator should become thoroughly familiar with all warnings instructions and recommendations in this manual Retain this manual for future reference and use Forward this manual to the 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 Safe au tasas iq M IA ton Lutetia dod Mu EAE aie oh deh mah RIS dat EIC D TE 3 Rep xod etum at lar breue Alc E Ea 4 uy cud d s c hd MM I DIM MPIRd IM MI MM e MM IC LU 5 SHIA WINS TC Malle A GIICE o dua coute ones wae adn dance IR I LI M ARN DC DD
2. OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 BRAKE FIELD ASSEMBLY INCLUDES COIL BRAKE ARMATURE BRAKE SPRING FIRST PINION SHAFT BRAKE DRIVER FRICTION DISC figure 7b reaches 012 inch 0 305 mm The brake spacer should be no more than 012 inch 0 305 mm thicker than the combined thickness of the brake disc and armature plate Refer to Figure 7B To inspect the brake gap disconnect the hoist from power and remove brake end cover 620 132 1 Refer to Figure 8 and disassemble the brake Depress and hold the field assembly 620 122 while removing the four brake screws 620 124 The field assembly is under spring pressure and will spring out if not held During disassembly note there is a small leaf spring 620 121 on the brake driver 620 119 and this will spring out when the brake disc 620 117 is removed Examine the base plate 620 116 hex driver 620 119 brake disc 620 117 and armature 620 118 for excessive wear scoring or war page Make sure the brake disc is not glazed the coil firmly fixed in the field 620 122 and the brake spring 620 123 is not damaged Worn scored warped glazed or damaged parts should be replaced before preceding 2 Reassemble the brake making sure to install and compress the leaf spring on the brake driver while sliding the brake disc onto the driver 3 Install the four brake screws through the brake parts and mount the brake on the gear housing 620 113 Tighten t
3. staan 8 Inspection and Maintenance Check tetto Los y Rat aa Cos tu unes cesa 13 aa Gaia wrest DL DO A 14 VS CUNO NU MEM oM MM MEM RM M IM DC E E EM 15 Disgssermbly ASSSImIDIV DU Med C Post iei ci ase ctus cu cc o P DIOS Seu teo ILS deus tuns 16 Repar Paises d tat toutes ue toC pe MM II PM LUUD 19 Exploded AA de rr TR 20 21 Replacement Pars Lisi eee ene ene eee td sms E mua tele 22 23 Rao ldem LR THEE aad TM 24 American Wire Gauge AWG decere MM MM RUM Uc UE 25 CE declatatlonm or cohblofrWlly isset eue genova tb tatus didt A o Lo MEL LM LM E M MEUS QUE 26 SAFETY PRECAUTIONS Each Prolyft Hoist is built in accordance with the specifications contained here in and at the time of manufacture complied with our interpretation of applicable sections of the National Electrical Code ANSI NFPA 70 Installers are requiredto provide current overload protection and grounding in keeping with the code Check each installation for compliance with theapplicable sections of the code as well as the National State and Local Codes that may apply to the installation In addition safety code requirements associated with the operation of a hoist in the inverted theatrical position chain port up as with any mechanical equipment vary depending upon locality Therefore before installing the hoist the user should consult his insurance c
4. 1029 grease SEALS When reassembling the unit wipe the inside surface of the seals 620 108 and 620 130 with American Lubricants 1029 grease HOOK BLOCK If the hook blocks are disassembled for inspection purposes wipe the grease from the hook knob and the hook knob cavities in the hook blocks At reassembly coat the underside of the hook knob and the knob bearing surfaces of cavities in the hook blocks with Molykote BR 2 S Dow Corning Corp grease or equivalent CHAIN GUIDE LIFT WHEEL AND SHEAVE WHEEL When the hoist is disassembled for inspection and or repair the chain guide stripper sheave wheel on double chain unit and lift wheel must be lubricated with Lubriplate Bar and Chain Oil 10 R Fiske Bros Refining Co prior to reassembly The lubricant must be applied in sufficient quantity to obtain natural runoff and full coverage of these parts LOAD CHAIN Refer to page 10 for lubrication of the load chain EXTERIOR FINISH The exterior surface of the hoist has a durable scratch resistant baked powder coating Normally the exterior surfaces can be cleaned by wiping with a cloth However if the finish is damaged compatible touch up paint can be purchased from the factory Refer to page 21 for information on ordering the paint ELECTRIC BRAKE The brake is non adjustable with a nominal 004 inch 0 102 mm air gap and the brake disc must be replaced when the air gap OProlyte Products Group 2004
5. If it is open allow motor to cool If this does not correct the trouble use wiring diagram to check electrical continuity of wiring transformer contactor and control station contacts Repair wiring or replace defective part Make sure that the power supply to hoist is the same as that shown on identification plate on button of hoist Check power supply system to make sure it complies with the requirements listed under power supply system starting on page 5 Check coil continuity diodes see page 14 and connections Make sure brake disc slides freely on brake driver and brake spring is not broken Replace coil brake field repair connections remove burrs from brake driver so that brake disc slides freely and or replace brake spring Reduce load to capacity limit as indicated on identification and capacity labels on hoist Check for electrical continuity and repair or replace defective part Use wiring diagram and check wiring connections Check connections to cut out device Replace damaged device or faulty capacitor See Three Phase Hoists on page 4 See item Use wiring diagram to check electrical continuity of wiring and control station contacts epair wiring or replace defective part eck cut out device and connections to same See page 15 Repair connections and or replace cut out device See item 1G See item 1B See item 3C See item 2 See item 1G Check electric brake see page 11 especially
6. HOISTS WITH CONTACTOR BLACK CONTROL STATION 220 3 50 230 3 60 HOISTS WITH CONTACTOR BLACK CONTROL STATION 380 3 50 415 3 50 460 3 60 HOISTS WITH CONTACTOR BLACK CONTROL STATION pages 17 of 26 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com figure 12a Pin Retainer Cut Out Device Jumpers 2 and Cap figure 12b 620 157 Hook Block Screw Double reeved 500 600 and 1 000 Ibs 226 272 and 453 kg 125 14 1 Single reeved 250 300 and 500 Ibs 113 136 and 226 kg 620 152 Power Cord Ground Screw the pin retainer plate 620 125 has been assembled to the main frame 620 107 On single phase units slide jump ers 2 and CAP through the wire slot in the main frame Route these wires around the rotor bearing boss in the main frame as shown in Figure 12A Attach the brown and blue stator leads and 2 jumper to cut out device refer to wiring diagram Slide the cut out device into the cavity as shown Push the cut out device down until it sets on the main frame Place the capacitor on top of th
7. OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 A WARNING Alterations or modifications of equipment and use of non factory repair parts can lead to dangerous operation and injury TO AVOID INJURY Do not alter or modify equipment Do not use equipment to lift support or otherwise transport people Do not suspend unattended loads over people 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 Prolyft Authorized Warranty service personnel 3 the hoist has been abused or damaged as a result of an accident 4 repair parts or accessories other than those supplied by Prolyft 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 Exc
8. Spline on end First Pinion and Shaft 28605 for 1 2 Ib Can 28616 for 1 lb Can 28617 for 4 16 Can Grease Century Lubricants HB 11 3 Oil Graphite Mixture Hercules Packing Co Moly Duolube 67 40628 for 1 Pint Can Oil Fiske Bros Lubriplate Bar and Chain Oil 10R Load Chain 28608 for 1 Pint Can 28619 for 1 Gal Can 28606 for 1 2 Ib Can 28618 for 1 lb Can Grease Dow Corning Molykote BR 2 S Lower Hook Knob When ordering lubricants specify the type of lubricant part number and packaged quantity required Touch up Paints for Prolyft Hoist Order 1 case 12 12 oz Aerosol Cans of Black Touch up paint Part Number 84189 Touch up paints are only available in case quantities NOTE When painting hoists also order warning labels etc that may be coated during painting OProlyte 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com pages 23 of 26 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 exte
9. TEKENAAR S HARBRINK eS DATUM 07 11 2007 MAATEENHEID MM GEWIJZIGD KLANT PRO A TEK NR GECONT DOOR PROLYTE PRODUCTS aou A m CHAIN 4 x 12 2 inae diui sisi pede dpt pare i fd ie A4 OProlyte Products Group 2004 pages 12 of 26 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com Inspection chart Prolyft hoist Hoist model PLE 10 amp 20 Hoist serial no Name inspector Possible Deficiencies Action Requirec ee me Chainbag APRI inspect chainbag for proper mounting size and for presence of rips or tear Nameplates Decals Warning Labels EE Missing damaged or illegible Check if the RF Tag can be read Missing damaged or not readable check operation of chain hoist with no load prensent up down check for ahy mE abnormal noises 1 Any deficiency causing improper operation 2 Pitting or deterioration remove brake ass 1 measure and record the combined thickness of the brake disc an brake armature 2 measure the thickness of the brake spacer The brake spacer should be no more than 012 inch 0 305mm thicker than the combined thic
10. and federal regulations pages 10 of 26 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com Star and 2 digit 3 digit year code date code Use only Star H grade load chain and factory replacement parts Use of other chain and parts may be dangerous and voids factory warranty figure 7a If the gears are removed from the housing wipe the excess grease off the outside surtaces of the Protector with a soft cloth and degrease the remaining gears and housings Upon reassembly add 2 oz of the above grease to gears and housing Also coat the spline on the end of the first pinion and shaft 620 131 with a Molydisulphide lubricant such as Moly Duolube 67 Hercules Packing BEARINGS Rotor bearings 620 102 and 620 103 are pre lubricated and require no lubrication Needle bearings 620 109 620 114 620 115 620 128 and 620 164 are packed at assembly with grease and should not need to be re lubricated However if the housings 620 113 and 620 107 litt wheel 620 127 or sheave wheel 620 162 have been degreased these bearings should be greased using American Lubricants
11. from the hoist head The UP and DOWN buttons are momentary type and the hoist will operate in the selected direction as long as the button 15 held in the depressed position Release the push button and the hoist will stop It is preferred that the load always be tied off with auxiliary chains or cables before access to the area beneath the load is permitted As an alternative the system may be designed such that malfunction or failure of one hoist s load bearing components does not cause load loss and or overloading of any other hoists in the system Note that in such a system hoist performance and function must be monitored visually or with the use of load cells Check the supporting structure to which the load hook is to be attached Make sure the attachment point as well as the structure have sufficient strength to safety absorb the load imposed If in doubt consult a registered engineer and local building codes pages 7 of 26 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com Orange Station for Hoists Without Contactor Black Station for Hoists With Contactor ye Control Station Depr
12. i my E nrc CONTROL i STATION CUT OUT DEVICE t B BLACK j Y YELLOW i BR BROWN BLUE G GREEN OW le unc tag kasd en weaned E R RED nue de EIE oe eo W WHITE HOIST CONNECTION LL MECHANICAL POWER INTERLOCK SUPPLY SkWHEN UP OR DOWN BUTTON IS DEPRESSED CONTACT OF DEVICE WIRE NUT CLOSES AS CURRENT THRU MOTOR O TERMINAL REDUCES THE CONTACT OPENS TO DE ENERGIZE START WINDING CONTROL CORD zE HOIST MOTOR CONTROL STATION 5 zu P PURPLE B BLACK Y YELLOW BR BROWN BL BLUE G GREEN R RED v rer en LM e 1 i i t i l i i H l i THERMAL CUTOUT W WHITE lucus x c xDD e CONNECTION G Y MECHANICAL BR b INTERLOCK BL B WIRE NUT POWER O TERMINAL SUPPLY CONTROL CORD HOIST MOTOR ee ee ee STATION P PURPLE O ORANGE B BLACK Y YELLOW BR BROWN BL BLUE G GREEN i i i i i i CONTROL i i i i i i i i R RED W WHITE Ne eoa tx CUTOUT 4 CONNECTION C Y HOIST iL MECHANICAL BR E INTERLOCK B YK WIRE NUT POWER TERMINAL SUPPLY Prolyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 115 1 60
13. lt gt O O o n 620 179 COMPONENTS BOARD OUTBOARD 620 180 COMPONENTS BOARD INBOARD 620 181 1 1 620 165 SHEAVE WHEEL THRUST WASHER Double reeved 2 620 169 CAPACITY WARNING LABEL 250 Ibs 300 Ibs xem pn 73715 48 Volt Secondary 220 380 primary A8 Volt Secondary 460 primary 115 Volt Secondary 230 460 primary 115 Volt Secondary 575 primary A8 Volt Secondary 575 primary 620 182 DIODE ASSEMBLY 620 183 CONTROL CORD PLUG 620 184 POWER CORD PLUG CONTACT 620 185 CONTACTOR JUMPER FACTORY Specify No Req d 24842 620 187 VOLTAGE SUPPRESSOR 20901 230 3 50 60 380 3 50 and 460 3 60 Hoists 1 920756 575 3 60 Hoists 20755 620 188 GROUND JUMPER 620 189 CHAIN GUIDE SCREW 620 190 CHAIN GUIDE SPACER 20669 20851 20834 20831 20876 1 20383 20861 20869 2 940802 600 Ibs 1 000 Ibs 1 620 170 1 0 LABEL ALL HOISTS 620 171 WARNING LABEL 620 172 PROSTAR LABEL 620 173 WIRE NUT Specify No Req d 620 174 GASKET 620 176 CONTROL CORD ASSEMBLY includes cord strain relief and warning tag 20 ft lift For black control station and Z m 73 620 193 BRAKE SPACER 620 196 HOOK BLOCK SCREW L W DOUBLE REEVED Part Number for Packaged Lubricants Used in the Prolyft Hoist Refer to Page 8 for Lubrication Instructions Part Numbers and Packaged Quantity of Lubricants Lubricant lype Usage Lubricant
14. 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com CLAIM PROCEDURE figure 2A INSTALLATION MOUNTING THE HOIST Attach the hoist to the truss structure to be lifted using the mounting hook Figure 3B Be sure that the attachment point is held in the lowermost part of the hook arc and the latch is tightly against the hook tip Also the attachment point must have sufficient strength to safety absorb the load imposed If in doubt consult a registered engineer and local building codes A WARNING Operating a unit with obvious external damage may cause load to drop and that may result in personal injury and or property damage TO AVOID INJURY Caretully check unit for external damage prior to installation POWER SUPPLY SYSTEM A WARNING An inadequate attachment point may allow the hoist and load to fall and cause injury and or property damage TO AVOID INJURY Make sure the attachment point has sufficient strength to hold several times the hoist and its rated load Refer to Figure 4A or 4B on page 7 To insure proper operation to avoid damage to hoist and electrical system and to reduce the risk of electric shock or fire the branch circuit supplying power to the hoist must 1 Have ample capacity to prevent excessive voltage drop during starting an
15. the open position A WARNING Failure to properly ground the hoist presents the danger of electric shock TO AVOID INJURY Permanently ground the hoist as instructed in this manual NOTE IN THIS MANUAL NOMINAL VOLTAGES ARE USED WHEN REFERRING TO POWER SUPPLY SYSTEMS HOWEVER WITH NO MODIFICATION THE PROLYFT HOIST WILL OPERATE ON A RANGE OF VOLTAGES AS INDICATED BELOW NOMINAL VOLTAGE VOLTAGE RANGE 208 240 440 480 200 240 400 430 E E 3935 ws 5545 pages 5 of 26 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com Making sure the hoist will operate on the power Power suppl BE supply system figure THREE PHASE HOISTS Since the motor in a three phase hoist can rotate in either direction depending on the manner in which it is connected to the power supply the direction of hook movement must be checked during the original installation and each time hoist is moved to a new location as follows 1 Move the manual disconnect switch handle to the OFF position 2 Connect the BROWN BLUE AND BLACK wires of hoist power cord to load s
16. 05mm of Chain Chain Stop figure 13b A WARNING Cutting chain can produce flying particles TO AVOID HEALTH PROBLEMS e Wear eye protection Place a shield over chain to prevent flying objects REPAIR PARTS ORDERING INSTRUCTIONS The following information must accompany all correspondence and orders for replacement parts Hoist rated load from identification plate Serial number of the hoist stamped below identification plate Voltage Phase Hertz from identification plate Length of lift Key number of part from parts list Number of parts required Part name from parts list Part number from the parts list CON AOOBRWDN NOTE When ordering replacement parts it is recommended that consideration be given to the need for also ordering such items as gaskets fasteners seals etc These items may be damaged or lost during disassembly or just unfit for future use because of deterioration from age or service A WARNING Using commercial or other manufacturer s parts to repair Prolyft Hoists may cause load loss TO AVOID INJURY Use only factory supplied replacement parts Parts may look alike but our parts are made of specific materials or processed to achieve specific properties pages 19 of 26 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
17. 1 Use a grinder and nick the link on both sides see right then secure the link in a vise and break off with a hammer 2 Usea 7 177 mm minimum diameter by 1 8 3 1 mm thick abrasive wheel or type recommended by wheel supplier that will clear adjacent links 3 Use a bolt cutter see right with special cutter jaws for cutting hardened chain Jaws should be 1 inch 25 4 mm long TESTING Before using all altered repaired or used hoists that have not been operated for the previous 12 months must be tested by the user for proper operation First test the unit without a load and then with a light load of 50 pounds 23 kg times the number of load supporting parts of load chain to be sure that the hoist operates properly and that the brake holds the load when control is released Next test with a load of 125 of rated capacity In addition hoists in which load sustaining parts have been replaced should be tested with 12596 of rated capacity by or under the direction of an appointed person and written report prepared for record purposes After this test check that the Protector functions If the Protector permits lifting a load in excess of 20096 of rated load it should be replaced If the Protector prevents lifting of a load of 125 of rated capacity reduce load to rated capacity OProlyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 p Myan fj Chain Stop Screw 12 3
18. 113 136 226 250 272 453 and 500kg Standard features of the Prolyft Electric Chain Hoist include e Alloy steel oblique lay lift wheel that provides constant chain speed and reduces chain wear e Hoistaloy load chain for long and dependable service Grease lubricated hardened spur gears provide smooth and quiet operation Thermally protected hoist duty motor e Forged steel upper and lower hooks with latch e Protector that prevents lifting dangerous overloads e D C disc type motor brake plus regenerative braking e 10 foot 3 M lift Longer lifts can be supplied on a per order basis e Lightweight die cast aluminium frames and covers Ball or needle bearings at all rotating points e Compact yet rugged design provides minimum headroom and long trouble free service e CUL listed e Lifetime Warranty UNPACKING After opening the carton Figure 2A carefully inspect the hoist frame cords hooks chain and control station for damage that may have occurred during shipment If there is damage refer to the packing slip envelope Make sure that the power supply Figure 3A to which the hoist is to be connected is the same as that shown on the identification plate located on bottom of hoist pages 4 of 26 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
19. 25 620 101 620 167 620 165 620 129 620 19 620 162 620 108 20143 620 164 620 14 i 620 157 620 163 e 620 189 7 620 165 2 E 620 156 620 192 620 146 620 157 620 190 4 9 620 161 620 147 620 160 Cane 5 58 620 168 fm x 620 159 Double Reeved Units Bc Lower Hook Block 620 157 620 156 PROLYFT a CHAIN HOIST le Reeved Units EXPLODED VIEW rer Hook Block OProlyte Products Group 2004 pages 21 of 26 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com REPLACEMENT PARTS LIST KEY PART NAME NUMBER PART NUMBER 620 100 uu 115 1 uu Hoists 220 1 50 Hoists 20328 220 3 50 60 Hoists EM 20329 380 3 50 415 3 50 and 460 3 60 Hoists L 20330 575 3 575 3 60 Hoists sd Hoists 620 101 ROTOR ASSEMBLY teks 620 109 and 620 10 620 105 MOTOR END COVER 20321 620 106 S ERN 115 1 50 60 Hoists 220 50Hoss S 620 107 MAIN FRAME Includes 620 108 AND 620 109 620 108 LIFTWHEEL SEAL EN 620 109 PROTECTOR BEARING MAIN FRAME SIDE 620 110 CUT OUT DEVICE Am min 133 fmp 1 20660 620 111 m b
20. D GROUND SCREW 982877 CONTROL STATION AND CORD ASSEMBLY Includes control station cord warning tag uppergrommet Orange Control Station for d a 1 20607 Black Control Station for ss 90608 For other lifts contact factory a al HOOK BLOCK Double reeved 620 157 HOOK BLOCK SCREW Single reeved 920730 pages 22 of 26 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 Prolyft ELECTRIC HOIST PARTS LIST PART NUMBER PART NAME NUMBER HOOK BLOCK SCREW Double reeved 620 159 HOOK Includes 620 138 620 159 LATCHLOK HOOK 1 620 160 DEAD END PLATE Double reeved 620 161 DEAD END PIN Double reeved 920724 m 2 1 920720 620 162 SHEAVE WHEEL W 620 164 Double reeved 620 163 SHEAVE WHEEL SHAFT Double reeved 620 164 SHEAVE WHEEL BEARING Double reeved PART NAME 10 ft lift 15 ft lift PART NUMBER N o p For other lifts contact factory 620 177 FRAME SPACER 620 178 CONTACTOR includes power jumpers 115 VAC Coils 20375 20814 20787 20777
21. ICATION A small amount of lubricant will greatly increase the life of load chain Do not allow the chain to run dry Keep it clean and lubricate at regular intervals with Lubriplate amp Bar and Chain Oil 10 R Fiske Bros Refining Co or equal lubricant Normally weekly lubrication and cleaning is satisfactory but under hot and dirty conditions it may be necessary to clean the chain at least once a day and lubricate it several times between cleaning When lubricating the chain apply sufficient lubricant to obtain natural run off and full coverage especially in the interlink area LUBRICATION Refer to Exploded View and Parts List pages 17 through 21 NOTE To assure extra long life and top performance be sure to lubricate the various parts of the Prolyft Hoist using the lubricants specified below If desired these lubricants may be purchased from the factory Refer to page 21 for information on ordering the lubricants GEARS e Protector 620 111 should operate for the normal life of the hoist without service The device has been lubricated and calibrated by the factory and should not be adjusted CAUTION The Protector is to be used with American Lubricants 1029 grease Do not use any other grease or the Protector will not operate properly and parts could be damaged OProlyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 MEASURE 11 PITCHES figure 6b The gears and Protector are
22. T attempt to lengthen the load chain or repair damaged load chain 11 NOT operate hoist when it is restricted from forming a straight line from hook to hook in the direction of loading 12 NOT use load chain as a sling or wrap load chain around load 13 NOT apply load to the tip of the hook or to the hook latch 14 NOT apply the load unless load chain is properly seated in the chain wheel s or sprocket s 15 NOT apply load if bearing prevents equal loading on all load supporting chains 16 NOT operate beyond the limits of the load chain travel 17 NOT leave load supported by the hoist unattended unless specific precautions have been taken 18 NOT allow the load chain or hook to be used as an electrical Due OProlyte Products Group 2004 19 20 OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 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 hoist 21 NOT operate a hoist on which the safety placards or decals are missing or illegible 22 NOT operate a hoist unless it has been securely attached to a suitable support 23 NOT operate a hoist unless load slings or other approved single attachments are properly sized and seated in the hook saddle 24 NOT use the hoist load limiting or warning device to measure load 25 NOT use limit devices as routine operating stops unless allowed by manufacturer They are emergency devi
23. ain hoist Reversing Contactor other Loose connections burned or pitted contacts Electrical Apparatus Apply statical loadtest to check clutch Correct slipage level and load holding level 1 remove the motor end cover and visually inspect the components for signg of wear deterioration or improper operation 2 Remove the rotor and visually inspect the splines of the first pinion shaft for signs of wear and break settings Additional remarks NI TROUBLE SHOOTING Always disconnect unit trom the power supply system before removing hoist covers or the back cover of control station 9 A Probable Cause Hook does respond control station No voltage at hoist Open control circuit due to loose connections or broken wires in circuit motor thermal protector open control station contacts not closing open or shorted winding in transformer transformer thermal cut out open mechanical binding in contactor open or shorted winding in contactor coil Wrong voltage or frequency Low voltage Brake not releasing due to open or shorted coil defective diodes or brake disc binding Excessive load Phase failure single phasing three phase units only open circuit grounded or faulty connection in one line of power supply system hoist wiring contactor motor leads or windings Hook moves in wrong direction Wiring connections reversed in control station or hoist Failure of cut out
24. amaged NOTE To perform some of the periodic inspections it is necessary to partially disassemble the hoist Refer to Disassembly Assembly starting on page 14 Any deficiencies noted must be corrected before the hoist is returned to service Also the external conditions may show the need for more detailed inspection which in turn may require the use of non destructive type testing Any parts that are deemed unserviceable are to be replaced with new parts before the unit is returned to service It is very important that the unserviceable parts be destroyed to prevent possible future use as a repair item and properly disposed of HOOK INSPECTION Hooks damaged from chemicals deformations or cracks or that have more than a 10 twist from the plane of the unbent hook or excessive opening must be replaced Any hook that is twisted or has excessive throat opening indicates abuse or overloading of the unit Other load sustaining components of the hoist should be inspected for damage On latch type hooks check to make sure that the latch 15 not damaged or bent and that it operates properly with sufficient spring pressure to keep the latch tightly against the tip of the hook and allow the latch to spring back to the tip when released If the latch does not operate properly It should be replaced See Figure 5B Pg 8 to determine when the hook must be replaced LOAD CHAIN Chain should feed smoothly into and away trom the hoist or hook
25. avoid moving a load over heads of other personnel Warn personnel of your intention to move a load in their area Do not leave unsecured load over people Do not leave the load suspended in the air unattended Permit only qualified personnel to operate unit Do not wrap the load chain around the supporting structure and hook onto itself as a choker chain Doing this will result in The loss of the swivel effect of the load hook which could mean twisted chain and a jammed liftwheel The chain could be damaged at the load hook After positioning secure load by using auxiliary cables and or chains On the Double reeved 500 600 and 1 000 lbs 226 272 and 453 kg hoists check for twists in the load chain A twist can occur if the lower block has been capsized between the strands of chain Reverse the capsize to remove twist Do not allow a load to bear against the hook latch The latch is to help maintain the hook in position while the chain is slack before taking up the slack chain pages 8 of 26 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com 12 Take up a slack load chain care
26. 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com
27. block Double reeved 500 600 and 1 000 Ibs 226 272 and 453 kg units If chain binds jumps or is noisy first clean and lubricate it see below If trouble persists inspect chain and mating parts for wear distortion or other damage CHAIN INSPECTION First clean chain with a non caustic non acid type solvent and make a link by link inspection for nicks gouges twisted links weld spatter corrosion pits striations minute parallel lines cracks in weld areas wear and stretching Chain with any one of these defects must be replaced Slack the portion of the chain that normally passes over the lift wheel Examine the interlink area for the point of maximum wear polishing see Figure 6A Measure and record the stock diameter at this point of the link Then measure stock diameter in the same area on a link that does not pass over the lift wheel use the link adjacent to the loose end link for this purpose Compare these two measurements If the stock diameter of the worn link is 0 010 inches 0 254mm or more less than the stock diameter of the unworn link the chain must be replaced On the Double reeved 500 600 and 1 000 Ibs 226 272 and 453 kg units repeat this examination of the chain that passes through the hook block Also check chain for stretch using a vernier caliper as shown in Figure 6B Select an unused unstretched section of chain usually at the loose end and measure and record the length over 11 chain links
28. ces only 26 NOT allow your attention to be diverted from operating the hoist 27 NOT allow the hoist to be subjected to sharp contact with other hoists structures or objects through misuse 28 NOT adjust or repair the hoist unless qualitied to perform such adjustments or repairs DO S 1 Maintain a firm footing or be otherwise secured when operating the hoist 2 Check brake function by tensioning the hoist prior to each lift operation 3 Use hook latches Latches are to retain slings chains etc under slack conditions only 4 Make sure the hook latches are closed and not supporting any parts of the load 5 Make sure the load 15 free to move and will clear all obstructions 6 Avoid swinging the load or hook 7 Make sure hook travel is in the same direction as shown on the controls 8 Inspect the hoist regularly replace damaged or worn parts and keep appropriate records of maintenance 9 Use factory parts when repairing the unit 10 Lubricate load chain per instructions in this manual 11 Protect the hoist s load chain from weld splatter or other damaging contaminants 25 Take up slack carefully make sure the load is balanced and load holding action is secure before continuing 26 Shut down a hoist that malfunctions or performs unusually and report such malfunction 27 Make sure hoist limit devices function properly 28 Warn personnel of an approaching load pages 3 of 26 Prolyte has made eve
29. circuits in electrical components may be detected by isolating the component and checking for continuity using an ohmmeter Short circuits are indicated by D C resistance substantially below the nominal D C resistance Motor current draw should be measured at the end of the power cord while the hoist is raising rated load Check cut out device on single phase units only by measuring coil resistance terminals 3 and 4 and making sure the contact terminals 2 and 4 is open Prolyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 BRAK ASSEMBLY Brake Screw 620 124 620 116 Brake Disc 620 117 AT Brake 620 193 Brake Armature Brake Field 620 118 620 122 figure 8 ELECTRICAL DATA FOR COMPONENTS STATORS Volts Phase Hertz Full Load Nominal D C Current Amps Resistance Ohms 110 to 120 1 60 2 7 Yellow to Red 7 7 Blue to Black 6 2 220 3 50 1 1 White to Red 26 8 230 3 60 0 6 White to Black 26 8 Red to Black 26 8 380 3 50 0 63 White to Red 72 6 415 3 50 0 58 White to Black 72 6 460 3 60 0 88 Red to Black 72 6 575 3 60 0 4 White to Red 140 0 White to Black 140 0 Red to Black 140 0 TRANSFORMERS D 11 7 C Black to 71 0 Purple White to 614 0 902 0 Yellow Red to 384 0 682 0 Yellow White to NENNEN 916 0 1100 1100 White to 228 0 224 0 Red Orange pages 15 of 26 Prolyte has made every effort to ensure the accuracy of this manual No liability wi
30. cuit with the original connection and continuity with reversed connections 220 volt brake coil is used on 220 3 50 60 380 3 50 415 3 50 and 460 3 60 hoists 280 volt brake is used on 575 3 60 hoists WIRING DIAGRAMS OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 DISASSEMBLY ASSEMBLY When disassembling and assembling the Prolyft Hoist refer to the exploded view and the parts list on pages 20 and 21 These show the proper relationship of the parts the names of the parts and the required quantities of the parts In addition please observe the following 1 Needle bearings are pressed into the gear housing 620 113 main frame 620 107 lift wheel 620 127 and lower sheave wheel 620 162 Unless they are to be replaced do not attempt to remove these bearings 2 A liftwheel seal 620 108 is pressed into the main frame 620 107 and a seal 620 130 is pressed into the endof the liftwheel shaft 620 148 Be careful that these seals are not cut or damaged during disassembly and reassembly 3 Refer to page 8 for disassembly inspection reassembly and adjustment of the brake 4 When removing the brake driver 620 119 it must be supported while driving out the retainer pin 620 120 At reassembly it must also be supported and the retainer pin must be driven in so that it is below the surtace of the driver File away any burrs and use the brake disc 620 117 as a gauge to make sure it will slide freely o
31. d Thermal Overload Relay 227 Green Yellow Receptacle Rated for 15 Amps Minimum 220 1 50 units do not include Power Cord Plug Wire Blue and Brown Wires to Fuses or Circuit Breakers and Green Yellow Wire to Ground figure 4a 115 1 60 units with contactor and three phase units hoists with black control station MAXIMUM LENGTH OF EXTENSION CORD WIRE SIZE SINGLE PHASE HOIST THREE PHAS HOIST 16 AWG 135 feet 40 M 245 teet 73 M 14 AWG 220 feet 66 M 395 feet 120 M 12 AWG 354 feet 107 After the hoist is suspended from its support and you have made sure the power supply complies with the above the hoist is ready for operation On the Double reeved 500 600 and 1 000 lbs 226 272 and 453 kg units cut and discard the ties used to hold the two strands of chain together With no load on the lower hook depress the UP button in the control station and raise the lower hook until it is about 2 feet below the bottom of the hoist Check both strands of chains for twists Twists occur if the lower hook block has been capsized between the strands of chain during packing shipment and or handling Reverse the capsize to remove twists OPERATING INSTRUCTIONS CHAIN CONTAINER If the chain container is to be used attach it to the hoist following the instructions provided The hoist is equipped with a Protector that is designed to allow the first gear to slip on an excessive over load An overload is indicated when
32. d operation refer to Checking for Adequate Voltage at Hoist on page 6 When determining the size of branch circuit components and conductors special consideration should be given to the starting current amps approximately three times that shown on the hoist identification plate and the length of the conductors As a minimum the system should be rated for 15 amps and it should have 16 AWG or larger wiring OProlyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 2 Bein accordance with the National Electrical Code ANSI NFPA 70 and applicable National State and Local Codes 3 Effectively ground the hoist in accordance with National Electrical Code and other applicable codes Proper grounding provides a path of least resistance for electric current to reduce the risk of electric shock The power cord of the hoist includes a green yellow wire for grounding the hoist to the external power supply system On the standard 115 1 60 units the power cord is equipped with a three prong plug Be sure that the receptacle opening that receives the longest prong is properly grounded If grounding is to be through the trolley track wheels each section of the runway must be grounded to the building ground system using metal to metal connections 4 Include slow blow type fuses or inverse trip time circuit breakers to permit the hoist to start and accelerate load 5 Include a disconnecting means capable of being locked in
33. device single phase units only to effect dynamic braking at time of reversal Phase reversal three phase units only Hook lowers but will not raise Excessive load Hoisting circuit is OPEN due to loose connections or broken wire in circuit control station contacts are not making open or shorted winding in contactor coil Motor cut out device not operating single phase units only Phase failure three phase units only Hook raises but will not lower Lowering circuit is OPEN due to loose connections or broken wire control station contacts not closing open or shorted winding in contactor coil Motor cut out device not operating single phase units only Phase reversal three phase units only Phase failure three phase units only Hook does not stop promptly Brake slipping Excessive load Hoist operates sluggishly Excessive load Low voltage Brake dragging Phase failure or unbalanced current in phases three phase units only AX 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 beforere moving cover or servicing this equipment Remedy Check for blown fuse or tripped circuit breaker or open disconnect switch in main line or branch circuit Replace fuse reset circuit breaker or close switch Check electrical continuity thru motor thermal protector
34. e ae 12 fpm 1 000 Ibs 16 fom 250 amp 300 Ibs Pomo 620 112 PROTECTOR THRUST WASHER 620 117 620 122 BRAKE FIELD Includes Brake Coil 115 1 50 60 Hoists 220 1 50 220 3 50 60 380 3 50 415 3 50 and 460 3 60 Hoists E 575 3 60 Hoists 620 123 BRAKE SPRING 620 124 BRAKE SCREW 620 125 mewa 620 126 RETAINER PLATE SCREW 620 127 LIFTWHEEL AND GEAR ASSEMBLY 6 1 000 165 20666 250 kg 20664 20698 20420 20659 20658 920740 Prolyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 Prolyft ELECTRIC HOIST PARTS LIST PART NAME PART NUMBER n w e 20664 20647 20664 LIFTWHEEL GEAR ASSEMBLY 620 127 12 fpm 600 amp 1 000 Ibs 16 fpm 250 300 amp 500 Ibs 20 fpm 500 amp 600 Ibs 20657 DERE a 40 2508300 2057 620 128 LIFTWHEELBEARING 2 8867 620 129 LIFIWHEELTHRUSTWASHER 2 620 130 LIFTWHEEL SHAFT SEAL c 131 ___ PINION AND SHAFT 620 132 BRAKE END COVER MEL 620 133 BRAKE END COVER SCREW con t Hoists without contactor 920715 hoists virout contator ee GeARHOUSING SCREW 620 142 CHAIN GUIDE STRIPPER PIN 4 20729 smmuroumcmwao aec auo 1s 620 147 CHAIN STOP SCREW 620 150 POWER CORD GROMMET 920718 620 152 620 153 10 ft lift oe 220 3 50 60 380 3 50 415 3 50 460 3 60 and 575 3 60 Hoists POWER COR
35. e cut out device and attach CAP jumper and the yellow stator lead to it Reroute jumpers 2 and CAP if necessary to make sure they clear the rotor bearing boss as shown in Main Frame OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 Welds Down and Towards Liftwheel figure 12c LOAD CHAIN REMOVAL INSTALLATION If unit has a chain container remove it from the chainguide Remove the chain stop 620 146 Depress DOWN button and run chain out of hoist Feed a short length of soft wire through the opening in the chain guide stripper 620 192 until it comes out of the hoist Attach new chain to end of the wire which is in the centre of the hoist Position the chain so that the welds will be down and towards the lift wheel as shown above in Figure 12C Jog the UP push button while pulling on the free end of wire until the chain comes out of the hoist Remove the wire and 9 When removing the stator 620 100 first remove the brake attach the chain stop as shown in Figure 13B On units with end cover 620 132 Disconnect stator leads from the wiring chain container place chain stop and loose end of chain in or contactor At the other end remove the motor end cover chain container Attach chain container to chain guide 620 105 On single phase units use an insulated screw On the 250 300 and 500 lbs single reeved 113 136 and driver to short between the bare terminals of the capacitor to 226 kg units remove the hoo
36. e of service to which the hoist will be subjected The inspection of hoists is divided into two general classifications designated as frequent and periodic OProlyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 Replace Hook When Opening is Greater Than 1 1 8 28 5 mm Normal Ok To Use Twisted Do Not Use figure 5b A WARNING n Allowing a load to bear against the hook latch and or hook tip can result in loss of load TO AVOID INJURY Do not allow a load to bear against the hook latch and or hook tip Apply load to hook bowl or saddle only When preparing to lift a load be sure that the attachments to the load hook are firmly seated in hook saddle Avoid off centre loading of any kind especially loading on the point of the hook When lifting raise the load only enough to clear the floor or support and check to be sure that the attachments to the hook and load are firmly seated Continue lift only after you are assured the load is free of all obstructions Do not load the hoist beyond the rated capacity shown on the brake end cover Overloading can cause immediate failure of some load carrying part or create a defect causing subsequent failure at less than rated capacity When in doubt use the next larger capacity of hoist Do not use this or any other overhead materials handling equipment for lifting persons or allow people on unsecured load Stand clear of all loads and
37. ept 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 The guarantee 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 or vendor or authorised agent All replaced parts become the property of the vendor and must be returned to the vendor at his prior approved expense For components of relative particular importance that are not manufactured by the vendor or his authorised service point and which carry the brand name of specialised manufactures the manufacture 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 fax 31 0 594 85 15 16 www prolyft com pages 24 of 26 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 par
38. es NOMINAL POWER SUPPLY MINIMUM OPERATING VOLTAGE MIN VOLTAGE AT INSTANT OF START The drop in voltage upon energizing the hoist should not be below the value listed Low voltage can also be caused by using an undersize extension cord to supply power to the hoist The following charts should be used to determine the size wires in the extension cord in order to minimize the voltage drop between the power source and the hoist 115 1 60 units without contactor hoists with orange control station LENGTH OF CONTROL CORD MAXIMUM LENGTH OF EXTENSION CORDBASED ONSIZEOFWIRE FT M 1 0 to 10 0 0 3 to 3 0 16 AWG 14 AWG 12 AWG 105 f 170 ft 270 ft 32 M 51 M 82 M 75 ft 120 ft 190 ft 22 M 36 M 58 M 10 1 to 20 0 3 1 to 6 0 20 1 to 30 0 6 1 to 9 0 30 1 to 40 0 9 1 to 12 0 45 ft 70 ft 110 f 14 21 M 33 M 15 ft 20 ft 35 ft 4 5 M 6 M 11 M pages 6 of 26 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com Single Phase Systems Manual Slow Blow Fuses Disconnect or Inverse Time Switch Circuit Breakers Hoist Power Cor
39. ess to Move Load Hook Towards Hoist Head Depress to Move Load Hook Away From Hoist Head figure 5a A WARNING Allowing the hook block to run into the hoist when raising a load or allowing the chain stop to run into the hoist when lowering a load may break the chain and allow the load to drop TO AVOID INJURY Do not allow the hook block or the chain stop to contact the hoist frame 4 WARNING Attaching the load hook to an inadequate support may allow the hoist and load to fall and cause injury and or property damage TO AVOID INJURY Make sure the structure and the load hook attachment point have sufficient strength to hold several times the hoist and rated load hook tip Apply load to hook bowl or saddle only 1 not allow the load to swing or twist while hoisting 2 Never operate the hoist when flammable materials or vapours are present Electrical devices produce arcs or sparks that can cause a fire or explosion 3 STAY ALERT Watch what you are doing and use common sense Do not use the hoist when you are tired distracted or under the influence of drugs alcohol or medication causing diminished control MAINTENANCE INSPECTION To maintain continuous and satisfactory operation a regular inspection procedure must be initiated so that worn or damaged parts can be replaced before they become unsafe The intervals of inspection must be determined by the individual application and are based upon the typ
40. frame Slide the rotor large bearing first into stator Place the rotor thrust washer 620 104 on top of the exposed rotor bearing and then assemble the motor end cover 620 105 to the main frame Using wir ing diagram complete the wiring at the brake end of the unit 11 Make sure the upper hook is properly installed as shown in Figure 12C 12 After reassembly test the unit per instructions on page 16 IMPORTANT Do not use old chain for other purposes such as lifting or pulling Load chain may break suddenly without visual deformation For this reason cut the old chain into short lengths to prevent use after disposal OProlyte Products Group 2004 pages 18 of 26 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com Single Reeved Double Reeved Chain HOOK OPENING TOWARDS HOOK OPENING AWAY FROM LOOSE END LOOSE END figure 13a CUTTING CHAIN Hoistaloy load chain is hardened and it is difficult to cut The following methods are recommended when cutting a length of new chain from stock or cutting off worn chain Always wear eye protection when cutting chain
41. fully and start load easily to avoid shock and jerking of hoist chain If there is any evidence of overloading immediately lower the load and remove the excess load WARNING TO AVOID INJURY more than rated load Operate with twisted kinked or damaged chain Operate damaged or malfunctioning hoist Litt people loads over people allow people on unsecured load or leave unsecured load over people Operate hoist when load hook is not centred over hoist Permit load hook block to contact hoist frame or chain container Replace damaged or malfunctioning hook latch Keep load chain well oiled FREQUENT INSPECTIONS These inspections are usually visual examinations by the operator or other designated personnel Frequent inspections are to be per formed daily or monthly and shall include the following items a Operate the hoist with no load and check for visual signs or abnormal noises which could indicate a potential problem daily Brake for evidence of slippage daily c Chain for lubricant wear damaged links or foreign material daily see below d Hooks for damage cracks twist latch engagement and latch operation daily see below Any deficiencies must be corrected before the hoist is returned to service PERIODIC INSPECTIONS There are visual inspections by an appointed person who records apparent external conditions to provide a basis for continuing evaluation Periodic inspections are
42. he four brake screws 620 124 to 25 in lb 2 8 NM PROTECTOR The Protector should operate for the normal life of the hoist without service The device has been lubricated and calibrated and it should not be adjusted If the Protector is not operating properly see testing on page 16 it must be replaced with a properly calibrated unit from the factory PREVENTATIVE MAINTENANCE A preventative maintenance program should be established to prolong the useful life of the hoist and maintain its reliability and continued safe use The program should include the periodic and frequent inspections with particular attention being paid to the lubrication of the various components using the recommended lubricants see page 21 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 beforere moving cover or servicing this equipment pages 11 of 26 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 i e
43. ide of disconnect switch Connect the GREEN YELLOW wire of hoist power cord to power supply ground 3 Move the manual disconnect switch handle to the ON position 4 Depress the UP control If the hook moves in the up direction the hoist is ready for operation If the hook lowers move the disconnect switch handle to the OFF position and interchange the BLACK and BROWN leads at the disconnect switch Move the disconnect switch handle to the ON position and the hoist is now ready for operation CHECKING FOR ADEQUATE VOLTAGE AT HOIST The hoist must be supplied with adequate electrical power for proper operation and to reduce problems that may result from insufficient power low voltage These include e Noisy hoist operation due to brake and or contactor chatter e Heating of the hoist motor and other internal components as well as heating of wires and connectors in the circuit feeding the hoist Failure of the hoist to lift the load due to motor stalling Blowing fuses or tripping circuit breakers e Dimming of lights or slowing of motors connected to the same circuit OProlyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 Chain Stop Loose End of Chain Mounting Hook figure 3b Low Voltage For proper operation and to avoid these low voltage problems voltage measured at end of the power cord while lifting rated load should be as the following chart indicat
44. ions A WARNING Alterations or modification of hoist and use of non factory repair parts can lead to dangerous operation and injury TO AVOID INJURY Do not alter or modify equipment Do use only factory replacement parts ACCESSORIES CHAIN CONTAINER This accessory item Figure 1A is used to hold the slack chain and it is supplied with mounting hardware and instructions Chain containers are recommended for those applications where slack chain will interfere with the load or drag on the floor as may more often be the case with the Double reeved 500 600 and 1 000 Ibs 226 272 453 and 500 kg units Chain containers are shipped separately and can be furnished for units already in service OProlyte Products Group 2004 figure 1b LATCHLOK HOOKS Latchlok Hooks Figure 1B are available to replace the standard lower latch type hooks The unique design of the Latchlok Hook assures that it will stay locked until the operator releases it by depressing the release button It will not open accidentally even if the load chain goes slack Once opened it can be shut with one hand or the weight of the load when it is lifted Latchlok Hooks can be supplied with the hoist or they can be provided in kit form for hoists already in service The Prolyft Electric Chain Hoist is a highly versatile materials handling device that can be used to lift loads that are within its rated load capacity It is available in seven load ratings
45. k block from the old chain and discharge it A spark may be produced Disconnect wiring to attach it to the new chain by reusing the chain pin 620 158 the capacitor and then remove the capacitor Remove the On the 500 600 and 1000 Ibs 226 272 and 453 kg units cut out device 620 110 and disconnect the wires from it Remove dead end plate 620 160 from hoist Remove the rotor assembly 620 101 and thrust washer Remove dead end pin 620 161 from the last link of chain 620 1 04 and pull chain out of dead end plate Then slide the stator out of the main frame 620 107 e Pull old chain out of hook block and disassemble the hook block 10 To install the stator Refer to Figure 12 A and make sure that sure the new chain is not twisted and wrap the chain around the sheave wheel 620 162 with welds down and towards the sheave wheel e Reassemble hook block and pull the new chain through the hook block Slide the dead end plate over the last link and secure it using the dead end pin e Making sure the chain is not twisted between the hook block and hoist attach the dead end plate to the chain guide stripper 620 192 Retrace the new chain and check for twists If chain is twisted start over Figure 12A On all units slide stator leads through wire slot Align the slots in the stator shell with the threaded holes in the main frame as shown in Figure 12B With the leads down slide the stator into the main
46. kness of the brake disc and armature if so than replace brake disc and armature page 11 of manual PLE 10 250kg Excessive throat opening 1596 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 page 9 of the mapual Inadequate lubrication excessive wear or stretch cracked damaged or twisted ee links corrosion or foreign substance page 9 amp 10 of manual PLE 10 250 1 inspect chain for twists 2 Inspect load wheel Operating Controls Limit Switches Brake Mechanism Chain Double reeving if configured Pins Bearings Bushings Shafts Excessive wear corrosion cracks distortion Looseness stripped and damaged threads corrosion hook block scremsst have lock washer amp dead end plate bolts hook retainer screws and tighten as required page 14 of manual PLE 10 250 kg Distortion cracks and excessive wear Build up of foreign substances 1 ing for chain lift wheel orientation welds must pass over the sheave wheel 2 inspect for chain reeve block orientation weld must pass over sheave wheel Cracks distortion Excessive wear internal build up of foreign substances Couplings Nuts Bolts Rivets Screws Sheaves Housings Load Block Wiring and Terminals grommets strain Fraying defective insulation correctly mounted in housing relief Ch
47. ll 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com COILS Voltage Current Draw Amps 115 0 02 48 0 2 Nominal D C Resistance Ohms 765 98 4 272 Contactor Coils Brake Field 115 77220 1120 280 1608 Cut out 115 0 1 Terminals 3 to 4 0 3 Device measure 115 volt brake coil resistance carefully cut and peel back the shrink tubing on the brake coil leads to expose the diodes Trace the leads from the coil to the diodes Connect the ohmmeter leads at the coil side of the diodes refer to the wiring diagram and measure the resistance If coil is ok reinsulate the brake coil leads and diodes using electrical tape Diodes are checked by connecting the ohmmeter to the ends of the brake coil leads checking for an open or short circuit reversing the connections to the ohmmeter and again checking for an open or short circuit If there is an indication of an open or short circuit with the original and reversed connections diodes are defective and the brake field 620 122 which includes the diodes must be replaced Usable diodes are indicated by continuity with the original connections and an open circuit when the connections are reversed or an open cir
48. n the driver Do not attempt to disassemble the Protector refer to page 11 Refer to page 10 for lubrication instructions See next section for load chain removal and installation Tighten the various screws as follows KEY NO PART NAME SEATING LB IN 520 126 Fin Relies Piate Serew 25 28 620 154 WoiorCoverScew 25 28 CNM THE FOLLOWING WIRING DIAGRAMS ARE REPRESENTATIVE FOR ACTUAL WIRING DIAGRAM REFER TO THE DIAGRAM SUPPLIED WITH THE HOIST NOTE FOR 575 3 60 UNITS REFER TO WIRING DIAGRAM SUPPLIED WITH HOISTS CUT OUT DEVICE CAPACITOR POWER SUPPLY CONNECTION MECHANICAL INTERLOCK X WIRE NUT O TERMINAL OProlyte Products Group 2004 WHEN UP OR DOWN BUTTON IS DEPRESSED CONTACT OF DEVICE CLOSES AS CURRENT THRU MOTOR REDUCES THE CONTACT OPENS TO DE ENERGIZE START WINDING B 20747 115 1 50 60 HOISTS WITHOUT CONTACTOR Orange Control CONTROL STATION Station WIRING DIAGRAM 15 1 60 16 26 Prolyte has made every effort to ensure the accuracy of this manual No liability will 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com CONTROL CORD
49. nd for a lifetime If not a normal 2 year warranty is applicable See regulations The hoist should not extend 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 guides 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 Prolyft 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 war
50. of 104 F 40 C the frequency of hoist operation must be limited to avoid overheating the motor Special provisions should be made to ventilate the space around the hoist and shield it trom radiant heat Avoid excessive inching jogging and reversing This type of operation drastically shortens motor cut out device capacitor control station and contactor contact life and causes excessive brake wear See item 6C See item 3C See 1G Check electric brake see page 11 and armature for binding broken brake spring first pinion shaft broke brake driver worn brake driver pin broke brake disc worn Correct binding of armature replace broken or worn parts See ltem 2C pages 14 of 26 ELECTRICAL DATA RECOMMENDED SPARE PARTS To insure continued service of the Prolyft Hoist the following is list of parts that are recommended to be kept on hand at all times to replace parts that have worn or failed Parts applicable to your hoist should be stocked KEY PART QTY KEY PART QTY NO NAME PER HOIST NAME PER HOIST 620 122 BRAKE FIELD 1 620 117 BRAKE DISC 1 ASSEM 620 186 CONTROL 1 620 110 CUT OUT DEVICE 1 STATION ORANGE 620 106 CAPACITOR 1 620 178 REVERSING 1 CONTACTOR 620 181 TRANSFORMER 1 627 563 CONTROL 1 STATION PARTS KIT 627 565 CONTROL 1 STATION SWITCH KIT Refer to page 20 for ordering instructions and the Parts List tor part numbers OPEN OR SHORT CIRCUIT IN ELECTRICAL COMPONENTS Open
51. ompany and or local authority to see if a deviation is required to permit the use of the hoist in this particular application The safety laws for elevators lifting of people and for dumbwaiters specify construction details that are not incorporated into the hoists For such applications refer to the requirements of applicable state and local codes and the American National Safety Code for elevators dumbwaiters escalators and moving walks ASME A17 1 We cannot be responsible for applications other than those for which the equipment is intended A WARNING THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH IF NOT FOLLOWED COULD ENDANGER THE PERSONAL SAFETY AND OR PROPERTY OF YOURSELF AND OTHERS READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL AND ANY PROVIDED WITH THE EQUIPMENT BEFORE ATTEMPTING TO OPERATE YOUR PROLYFT HOIST DONT S 1 NOT operate a damaged malfunctioning or unusually performing hoist 2 NOT operate the hoist until you have thoroughly read and understood this Operating Maintenance and Parts Manual NOT operate a hoist which has been modified NOT lift more than rated load for the hoist 5 NOT use a hoist with twisted kinked damaged or worn load chain 6 NOT use the hoist to lift support or transport people 7 NOT lift loads over people 8 NOT operate a hoist unless all persons are and remain clear of the supported load NOT operate unless the load is centered under hoist 10 NO
52. 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 620 178 620 184 620 177 620 181 620 180 See 620 179 Upper Hoo 620 112 620 109 620 RG 226 a 620 111 620 136 perm E 620 112 620 128 620 11 Yo 620 127 620 182 N d NDS E 620 116 Bi Ts 620 193 Pad 620 173 620 171 620 117 620 169 920 197 Mu 620 118 is of E 620 152 620 123 620 156 620 122 620 151 620 158 620 138 4 620 176 Sepia Single R Lower 620 186 627 552 See Page 15 Prolyte Products Group 2004 pages 20 of 26 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 620 154 620 105 it 620 106 620 110 620 137 620 140 See Page 13 for r Hook Installation 620 138 620 155 620 129 gt 620 126 X5 620 172 620 171 620 103 620 1
53. packed at assembly with grease and should not need to be renewed unless the gears have been removed from the housing and degreased CAUTION Never degrease the Protector or attempt to disassemble this device Degreasing the Protector may damage parts and using a device that has been degreased may cause erratic inconsistent operation If the Protector has been degreased it must be replaced by a factory calibrated device Use only Star H grade load chain and factory replacement parts Use of other chain and parts may be dangerous and voids factory warranty A WARNING Use of commercial or other manufactures chain and parts to repair hoists may cause load loss TO AVOID INJURY Use only factory supplied replacement load chain and parts Chain and parts may look alike but our chain and parts are made of specific materials or processed to achieve specific properties A WARNING Used motor oils contain known carcinogenic materials TO AVOID HEALTH PROBLEMS Never use used motor oils as a chain lubricant Only use Lubriplate Bar and Chain Oil 10 R as a lubricant for the load chain A WARNING The lubricants used in and recommended for the Prolyft Hoist may contain hazardous materials that mandate specific handlingand disposal procedures TO AVOID CONTACT AND CONTAMINATION Handle and dispose of lubricants only as directed in applicable material safety data sheets and in accordance with applicablelocal state
54. pitches Measure and record the same length on a worn section of chain Obtain the amount of stretch and wear by subtracting the measurement of the unworn section from the measurement of the worn section pages 9 of 26 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com 157 INCHES 4mm DIAMETER WEAR IN THESE AREAS figure 6a If the result amount of stretch and wear is greater than 0 145 inch 3 7mm the chain must be replaced Use only a Knife edge vernier caliper to eliminate possibility of false reading by not measuring full pitch length Note that worn chain can be an indication of worn hoist components For this reason the hoist s chain guide hook block and lift wheel should be examined for wear and replaced as necessary when replacing worn chain Also these chains are specially heat treated and hardened and should never be repaired IMPORTANT Do not use replaced chain for other purposes such as lifting or pulling Load chain may break suddenly without visual deformation For this reason cut replaced chain into short lengths to prevent use after disposal CHAIN LUBR
55. ranted 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 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 returned to the vendor at his prior approved expense For components of relative particular importance that are not manufactured by the vendor or his authorised service point and which carry the brand name of specialised manufactures the manufacture s guarantee which can vary is applicable TWO YEAR WARRANTY The hoist should not extend 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 OProlyte Products Group 2004
56. rmal operating conditions and present possibility of damage or injury On units without contactor hoists with orange control station it is necessary to stop the hoist before changing direction Therefore when lowering a load the push button in the control station must be released momentarily before the UP button is depressed to raise the load If this is not done the hoist will continue to operate in the down direction while the UP push button is depressed and it will continue to lower the load until the control push button is released As a result the direction must not be reversed quickly plug reversed There are no electrical switches to stop the operation of the hoist at the upper and lower limits of lift As a result it is necessary to release the push button in the control station to stop the hoist before the hook block or chain stop contacts the bottom of the hoist frame If the hook block or chain stop contacts the hoist frame the Protector will function to stop the hoisting or lowering operation and protect the hoist components from damage However continued prolonged or repeated slipping of the Protector will damage the Protector and cause overheating of the internal hoist components Hoist operation is controlled by depressing the control station push buttons Refer to Figure 5A pg 8 Depressing the UP push button will move the load hook toward the hoist head depressing the DOWN push button will move the load hook away
57. rt1 Safety of machinery EN292Part2 Safety of machinery EN 50081 1 Electromagnetic compatibility EN 50082 2 Electromagnetic compatibility EN 60034 1 Rating and performance EN 60034 5 Types of enclosures IP code EN 60947 1 Low voltage switchgear Applied standards and technical specifications in particular ASME B30 16 Overhead hoists underhung ASME HST 1 Performance standard for electric chain hoists FEM 9 511 Classification of mechanisms FEM 9 671 Chain qualities selection criteria and requirements FEM 9 811 Specifications FEM 9 683 Selection of hoist and travel motors FEM 9 941 Control symbols FEM 9 755 Safe working periods S W P As stipulated by Annex V of the EC machinery directive CE symbol affixed to hoist Technical documentation filed in manufacturer s works Coffing Hoists Wadesboro NC USA 31 08 2004 The EC declaration of conformity is only valid in conjunction with confirmation that the hoist has been correctly applied installed inspected and maintained according to the operating instructions provided Furthermore the validity of the declaration will cease in case of any modification and or supplement not previously approved by Coffing Hoists Coffing Hoists PO Box 779 Wadesboro NC USA Tel 704 694 2156 Fax 704 694 6829 OProlyte Products Group 2004 pages 26 of 26 Prolyte has made every effort to ensure the accuracy of this manual No liability will
58. ry 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 figure la REPAIR REPLACEMENT POLICY All Prolyft Electric Chain Hoists are inspected and performance tested prior to shipment If any properly maintained hoist develops a performance problem due to a material or workmanship defect as veritied by the factory repair or replacement of the unit will be made to the original purchaser without charge This repair replacement policy applies only to Prolyft Hoists installed maintained and operated as outlined in this manual and specifically excludes hoists subject to normal wear abuse improper installation improper or inadequate maintenance hostile environmental effects and unauthorized repairs modifications We reserve the right to change materials or design if in our opinion such changes will improve our product Abuse repair by an unauthorized person or use of non factory replacement parts voids the guarantee and could lead to dangerous operation All Prolyft Electric Chain Hoists are backed with a lifetime warranty Refer to the back cover for details and limitat
59. t of this manual may be reproduced in any form or by any means without prior written permission Prolyte Products Group Phone 31 0 594 85 15 15 Fax 31 0 594 85 15 16 www prolyte com American Wire Gauge AWG AWG conversion to CEE mm 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 CEE equiv 6 63 7 7 7 7 10 55 6 63 4 17 2 0 165 1 04 052 0 41 Prolyte Products Group Phone 31 0 594 85 15 15 Fax 31 0 594 85 15 16 www prolyte com OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 pages 25 of 26 OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 EC declaration of conformity COFFI NG as defined by machinery directive 89 392 EEC Annex HOISTS Herewith we declare that the design construction and commercialized execution of the Prolyft hoist type PLE complies with the following essential health and safety provisions applying to it EC machinery directive 88 392 EEC amended by 91 368 EEC 93 44 EEC and 93 68 EEC EClow voltage directive 73 23 EEC amended by 93 68 EEC EC EMC directives 89 336 EEC amended by 92 31 EEC and 93 68 Applied harmonized standards in particular EN292Pa
60. the brake disc for wear or glazing and make sure brake spring is not broken Replace worn or glazed brake disc or replace brake spring See item See item See item 1D Check electric brake see page 11 Check to make sure brake disc is free to move on brake driver Check for warped or bent brake disc and base plate Free up brake disc by removing burrs on driver Replace warped armature base plate or brake disc See item 1G Motor overheats Hoist will not operate down direction motor thermal protector open Excessive load Low voltage Extreme external heat Frequent starting or reversing Brake dragging Motor cut out device not opening start winding circuit single phase units only Phase failure or unbalanced current in phases three phase units only Hook fails stop either direction Brake not closing or ineffective Hook lowers when up button is depressed Phase reversal three phase units only 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 85 15 15 Fax 31 0 594 85 15 16 www prolyte com See item See item 1D Above an ambient temperature
61. the hoist speed slows down it raises the load in a jerky manner or it will not lift the load at all Also some clutching noise may be heard if the hoist is loaded beyond rated capacity Should this occur immediately release the UP button to stop the operation of the hoist At this point the load should be reduced to the rated capacity or the hoist should be replaced with one of the proper capacity When the excessive load Is removed normal hoist operation is automatically restored CAUTION The Protector is susceptible to overheating and wear when slipped for extended periods Under no circumstance should the Protector be allowed to slip for more than a few seconds Due to the above the hoist is not recommended for use in any application where there is a possibility of adding to an already suspended load to the point of overload This includes dumbwaiter installations containers that are loaded in mid air etc OProlyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 Three Phase Systems Green Yellow Hoist Power Cord Manual Disconnect Switch Slow Blow Fuses Must be per National Electrical or Inverse Time Code and These Devices are to be Circuit Breakers Supplied by the User figure 4b Also if the hoist is used at unusual extremes of ambient temperatures above 150 F 65 C or below 15 F 9 C changes in lubricant properties may permit the hoist to raise larger loads than under no
62. to be performed semi annual and they should include the following a All items listed under frequent inspections b External evidence of loose screws c External evidence of worn corroded cracked or distorted hook block gears bearings chain stop and hook retainer d External evidence of damage or excessive wear of the liftwheel or sheave double reeved unit Widening and deepening of pockets may cause chain to lift up in the pockets and cause binding between liftwheel and chain guide or between lower sheave and hook block Check chain guide for wear or burring where the chain enters the hoist Severely worn or damaged parts should be replaced e External evidence of excessive wear of brake parts see page 11 f Check the control station push buttons to make sure they operate freely and spring back when released g Check power cord control cord and control station for damaged insulation h Check for pitting and any deterioration of contactor contacts hoists with black control station I Check the chain pin or dead end pin and chain stop for wear and cracks Check for lubricant leaks at gasket between main frame and gear housing Tighten gear housing screws to stop leak If leak persists replace gasket OProlyte Products Group 2004 OPERATING MAINTENANCE EN SERVICE MANUAL PLE 10 k Inspect splines on first pinion shaft and motor coupling for signs of wear or deterioration Replace splined parts if worn or d

Operating, maintenance and service manual Prolyft PLE-10

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