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Milwaukee 9573 Use and Care Manual

1. Maximum permissible throat opening of hook Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 CHAIN Chain is to be kept clean and lubricated See LUBRICATION page 9 Visually check chain every time hoist is used Hoist must not be operated when chain is twisted or kinked An important phase of hoist maintenance is chain inspection Check individual links and check for chain elongation 1 Check the chain for overall wear or stretch by selecting an unworn unstretched length of chain at the slack end for example Let the chain hang vertically with a light load about 20 pounds on the chain to pull it taut Use a large caliper to measure the outside length of a convenient number of links about 12 Measure the same number of links in a used section of chain and calculate the percentage increase in length of the worn chain 2 If the length of the worn chain is more than 112 longer than the unused chain 0 015 per inch of chain measured then the chain should be replaced If the chain is worn less than 112 check it at several more places along its length If any section is worn more than 112 the chain should be replaced CAUTION The chain used on this hoist has very carefully controlled dimensions and has been heat treated Do not attempt to substitute other manufacturer s chain Silver Nut Down Gold Nut Up Figure 3
2. OPERATOR S MANUAL ELECTRIC CHAIN HOIST Catalog No Rated Load 9560 1 2 Ton 9561 9562 9565 1 Ton 9566 9567 9568 9570 2 Ton 9571 9572 9573 A WARNING equipment described and illustrated these instructions is intended for industrial use only and should not be used to lift support or otherwise transport people Fouow 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 Before using the hoist fill in the information below Model and serial numbers are stamped into the aluminum hoist housing Model Number Serial Number Purchase Date Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 SAFETY PRECAUTIONS Each MILWAUKEE Electric Chain Hoist is built in accordance with the specifications contained herein and at the time of manufacture complies with our interpretation of applicable sections of
3. Brake Assembly 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 Adjustment is now complete and the brake properly set Replace the electrical cover reconnect the power supply and check hoist brake action A CAUTION Be sure the bottom of the armature does not bear against the splined adapter As adjustments are made the built in clearance will be reduced When this clearance is gone REPLACE BRAKE DISCS Minimum allowable disc thickness is 162 See Figure 15 for further illustration HOIST CONTROLS Both the pushbutton and the reversing contactor are mechanically interlocked to prevent shorting the circuit and causing serious damage As part of maintenance always check for proper closure of contact points as well as for burned contacts If replacement is necessary see Figures 16 amp 18 for replacement parts WIRING Refer to Figures 9A and 9B MILWAUKEE Electric Chain Hoists which are available for 115 230V or 230 460V are shipped wired for 115V and 460V respectively Conversion of dual voltage hoists to either the higher or lower voltage can be done simply and quickly as follows 1 DISCONNECT HOIST FROM POWER SUPPLY and remove the electrical cover 2 Each dual voltage hoist has a terminal block assembly for the interconnection of the electrical components of the hoist To convert voltage reconnect the l
4. NOTE Refer to Maintenance and Inspection Sections of the Hoist 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 annually or annually based on user s monthly experience Figure 10A 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 ASME B30 16 It is however the ultimate responsibility of the employer user to interpret and adhere to the applicable requirements of this safety standard 14 Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 INSPECTOR S REPORT ITEM REMARKS LIST DEFICIENCIES AND RECOMMENDED ACTION Inspector s Date Signature Inspected Approved by Date Figure 10B Recomm
5. 343 7304 OREGON GENERAL TOOL amp SUPPLY CO 2705 N W Nicolai Portland OR 97210 505 226 3411 800 783 3411 ax 503 778 5518 PENNSYLVANIA AMERICRANE 1558 Myers Road Indiana PA 15701 888 963 9900 or 724 479 9100 GLOBE ELECTRIC CO 200 23rd Street Pittsburgh PA 1521 mar 1 2677 or 50 0 850 4440 412 781 1812 PENNSYLVANIA cont d KEYSTONE CRANE amp HOIST CO 861 S Washington Roag McMurray PA 15317 724 746 5080 724 746 5082 MCDAL CORP 475 East Church Road King of Prussia PA 19406 61 271 5484 or 800 626 2325 ax 610 277 4690 MORRIS MATERIAL HANDLING Tinicum Ind Park Building E 10 Industrial Highway MS 80 Lester PA 19113 800 346 2098 ax 610 521 5907 REPAIR UNLIMITED 1730 Rockwell Road Abington PA 19001 657 3335 800 369 5891 215 784 0343 RHODE ISLAND MOTORS HOIST amp CONTROLS INC 179 Railroad a Woonsocket RI 02895 401 767 4568 Fax 401 767 4567 SOUTH CAROLINA ENGINEERED SYSTEMS INC 1121 Duncan Reidville Road Duncan SC 29334 864 879 7438 800 879 7438 864 848 3143 HOIST amp CRANE CO 2508 Perimeter Place Nashville TN 37214 615 242 3383 888 464 7811 ax 615 255 437 HI SPEED ELECTRICAL CO 3013 Thomas Street Memphis TN 38127 901 357 6231 Fax 901 357 6238 TEXAS ABEL EQUIPMENT CO INC 3710 Cavalier Drive Garland TX
6. 7 Chain Guide 1 8 Oil Plug Drain 1 9 Oil Plug Fill 1 10 Oil Plug Level 1 11 Oil Seal 3 12 Screw HWH Self threading 5 13 Motor Coupling 1 14 Bearing 2 15 Input Pinion 16 Retaining Ring 3 17 Brake Adapter 1 18 Bearing for 8 amp 16 fpm 2 19 High Speed Pinion for 8 amp 16 fpm 1 20 Intermediate Pinion 1 2 ton 1 1 amp 2ton 1 21 Bearing 2 22 Output Pinion 1 23 Overload Clutch Assembly 1 2 ton 1 1 amp 2ton 1 24 Retaining Ring 2 25 Bearing 1 26 Bearing 1 27 Spacer Load Sheave 1 28 Load Sheave 9 32 Chain 1 29 Load Sheave Shaft 1 30 Stub Shaft Limit Switch Drive 1 31 Oil Seal 1 32 Retaining Ring 1 33 Output Gear 1 34 Dowel Pin 2 i Gear Oil 1 pt Not Shown 25 f Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 Figure 20 Chaining Parts 1 Ton Under Models 2 Ton Models 32 Parts List for Chaining Parts Ref No 1 2 Description Housing Transmission Cover Electrical Cover Anchor Pin 2 ton only Anchor 2 ton only Chain Stripper Chain Stop Kit Qty Kits include halves sleeve and retaining ring Load Chain Attachment Pin Retaining Clip 1 4 20UNC x 114 Socket Head Cap Screw Bottom Block Assembly 1 ton amp Under 1 4 20UNC x 114 Socket Head Cap Screw 1 4 Internal tooth Lockwasher Load Block Frame Load Block Pin Slotted Hex Nut Bearing Latch Kit Ref No
7. 14 NOT apply the load to the tip of the hook or to the hook latch 15 NOT apply load unless load chain is properly seated in the chain sprocket s 16 NOT apply load if bearing prevents equal loading on all load supporting chains 17 NOT operate beyond the limits of the load chain travel 18 NOT leave load supported by the hoist unattended unless specific precautions have been taken 19 NOT allow the load chain or hook to be used as an electrical or welding ground 1 Maintain 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 is 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 MILWAUKEE recommended parts when repairing the unit 10 Lubricate load chain per hoist manufacturer s recommendations 11 NOT use the hoist s overload limiting clutch to measure load 12 NOT use limit switches as routine operating stops They are emergency devices only 13 NOT allow your attention to be diverted from operati
8. 4025 1st Ave Billings Montana 59101 405 252 8114 800 823 8665 406 259 3956 30 Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 UNITED STATES NEW JERSEY SISSCO 186 Route 206 South Hillsborough NJ 08844 908 359 9767 800 392 0146 ax 908 359 9773 NEW YORK ABC ELECTRIC 24 25 46th Street Long Island City NY 11103 p 956 000 E only 800 562 1919 AX 718 956 445 BEATON INDUSTRIAL INC 6083 Trenton Rd Utica NY 13502 319 797 9346 N Y only 800 724 4052 ax 315 797 9321 VOLLAND ELECTRIC EQUIPMENT CO 75 Innsbruck Drive Buffalo NY 14227 716 656 9900 Fax 716 656 8899 NORTH CAROLINA CAROLINA HOIST 3310 E Wendover Avenue Greensboro NC 27405 336 375 6050 or 800 326 3655 ax 336 375 6053 SOUTHERN ELECTRIC SERVICE 2225 Freedom Drive Charlotte NC 28266 372 4832 800 487 3726 704 342 2604 OHIO CRANE AMERICA H W HOUSE 920 Deneen Avenue Monroe OH 45050 219 539 9770 800 331 5326 513 539 957 AMERICRANE amp HOIST CORP 13224 Eritergrise Avenue Cleveland OH 44135 E 6 267 9100 or 800 652 1932 ax 216 267 9131 SAMSEL SUPPLY CO 1285 Old River Road Cleveland OH 44113 216 241 0333 or 800 892 8012 ax 216 241 3426 OKLAHOMA GAFFEY INC 9655 E 522 on Claremore OK 7 218 343 1191 i m 331 3916 ax 918
9. 6011 337 882 0527 DRILLCO 12649 S Choctaw Dr Baton Rouge LA 70815 225 272 82510r 800 851 3821 ax 800 315 922 MASSACHUSETTS ABEL DISTRIBUTORS INC 50 Parker St Newbury Port MA 01950 979 4 3 0700 ax 978 463 5200 MICHIGAN COMMERCIAL GROUP 9955 Grand River Detroit MI 48204 313 931 6100 or 800 931 7701 ax 313 491 1753 CONTINENTAL CRANE amp SERVICE CO 33681 Groesbeck Hwy Fraser MI 48026 586 293 3870 Fax 586 293 0017 STEWART ENGINEERING amp SALES 2140 Aurora Ave Muskegon MI 49442 231 767 2140 Fax 231 767 2233 MINNESOTA AA MOTOR REPAIR INC 2010 N 4 Musset MN 5541 612 522 3318 or 300 345 0198 ax 612 588 161 J amp B EQUIPMENT 8200 Grand Avenue South Bloomington MN 55420 952 884 2040 Fax 952 346 1139 PERFECTION CRANE amp HOIST INC 201 DeGraff Ave Swanville MN 56382 820 547 2401 or 800 253 6829 ax 800 353 2254 TOTAL TOOL SUPPLY 315 N Pierce St St Paul MN 5510 352 646 4055 or em 444 4899 952 646 8610 MISSOURI HERTZ EQUIPMENT RENTAL amp SUPPLY 800 E 18th St Kansas City MO 64108 p 6 221 7788 or 800 669 7788 ax 816 221 081 HANDLING SYSTEMS INC 11678 Gravois Rd St Louis MO 63126 314 842 7263 Fax 314 842 5041 ZELLER ELECTRIC 4250 Hoftmeister St Louis MO 63125 314 638 9641 Outside MO 800 530 5810 ax 314 638 6318 MONTANA POWER SERVICE OF MONTANA INC
10. 75042 972 272 7706 Fax 800 272 2235 GAFFEY INC 4301 Garland Drive Ft Worth TX 76117 81 7 281 1994 or 800 284 4233 ax 817 581 7831 GAFFEY INC 4003 S county Road 1297 Odessa TX 79765 gui 563 2897 or 800 733 0006 ax 915 563 4703 GAFFEY INC 1436 N Duck SEA Road Cleveland TX 77327 281 443 6690 4800 233 8179 ax 281 592 6984 HYDRAULIC EQUIPMENT SER 1021 N San Jacinto Street Houston TX 77002 713 228 4073 Fax 713 228 0931 UTAH ROCKY MOUNTAIN WIRE ROPE amp RIG 2421 South 2570 West Salt Lake City UT 84119 801 972 4972 or 800 615 3193 ax 801 974 0621 VIRGINIA FOLEY MATERIAL HANDLING CO 11327 Va Crane Drive Ashland VA 23005 804 798 1343 Fax 804 798 7843 WISCONSIN ALFERI INDUSTRIAL SALES amp SERVICE 346 Smith Street Neenah WI 54956 920 722 6483 Fax 920 722 6489 LIFT INC 6667 W Mill Road Milwaukee WI 53218 4 353 5353 or 800 728 5438 ax 414 353 4444 TRESTER HOIST amp EQUIPMENT W136 N4863 Campbell Dr Suite 4 Menomonee Falls WI 53051 262 790 0700 or 800 234 6098 ax 262 790 1009 PARTS DEPOT amp REPAIR CENTERS PARTS DEPOT amp WARRANTY REPAIR CENTER PARTS DEPOT 31 58 12 9575d1 WARRANTY Every MILWAUKEE hoist is thoroughly inspected and tested before leaving the manufacturing facilities Should any trouble develop return the complete hoist prepaid to the Factory Branch or nearest Auth
11. American Society of Mechanical Engineers Code ASME B30 16 Overhead Hoists the National Electrical Code ANSI NFPA 70 and the Occupational Safety and Health Act OSHA Since OSHA states the National Electrical Code applies to all electric hoists installers are required to provide current overload protection and grounding on the branch circuit section in keeping with the code Check each installation for compliance with the application operation and maintenance sections of these articles Copies of this standard can be obtained from ASME Order Department 22 Law Drive Box 2300 Fairfield NJ 07007 2300 U S A 20 NOT allow the load chain or hook to be touched by a live welding electrode 21 NOT remove or obscure the warnings on the hoist 22 NOT operate a hoist on which the safety placards or decals are missing or illegible 23 NOT operate a hoist unless it has been securely attached to a suitable support 24 NOT operate a hoist unless load slings or other approved single attachments are properly sized and seated in the hook saddle 25 Take up slack carefully make sure 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 switches function properly 28 Warn personnel of an approaching load A WARNING Improper operation of a hoist can create a potentially hazar
12. HOIST FROM POWER SUPPLY 10 Remove the 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 side of the hoist by removing the dead end screw and washers note placement of washers 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 hoist 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 side of the hoist using the dead end screw and washers With factory supplied hardware there should be six washers between the hoist and chain link and two washers between the chain link and screw head DO NOT allow twists in the chain 12 Adjust the lower limit switch See ADJUSTING LOWER LIMIT page 8 13 Attach the bottom block on single chained hoists using a new load block screw See Figure 20 On double chained hoists 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 20 Be sure there are no twists in the chain 14 Adjust the upper limit switch See ADJUSTING UPPER LIMIT page 8 Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wiscon
13. Limit Switch Assembly Chain Replacement with Chain in Hoist Refer to Figures 3 amp 4 1 Run hook up to its top limit 2 DISCONNECT 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 3 Turn the slotted nut nearest you the gold nut back to about the center of the threaded screw Do not disconnect the wires from the limit switches 4 Remove the load block assembly from the old chain On double chained hoists detach the chain from the chain support and pull it through the load block assembly See Figure 4 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 screw and the chain support double chained only without any twist in the chain Double Chain Only gt Figure 4 Chain Replacement Diagram 7 With the electrical cover off connect the hoist to the power supply Be sure that the green ground wire is properly grounded See INSTALLATION page 4 8 Carefully jog the UP button and run the joined pieces of chain into the hoist until about 15 of the new chain comes out the other side 9 DISCONNECT
14. Pushbutton Station Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 Parts List for Pushbutton Station Ref No Description Qty 1 Pushbutton Station amp Control Cable Assembly 6 ft Cable Length 1 11 ft Cable Length 1 16 ft Cable Length 1 Special Drop 1 2 Pushbutton Station Assembly 1 3 Control Cable Assembly 6 ft Cable Length 1 11 ft Cable Length 1 16 ft Cable Length 1 Special Drop 1 4 Enclosure 1 5 Gasket 1 6 Contact Assembly 1 Includes Item 7 7 Button Assembly 1 8 Grommet 1 Hardware Kit 1 Includes Items 9 16 A Warning Tag 1 t Equal to cable length pushbutton drop A Not shown 23 f Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 Figure 19 Transmission Parts E Pm uo d NOTE This stage of gearing is not required on 32 24 FPM models NOTE Orient output gear 32 with long boss towards gear housing 2 on 1 2 ton amp under models and towards transmission cover 3 on 1 amp 2 ton models Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 Parts List for Transmission Parts a Description Oty 1 Sheave Housing 1 2 Transmission Gasket 1 3 Transmission Cover 1 Includes Oil Seals 4 Spring Washer 1 5 O ring 1 6 Pressure Relief Fitting 1
15. SWITCH ADJUSTMENT page 8 Test without load each shift Table 2 Optional Chain Container Standard Shipping Hoist Lifts Chain Container Weight Dimensions in Inches Capacity ft Required Length Depth 1 2 amp 1 Ton 10 15 amp 20 48 12 0116 3 3 6 11 2 Ton 10 48 12 0116 3 3 6 11 2 Ton 15 48 12 0117 4 3 6 18 2 Ton 20 48 12 0118 5 6 6 27 Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 A WARNING Do not use hoist to lift support or otherwise transport people 12 Do not operate when hoist is not centered over load 13 Do not operate if chain is not seated properly in sprockets or sheave grooves 14 Do not operate damaged or malfunctioning hoist OVERLOAD LIMITING PROTECTION This 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 hoist is being operated If the load being lifted exceeds the lifting capability of the overload clutch the hoist motor will continue to run causing overheating of both the clutch and hoist motor This condition should be avoided by immediately releasing the UP button and reducing the load to within the rated capacity of the hoist See GEARING page 10 for additional instructions on this device CAUTION The overload limiting clutch is an emergency protective
16. clutch assembly from another hoist 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 5 Remove four screws attaching transmission cover to gear housing and remove transmission cover Limit switch drive shaft will come along with the cover 6 Inspect gears for 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 Figure 7 Assembled Gearing Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 7 Reassemble in reverse order of disassembly making sure 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 Check all wire terminals to be sure they are properly seated and in accordance with wiring diagram Before placing hoist back into service check brake adjustment and limit switch stops A OwanNING Failure to follow proper lockout tagout procedures may resent the danger of electrical shock TO AVOID INJURY Disconnect power and lockout tagout disconnecting means before removing cover or servicing this equipment Suspension Use Replacement Parts List for Basic Hoist and Chaining Parts to help in repairs in this sect
17. 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 hoist from damaging overloads it will not ensure that a load is within the rated capacity of the hoist MAINTENANCE INSPECTIONS A planned inspection routine should be established for this hoist based upon frequency of use severity of use and environmental conditions Reference ASME Standard B30 16 Some inspections should be made frequently daily to monthly and others periodically monthly to yearly It is strongly recommended that an Inspection and Maintenance Check List and an Inspector s Report similar to those shown in Figures 10A and 10B 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 hoist s capability may have been impaired J LOWERING WITHOUT POWER If the power fails with a load suspended the hoist will automatically stop In an emergency the load can be lowered without power as follows 1 DISCONNECT 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
18. eX c Faulty hoist reversing contactor cime commo 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 hoists for proper voltage connections Check connections to the solenoid coil Check for open or short circuit Check for proper adjustment See BRAKE ADJUSTMENT page 9 Check coils for open or short circuit Check all connections in control circuit Check for burned contacts Replace as needed Hook does not stop promptly 1 Hoist overloaded 2 Brake not holding Reduce load to within rated capacity of hoist Check brake adjustment See BRAKE ADJUSTMENT page 9 It may be necessary to replace discs Hook moves in wrong direction 1 Three phase reversal 2 Improper connections Reverse two wires except the green ground wire at the power source See INSTALLATION 2c page 5 Check all connections against wiring diagram Hoist hesitates to lift when energized 1 Hoist overloaded 1 Reduce load within rated capacity of hoist 2 Motor brake requires adjustment 2 Check motor brake adjustment See BRAKE ADJUSTMENT page 9 3 Worn overload limiting clutch 3 Replace clutch 4 Low voltage 4 Determine cause of low voltage and bring up to
19. hoist housing This condition should be constantly Containers checked on double chain hoists because it is possible for the load block to be capsized or turned over one or more times 1 Remove retaining clip and attachment pin and let the slack 6 Before raising a load always check inso that it is held securely in the hook or sling chains etc Raise the load chain hang free M only until the load chain is taut and then double check the 2 Run load hook down to its lowest position Place the slack end rigging before continuing to raise the load of chain in chain container Do not remove the chain stop 4 7 Do not stand beneath a load Do not move a load in such a 3 Place chain container flush against housing with chain manner as to endanger personnel stripper between top lugs Insert long attachment pin and replace retaining clip Refer to Figure 1 8 Do not lower into areas where visibility is obscured unless someone else is guiding the operation 9 Use common sense at all times when operating a hoist 10 Do not operate if direction of hook travel is not the same as Do not allow load to come in contact with the chain indicated on button being pushed container If this situation exists reset the UP limit ini switch so that the hook block stops below the chain 11 Do not operate unless hook travel limit devices function container See LIMIT
20. upper and lower limits of travel 6 Refer to Figure 18 for repairs on the pushbutton station Also refer to the wiring diagram inside the electrical cover or Figures 9A and 9B for wiring instructions Figure 6 Electrical Panel Removed Motor Refer to Figures 12 13 and 14 The hoist 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 itis necessary to replace or repair the motor DISCONNECT THE 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 Figure 16 3 Remove the four motor mounting bolts attaching the motor to the housing It will come loose at the motor coupling 4 Inspect the motor coupling motor shaft and all the bearings Replace as necessary 5 Install new or repaired motor according to the wiring diagram located inside the electrical cover or Figures 9A and 9B Gearing Use the Replacement Parts List for Basic Hoist and Transmission Parts to help in repairs on gearing See Figures 12 and 19 As disassembly is extensive for gearing disconnect hoist and move to a workbench 1 Remove electrical cover 2 Remove electrical panel 3 Remove brake assembly and limit switch assembly 4 Drain oil from transmission CAUTION Do not disassemble or readjust clutch or replace with a
21. within plus or minus 1096 of the voltage specified on the motor Measure voltage at the hoist reversing contactor while lifting a load 5 Faulty SINPAC starting switch or start capacitor 5 Replace faulty component single phase hoists only Hook raises but will not lower 1 DOWN circuit open 1 Check circuit for loose connections Check DOWN limit switch for malfunction 2 Broken conductor in pushbutton cable 2 Check each conductor in the cable If one is broken replace entire cable 3 Faulty hoist reversing contactor 3 Check coils for open or short circuit Check all connections in control circuit Check for burned contacts Replace as needed 4 Loose screw clamps 4 Ensure that screw clamps are tightened on the terminal blocks and reversing contactor Hook lowers but will not raise 1 Hoist overloaded Low voltage circuit open Broken conductor in pushbutton cable Faulty hoist reversing contactor D Fra Faulty capacitor single phase hoist only Worn overload limiting clutch Loose screw clamps 0 40 Reduce load to within rated capacity of hoist Determine cause of low voltage and bring up to within plus or minus 10 of the voltage specified on the motor Measure voltage at the hoist reversing contactor while lifting a load Check circuit for loose connections Check UP limit switch for malfunction Check each conductor in the cable If one is broken replace
22. 20 21 22 23 24 25 26 27 28 29 30 31 32 Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 Description Bottom Hook Assembly with Latch for 1 Ton amp Under Bottom Block Assembly for 2 Ton 3 8 24 Hex Locknut Load Block Screw Load Block Frame Sheave Shaft Assembly Sheave Shaft Sheave amp Bearing Assembly Roll Pin 3 8 24 Hex Locknut Bearing Latch Kit Bottom Hook Assembly with Latch for 2 Ton Qty 1 27 Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 NOTES Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 NOTES Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 AUTHORIZED WARRANTY REPAIR CENTERS AND PARTS DEPOTS As a user of MILWAUKEE hoists you are assured of reliable repair and parts services through a network of Master Parts Depots and Service Centers that are strategically located across the United States its territories and Canada These facilities have been selected on the basis of their demonstrated ability to handl
23. 89 15 1800 878 7918 ax 303 791 7179 FLORIDA HERBERT CORP 1751 S John Youn Parkway Kissimmee FL 32741 407 846 0588 2809 255 0588 407 846 8042 MATERIAL HANDLING SYSTEMS 720 S W 4th Court Dania FL 33004 54 921 1171 or 888 424 6478 ax 954 921 711 GEORGIA ACE INDUSTRIES INC 6295 McDonough Drive Norcross GA 30093 0 441 0898 800 733 2231 800 628 3648 GAFFEY INC 471 Sessions St Marietta GA 30060 939 6443 800 820 6443 70 422 2255 ILLINOIS INDUSTRIAL TOOL PRODUCTS 919 N ee ane Woodale IL 60191 690 4040 or 800 525 9654 630 766 41 S amp K AIR POWER Rt 316 E Box 1279 Mattoon IL 61938 217 258 8500 800 955 8501 217 258 857 SIEVERT ELECTRIC SERVICE 1230 South Forest Park IL 60130 708 111 1600 or 800 322 9144 08 771 3124 INDIANA BREHOB CORP 1334 S Meridian Indianapolis IN 462 B 231 8080 or 800 632 4451 ax 317 231 807 dem HANDLING EQUIPMENT 7433 US 30 E Fort Wayne TE 6803 19 749 0475 or or 800 443 6432 219 749 048 IOWA SE A SONS INC 514 S Howell St Davenport IA 52808 208 23 3601 800 553 1111 563 324 0138 KENTUCKY ADVANCED SHERMAN 330 North Spring St Louisville KY 40206 oe 896 2166 a only 800 633 8186 ax 502 897 9837 LOUISIANA RENTAL SERVICE 3301 Cities Service Hwy West Lake LA 70669 337 882
24. Ha Blaci Fog Figure 9B Wiring Diagram for 1 Speed 3 Phase Models REVERSING CONTACTOR SEE XFMR CHART H1 H2 XFMR NOTE DIAGRAM IS SHOWN FOR 8 AND 16 FPM HOIST MODELS ON 32 FPM MODELS THE LOCATIONS OF MOTOR LEADS T5 AND T8 ARE SWAPPED AT THE CONTACTOR AND TERMINAL BLOCK XFMR CHART 14 C15 UPL S DOWNLS GOLD NUT SILVER NUT 20 WIRING DIAGRAM 115 230 VOLT SINGLE PHASE DWG 981CE2100 000 WIRING DIAGRAM 2304480 THREE PHASE SINGLE SPEED HOIST DWG 983CE2100 000 12 Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 TROUBLE SHOOTING Always disconnect unit from the power supply system before removing hoist covers or the back cover of control station Probable Cause Remedy Hook fails to stop at end of travel 1 Limit switch not operating 2 Brass limit switch nuts not moving on shaft 3 Hoist reversing contactor malfunctioning EON Check adjustment See LIMIT SWITCH ADJUSTMENT page 8 Check connections against wiring diagram Tighten loose connections or replace Check for stripped threads or bent nut guide Remove electrical cover and check reversing contactor Hoist does not respond to pushbutton Power failure in supply lines Wrong voltage or frequency Improper connections in hoist or pushbutton station Brake does not release OL m
25. ained 1 115 230V 14 7 Single 9571 2 8 10 6 Double chained 1 230 460V 3 2 1 6 Three At full load it is not unusual for the hoist to draw in excess of The 1HP 115 230V models must have a dedicated power the values listed when lifting It is critical to ensure that the voltage at the hoist contactor does not drop below 10 of the nominal voltage of the hoist while it is lifting a load Low voltage will result in higher amp draw damage to the hoist and potential fire hazards MILWAUKEE is not responsible for any damages caused by an inadequate power source circuit rated for at least 20A 125V when they are wired for 115V It is not unusual for these models to draw up to 20 amps at 115V when lifting at rated capacity Refer to Table 3 before installation Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 APPLICATION INFORMATION This hoist is intended for general industrial use for lifting and transporting freely suspended material loads within its rated capacity MILWAUKEE cannot be responsible for applications other than those for which MILWAUKEE equipment is recommended 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 hoist in areas containing flammable vapors l
26. anism 1 Slippage or excessive drift N 2 Glazing contamination or excessive wear Hooks 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 Suspension Lug if used Cracks excessive wear or other damage which may impair the strength of the lug To find cracks use dye penetrant magnetic particle or other suitable detection methods Chain Inadequate lubrication excessive wear or stretch cracked damaged or twisted links corrosion or foreign substance Hook and Suspension Lug Connections Cracks bending stripped threads Pins Bearings Bushings Shafts Couplings Excessive wear corrosion cracks distortion Nuts Bolts Rivets Looseness stripped and damaged threads corrosion Sheaves Distortion cracks and excessive wear Build up of foreign substances Housings Load Block Cracks distortion Excessive wear internal build up of foreign substances Wiring and Terminals Fraying defective insulation Hoist Reversing Contactor other Electrical Apparatus Loose connections burned or pitted contacts Supporting Structure and Trolley if used Damage or wear which restricts ability to support imposed loads Nameplates Decals Warning Labels Missing damaged or illegible
27. c 24V Terminal Block 115 230V 230 460V Terminal Block 115 230V End Plate 115 230V 230 460V End Clamp Marking Strip Qty wo a Ref Description No 10 15 ft Power Cord Assembly 115 230V 1 2 hp 3 cond 14 AWG 115 230V 1 hp 3 cond 12 AWG 230 460V 4 cond 14 AWG 11 PB amp Cable Assembly See Figure 18 12 Panel Standoff Spacer 13 1 4 Internal tooth Lockwasher 14 1 4 20UNC X 4 Screw 15 8 32UNC X 5 16 Screw 16 8 External tooth Lockwasher 17 1 4 Flatwasher 18 10 24UNC X 1 2 Screw 19 Can Mounting Bracket 20 SINPAC Starting Switch 21 Capacitor 1 hp motor 1 2 hp motor Qty DN N N O O O 20 Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 Figure 17 Limit Switch Parts Parts List for Limit Switch Parts Ref Description Qty Ref Description Qty No No 1 Transmission Cover 1 9 Limit Switch Shaft 1 2 Limit Switch amp Shaft Assembly 1 10 Limit Switch Nut Silver 1 Includes Items 4 12 11 Limit Switch Nut Gold 1 3 Limit Switch Bracket Assembly 1 12 Retaining Ring 1 Includes Items 4 8 13 Insulator 1 4 Switch 2 14 Spring 1 5 6 32UNC X 1 Screw 4 15 10 24UNC X 1 2 Screw 2 6 6 32UNC Elastic Locknut 4 7 Limit Switch Bracket 1 Includes Item 8 8 Bushing 1 21 f Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 Figure 18
28. cal Cover Gasket Electrical Cover Hook Retainer Screw Top Hook Assembly with Latch Rigid Hook Standard tSwivel Hook Optional Part Latch Kit Assembly Hook Retainer Qty A lt n A lt ono I Cd 2 ad gu Ref Description No 13 MILWAUKEE Decal 14 Capacity Decal 1 2 ton 1 ton 2 ton A Nylon Cover 11 2 ton T1 ton T2 ton A Chain Container n 16 Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 Figure 13 Hoist Motor 1 Phase 1 Refer to the motor nameplate for part number voltage full load amperage horsepower and other motor information Parts List for Hoist Motor 1 Phase Ref No Description 1 Hoist Motor 1 2 hp 115 230V 1Ph 1 1 hp 115 230V 1Ph 1 2 Stator Assembly 1 3 Rotor Assembly 1 4 End Shield 1 5 Rear Bearing 1 6 Front Bearing 1 7 Shim Washer 1 8 Thru Bolt 4 9 10 Spring Lockwasher 4 Not available as an individual part 17 f Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 Figure 14 Hoist Motor 3 Phase 1 Refer to the motor nameplate for part number voltage full load amperage horsepower and other motor information Parts List for Hoist Motor 3 Phase Ref No Description 1 Hoist Motor 1 2 hp 230 460V 3Ph 60Hz 1 1 hp 230 460 V 3Ph 60Hz 1 2 Stator Assembly 1 3 Rotor Assembly 1 4 End Sh
29. ctor is within 10 of the nominal voltage while lifting a load Replace overload clutch assembly Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 TROUBLE SHOOTING Continued Motor brake noise or chatter while starting hoist 1 Brake needs adjustment 1 See BRAKE ADJUSTMENT page 9 2 Low voltage 2 Check voltage at the hoist reversing contactor while the hoist is lifting a load Voltage should be no less than 9096 of the voltage specified 115 volt hoists are particularly subject to voltage drop problems due to their high current draw Conversion to 230 volt operation is suggested in extreme cases Motor brake buzz anytime hoist is running 1 Brake needs adjustment 1 See BRAKE ADJUSTMENT page 9 2 Broken shading coil on brake frame 2 Replace shading coil or complete brake frame assembly INSPECTION AND MAINTENANCE CHECK LIST ELECTRIC POWERED OVERHEAD CHAIN HOIST Type of Hoist Capacity Tons Location Original Installation Date Manufacturer Manufacturers Serial No Item Frequency of Inspection Possible Deficiencies OK Action Required Frequent Periodic Daily Monthly 1 12 Mo Operating Controls Any deficiency causing improper operation Limit Switches 1 Any deficiency causing improper operation 2 Pitting or deterioration Brake Mech
30. d as a hoist hanger must have a greater load capacity than the hoist 13 Do not attempt to operate hoist beyond normal maximum lift range 14 Align hoist for a straight line pull Avoid side pull or end pull 15 Do not operate hoist with twisted or damaged chain 16 Do not operate a damaged or malfunctioning hoist until necessary adjustments or repairs have been made 17 Do not use 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 INSTALLATION 1 Before installing the hoist check the following a Make sure all supporting structures and attaching devices are strong enough to hold your intended loads If in doubt consult a qualified structural engineer b Provide proper branch circuit protection for the hoist as recommended in the National Electrical Code c The power supply should be within plus or minus 10 of the voltage specified on the motor nameplate It is critical to use adequate sized power cables especially with 1 phase hoists See Table 3 Be sure dual voltage hoists are connected or wired to correspond with your power supply See WIRING page 9 d Installation area must provide operating conditions for the operator including sufficient room for the operator and other personnel to stand clear of the load at all times e For installations where
31. dous situation which if not avoided could result in death or serious injury To avoid such a potentially hazardous situation THE OPERATOR SHALL A CAUTION Improper operation of a hoist can create a potentially hazardous situation which if not avoided could result in minor or moderate injury To avoid such a potentiall hazardous situation THE OPERATOR SHALL 1 NOT operate a damaged malfunctioning or unusually performing hoist 2 NOT operate the hoist until you have thoroughly read and understood the manufacturer s Operating and Maintenance Instructions or Manuals 3 NOT operate a hoist which has been modified without the manufacturer s approval or without certification that it is in conformity with ANSI ASME B30 volumes 4 NOT lift more than rated load for the hoist 5 NOT use 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 9 NOT operate unless load is centered under hoist 10 NOT attempt to lengthen the load chain or repair damaged load chain 11 Protect the hoist s load chain from weld splatter or other damaging contaminants 12 NOT operate hoist when it is restricted from forming a straight line from hook to hook in the direction of loading 13 NOT use load chain as a sling or wrap chain around load
32. e all parts and repair requirements promptly and efficiently Below is a list of the Authorized Warranty Repair Centers and Parts Depots located in United States its territories and Canada UNITED STATES ALABAMA TOOL SMITH CO 1300 4th Ave S Birmingham AL 35233 20 5 323 2576 or 500 317 8665 205 323 9060 ARKANSAS HJ SPEED HOIST amp CRANE 701 N N Little Rock 3h 7211 501 375 9178 Fax 501 375 4254 HANDLING SYSTEMS A CONVEYORS INC 10909 East Otter Creek Rd Mabelville AR 72103 501 455 5898 Fax 501 455 6179 ARIZONA MECHANICS TOOL SERVICE 1301 a ache Park Place Tusco 85714 520 ood 8484 AZ only 800 372 6700 ax 520 889 6668 CALIFORNIA ARROW CRANE HOIST CORP 12714 South Carmenita Road Santa Fe Springs CA 90670 562 921 8328 Fax 562 921 9307 IDG CALIFORNIA 6842 Walker Street LaPalma CA 90623 994 6960 x 800 464 5669 x 714 521 0105 CRANEWORKS INC 2585 Nicholson Street San Leandro CA 9457 510 357 4000 Fax 510 357 4099 KIMMERLE BROTHERS INC 12060 East Florence St Santa Fe Springs CA 90670 562 946 6771 Fax 562 944 3473 KIMMERLE BROTHERS INC 226 11th St San Franciso CA 94103 415 431 1163 Fax 415 431 1693 KIMMERLE BROTHERS INC 337 M St Fresno CA 93721 559 233 1278 Fax 559 233 4678 COLORADO CRANE REPAIR CO 3718 Norwood Littleton CO 8 303 791 200
33. eads to the terminal blocks according to the wiring diagram located inside the electrical cover and also in Figures 9A amp 9B DO NOT move any wires or make any changes to the electrical circuit except at the terminal block assembly Tug on wires to ensure they are securely connected 3 After converting voltage recheck phasing and limit switch operation See INSTALLATION 2 c amp 4 page 5 IMPORTANT Always refer to the wiring diagram located on the inside of the electrical cover or Figures 9A and 9B when performing electrical repairs Make sure all connections are secure and check for damaged insulation It is also imperative that the power circuit has conductors of adequate size See Table 3 LUBRICATION Refer to Figure 11 Proper lubrication is necessary for a long and relatively trouble free hoist operation Refer to the following and the RECOMMENDED LUBRICATION SCHEDULE for lubrication points type of lubricant and frequency of lubrication Load Chain Clean the load chain with acid free solvent and coat with SAE 90 gear oil Wipe excess oil to prevent dripping Never apply grease to the chain Gearing The gear case of this hoist is filled at assembly with approximately 11 2 pints of SAE 90 EP gear oil Check oil level by removing the oil level check plug from the side of the hoist With the hoist hanging level gear oil should be even with the hole Change oil periodically depending on the severity of the applica
34. ended Inspector s Report RECOMMENDED LUBRICATION SCHEDULE MILWAUKEE ELECTRIC POWERED CHAIN HOIST PAGE AND COMPONENT TYPE OF LUBRICANT TYPE OF SERVICE AND REFERENCE NO FREQUENCY OF LUBRICATION HEAVY NORMAL INFREQUENT GE 8 Load Chain SAE 90 gear oil Daily Weekly Monthly Figure 19 Gearing SAE 90 extreme pressure gear oil At periodic inspection See Figure 10A Figure 17 Limit Switch Shaft General purpose spray lubricant Monthly Yearly Yearly Ref No 9 Rot NC 38 50 Load Hook Bearing SAE 30 gear or motor oil Weekly Monthly Yearly NLGI 2 multi purpose A dep Bashing lithium base grease At periodic inspection See Figure 10A NOTE All bearings except hook and idler sheave bearings are prelubricated and sealed This lubrication schedule is based on a hoist operating in normal environment conditions Hoists operating in adverse atmospheres containing excessive heat corrosive fumes or vapors abrasive dust etc should be lubricated more frequently Figure 11 Recommended Lubrication Schedule 15 Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 Figure 12 Basic Hoist Parts List for Basic Hoist Ref No 1 O O Jo 0 s O N 11 12 A Not Shown t Optional Description Motor See Figures 13 amp 14 Cover Screw Trim Cover Transmission Housing Transmission Case Gasket Transmission Cover Electri
35. entire cable Check coils for open or short circuit check all connections in control circuit Check for burned contacts Replace as needed Check starting capacitor on motor Replace if necessary Replace overload clutch assembly Ensure that screw clamps are tightened on the terminal blocks and reversing contactor Motor overheats Excessive load Low voltage Extreme external heating Frequent starting or reversing OL lt Sa CILE Brake dragging ao Roo wma Reduce load to within rated capacity of hoist Determine cause of low voltage and bring up to within plus or minus 10 of the voltage specified on the motor Measure voltage at the hoist reversing contactor while lifting a load As the ambient temperature rises towards the 130 F limitation of the unit frequency of the hoist operation must be limited to avoid overheating of the motor See ADVERSE ENVIRONMENTAL CONDITIONS page 4 Excessive inching jogging or reversing should be avoided since this type of operation will drastically shorten the life of motor contactor and brake Check brake adjustment See BRAKE ADJUSTMENT page 9 Lack of proper lifting speed Hoist overloaded Brake dragging Low voltage Overload limiting clutch intermittently slipping fon Reduce load to within rated capacity of hoist Check for proper brake adjustment or other defects Ensure that the voltage at the reversing conta
36. he 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 Refer to Figure 3 1 Suspend the hoist Carefully lower the load block to a point where the slack end loop of the chain hangs down 6 or more from the hoist housing or the limit desired in any particular application allowing the minimum 6 There should be a minimum clearance of 1 between the chain stop and the bottom of the hoist 2 DISCONNECT HOIST FROM POWER SUPPLY and remove the electrical cover 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 disturb the gold slotted nut if it has been set previously Check Both Upper and Lower Limits 1 Connect the hoist to the power supply Be sure the green ground wire is properly grounded 2 Check load hook direction See INSTALLATION 2 c page 5 3 Carefully raise load block to upper limit and observe if it stops automatically at desired level Do not allow load block to run into hoist housing this will damage the hoist Maintain a minimum clearance of 2 from the hoist housing and the top of the load block on single chained
37. ield 1 5 Rear Bearing 1 6 Front Bearing 1 7 Shim washer 1 8 Thru Bolt 4 9 10 Spring Lockwasher 4 Not available as an individual part Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 Figure 15 Brake amp Solenoid Parts NOTE Refer to wiring diagram inside electrical cover of hoist or Figures 9A or 9B when connecting any wires E 10 Parts List for Brake amp Solenoid Parts Ref No Description Qty 1 Disc Brake Assembly 1 2 hp 115 230V 1 1 hp 115 230V 1 1 2 hp 230 460V 1 1 hp 230 460V 1 2 Plate amp Stud Assembly 1 3 Brake Disc 1 2 hp 2 1 hp 3 4 Brake Plate 2 5 Plate amp Armature Assembly 1 6 Spring 3 7 Retainer 1 8 Plate amp Frame Assembly 1 9 Brake Coil 115 230V 1 230 460V 1 10 Locknut 3 11 Adapter 1 12 Screw 3 13 Retaining Ring 2 14 Shading Coil 2 Shading Coil Adhesive 1 15 Lockwasher 3 16 Spacer for 1 2 hp 3 Dual voltage 115 230V models use 115V Brake Assembly and Coil Dual voltage 230 460V models use 230V Brake Assembly and Coil 19 f Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 Figure 16 Electrical Parts Parts List for Electrical Parts Ref No 1 2 3 Description Transmission Cover Panel Plate Reversing Contactor 1 hp 115 230V 1 hp 230 460V 1 2 hp Transformer Pri 115 230V Sec 24V Pri 230 460V Se
38. ion See Figures 12 and 20 The hoist sections must be separated at the top hook line in order to inspect the load sheave and chain guides See CHAIN REPLACEMENT WITH NO CHAIN IN HOIST page 8 While this section is apart check the following Load sheave Chain guides and plates Chain Chain support on 2 ton models Bearings Replace parts as necessary including screws lockwashers etc When reassembled recheck limit switch operation See LIMIT SWITCH ADJUSTMENT page 8 Periodic inspections of the top suspensions can be made without disassembly For more extensive inspections the lug maybe removed as follows 1 Disconnect the hoist and remove it to workbench 2 Remove the lug retaining screw 3 Remove the lug retainer 4 Remove the lug Figure 8A Single Chain Lug Orientation Figure 8B Double Chain Lug Orientation Care must be taken during reassembly to have the hook in proper orientation Refer to figures 8A amp 8B for proper orientation The transmission must be disassembled in order to inspect load sheave and chain guide see CHAIN REPLACEMENT WITH NO CHAIN IN HOIST page 8 When reassembled recheck the limit switch settings See LIMIT SWITCH ADJUSTMENT page 8 POWER CORD PRECAUTIONS WITH 1 PHASE HOISTS Electric hoists require a sufficient power supply It is especially important with single phase voltage to ensure that the conductors running to the hoist from the power source are ade
39. iquids gases or any combustible dusts or fibers Refer to Article 500 of the National Electrical Code Do not use this hoist in highly corrosive abrasive or wet environments Do not use this hoist in applications involving extended exposure to ambient temperatures below 10 F or above 130 F LIFTING OF HAZARDOUS LOADS This hoist is not recommended for use in lifting or transporting 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 hoist LIFTING OF GUIDED LOADS This hoist is not recommended for use in the lifting of guided loads including dumbwaiters and elevators Such applications require additional protective devices which are not incorporated into this hoist 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 A WARNING Failure to comply with Safety Precautions outlined throughout this manual can result in serious injuries or death Before using this hoist each operator should become thoroughly familiar with all warnings instructions and recommendations in this manual y SAFETY INFORMATION 1 Follow all local electrical and safety codes as well as the Nati
40. models and 1 from the chain support to the top of the load block on double chained models 4 Carefully lower load block 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 hoist housing This will damage the hoist There should be a minimum clearance of 172 between the chain stop and the bottom of the hoist 5 If upper and lower limits operate satisfactorily 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 hoist If the hoist develops either undesirable over travel after the pushbutton is released this condition is most noticeable in the lowering direction or hesitates to lift the load promptly when the pushbutton is depressed this condition is most noticeable in the hoisting direction the brake should be adjusted Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 Brake Adjustment Refer to Figure 5 1 DISCONNECT HOIST FROM POWER SUPPLY and remove the electrical cover 2 With reference to Figure 5 the gap between the brake armature A and the field B should be checked The correct gap is 0 015 Adjustment should not be necessary until gap reaches 0 040 Figure 5
41. ng the hoist 14 NOT allow the hoist to be subjected to sharp contact with other hoists structures or objects through misuse 15 NOT adjust or repair the hoist unless qualified to perform such adjustments or repairs Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 TABLE OF CONTENTS Safety Precautiorns dun eee tera tue ur Hoist Specifications Application Information Safety Information Installation Operation Maintenance Wiring Diagrams Trouble Shooting Inspection and Maintenance Check List Recommended Lubrication Schedule Replacement Parts List Parts Depot amp Warranty Repair Centers odi iiec an e ou HOIST SPECIFICATIONS MILWAUKEE Electric Chain Hoists are rugged portable hoists that provide quick precise lifting The hoists are constructed of tough but lightweight die cast aluminum alloy housings An oil bath transmission equipped with heat treated alloy steel gears and an overload limiting clutch provides smooth and reliable operation With a pushbutton station that fits comfortably in one hand the operator can safely control the hoist while the other hand is free to guide the load The electrical controls which are readily accessed under the electrical cover utilize quick connections f
42. of the armature plate points X Figure 5 page 9 to close the solenoid and release the brake A WARNING Do not allow screw driver blades to touch rotating friction disc CAUTION Do not allow the load to descend rapidly This causes the motor to race and serious damage may result E 3 Use several guick releases instead of holding brake open continuously Do not exceed normal lowering speed HOOKS Refer to Figure 2 1 Inspect hooks once daily for cracking extreme wear or spreading Replace hooks showing any of these signs If the throat openings are spread wider than the maximum permissible 15 increase listed here the hooks have been overstressed and must be replaced Any hook that is bent or twisted more than 10 from the plane of an unbent hook must also be replaced 2 The hock latches should be inspected to ensure that they close the hook throat opening in a secure manner when a load is applied Inspect the hook shank and nut for any stripping of the threads or other damage The hook nut should be fully restrained by the retaining pin 3 In addition to above load hooks should be inspected for cracks by the magnetic particle dye penetrant or other suitable crack testing inspection method This should be done at least once a year Figure 2 Hook Inspection Dimension Hoist Bottom Capacity Hook 1 Ton amp Under 1 22 17 32 2 Ton 1 52
43. onal Electrical Code NEC and the Occupational Safety and Health Act OSHA in the United States 2 Hoist must be securely and adequately grounded The hoist power cable is provided with an additional lead green for grounding purposes 3 Be careful when touching the exterior of an operating motor it may be hot enough to be painful 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 A WARNING Always disconnect the power source before working on or near a 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 cable and control cable from coming in contact with sharp objects 5 Do not kink power cable and control cable and never allow the cable to come in contact with oil grease hot surfaces or chemicals 6 Make certain that the power source conforms to the requirements of your equipment 7 Inspect the unit daily before operating hoist 8 Cluttered areas and benches invite accidents 9 The operator should not engage in any practice which will divert his attention while operating the hoist 10 Before using the hoist the operator should be certain that all personnel are clear 11 Do not operate hoist with loads exceeding its rated capacity 12 Supporting frames or beams use
44. or easy voltage conversions and a 24V control circuit for added safety Table 1 Hoist Specifications Lifting Control Cord Speed Length fpm ft Model Capacity tons Reeving Other features that ensure the safe operation of MILWAUKEE Electric Chain Hoists include a magnetic disc brake that delivers sure stopping and secure holding of the load Adjustable upper and lower limit switches regulate the load travel As a standard hooks are supplied with safety latches For additional safety a chain stop is attached to the slack end of the load chain MILWAUKEE Electric Chain Hoists are designed and tested in accordance with the American Society of Mechanical Engineers Code B30 16 Safety Standard for Overhead Hoists Hoists are built in compliance with CSA file number LR 44484 Made in U S A Full Load Motor Amps Voltage Phase AC 9560 1 2 16 10 6 Single chained 1 2 115 230V 7 6 3 8 Single 9561 1 2 16 15 11 Single chained 1 2 115 230V 7 6 3 8 Single 9562 1 2 16 20 16 Single chained 1 2 115 230V 7 6 3 8 Single 9565 1 16 10 6 Single chained 1 115 230V 14 7 Single 9567 1 16 15 11 Single chained 1 115 230V 14 7 Single 9568 1 16 20 16 Single chained 1 115 230V 14 7 Single 9566 1 16 10 6 Single chained 1 230 460V 3 2 1 6 Three 9570 2 8 10 6 Double chained 1 115 230V 14 7 Single 9572 2 8 15 11 Double chained 1 115 230V 14 7 Single 9573 2 8 20 16 Double ch
45. orized MILWAUKEE Service Station If inspection shows the trouble is caused by defective workmanship or material all repairs will be made without charge and the hoist will be returned transportation prepaid This warranty does not apply where 1 repairs or attempted repairs have been made by persons other than MILWAUKEE personnel or Authorized Service Station Personnel 2 repairs are required because of normal wear 3 the hoist has been abused or involved in an accident 4 misuse is evident such as caused by overloading the hoist beyond its rated Capacity 5 the hoist has been used after partial failure 6 the hoist has been used with an improper accessory No other warranty written or verbal is authorized AWARNING 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 NN Do not suspend unattended loads over people Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield WI U S A 53005 04 04 Printed in USA
46. protect the hoist against damage resulting from overtravel or to allow setting the hook travel within the factory set limits of travel For easy identification and association with the proper direction of travel the upper and lower limit switch adjusting nuts are color coded gold and silver respectively Each limit nut has 10 slots for fine adjustment and the increment of adjustment is such that one slot is equivalent to approximately one link of chain travel Movement of the limit switch nuts toward or away from each other increases or decreases the hook travel respectively Care should be exercised when adjusting either limit of travel 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 WIRING DIAGRAMS page 12 Adjusting Upper Limit Gold Nut Refer to Figure 3 1 Suspend the hoist For single chained models raise the load block until there is a minimum clearance of 2 from the hoist housing and the top of the block Double chained models require a minimum clearance of 1 from the chain support to the top of the load block 2 DISCONNECT HOIST FROM POWER SUPPLY and remove the electrical cover 3 With a screwdriver pry the spring guide plate out of the slots in the limit switch nuts 4 Turn the slotted gold nut toward its limit switch until the switch clicks then turn two slots farther Release t
47. quate in size to handle the power requirements of the hoist Inadequate power cables and branch circuits will cause low voltage high amperage damage to the hoist and potential fire hazards Such problems can be minimized by using 230V power on 115 230V hoists The following are recommendations for the conductor gage size depending on the length horsepower and voltage Table 3 Recommended Conductor Sizes for 1 Phase Hoists Maximum Length of Power Cord in Feet HP Voltage 14 AWG 12 AWG 10 AWG 8 AWG 1 Phase 1 2 115V 40 60 100 150 230V 200 330 520 810 1 115V 50 75 230V 120 190 310 490 11 Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 IMPORTANT DUAL VOLTAGE HOIST SINGLE PHASE HOISTS ARE FACTORY WIRED FOR 115V TO CONVERT VOLTAGE RECONNECT LEADS TO THE TERMINAL BLOCKS EXACTLY AS SHOWN BELOW FOR THE REQUIRED VOLTAGE BEFORE APPLYING POWER TO THE HOIST SINGLE PHASE POWER TERMINAL BLOCKS 230V SINPAC SWITCH 1 C20 xt 2 3 4 DOWN C21 BRAKE SOLENOID c2 PB STATION 115V COIL CAPACITOR Figure 9A Wiring Diagram for 1 Speed 1 Phase Models IMPORTANTI DUAL VOLTAGE HOIST THREE HAEE HOIETE ARE FACTORY WIRED FOR ARM TO CONVERT VOLTAGE LEADG TO THE TERMINAL BLOCKS EXACTLY AS SHOWN BELOW THE REQUIRED VOLTAGE BEFORE APPLYING POWER TO THE HOIBT 1 E Hn Orange
48. rse any two wires except the green ground wire at the power source to correct the load hook direction phasing Do not change connections in the OPERATION hoist or pushbutton assembly d Make sure load chain is not twisted as it travels into the This hoist is designed for safe operation within the limits of its hoist rated capacity It is controlled with the UP and DOWN buttons of the pushbutton station There are many safety features to protect the operator from injury due to failure of the hoist Here are some points which should be observed to maintain safe operation e Operate hoist in a hanging position only Hoist should be permitted to align itself for a straight line pull Do not attempt to pull around corners f Read ASME B30 16 Safety Code for Hoists 3 If necessary lubricate the chain see LUBRICATION 1 Do not overload the hoist page 9 2 Do not make extreme side pulls with the hoist 4 Check the function of the limit switches Before placing hoist 3 Operate the hoist only in a hanging position with in operation check limit switch adjustment Operate adequate support pushbutton until near stop point and inch into stop limit both 4 Do not sling the load hook and chain around the load top and bottom If either switch is not correct adjust Use an approved sling according to LIMIT SWITCH ADJUSTMENT page 8 5 Be sure there are no twists in the load chain as it travels into Installation of Standard Chain the
49. sin 53005 TEL 800 729 3878 Chain Replacement with No Chain in Hoist Refer to Figures 4 and 5 1 DISCONNECT HOIST FROM POWER SUPPLY and move hoist to a work table Remove the electrical cover electrical panel and the electric brake assembly 2 Detach the chain stripper from the bottom of the hoist 3 Insert the new chain between the load sheave and the chain guide Feed the chain into the hoist by manually turning the brake hub Allow about 15 of chain below the 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 center of the hoist or to your right looking from the transmission end CAUTION There are wires running through the hoist Carefully ease the hoist sections apart Do not jerk them apart 4 Reinstall the chain stripper with the chain anchor on double chained hoists See Figure 4 observing proper chain alignment and avoiding any twist in the chain Follow steps 11 through 14 in previous section CHAIN REPLACEMENT WITH CHAIN IN HOIST to complete the chain replacement procedure NOTE Inspect chain guides and load sheave for wear replace as needed LIMIT SWITCH ADJUSTMENT IMPORTANT Before placing hoist in operation check the limit switch adjustment Limit switches are provided to
50. the Replacement Parts List starting on page 16 For clarity these are broken down into areas Electrical Parts and Brake Refer to Figures 9A 9B amp 16 1 Remove the cover to access the controls Single phase models also have a starting switch and capacitor mounted on the motor as shown in Figure 13 The terminal blocks and end clamps snap off of the rails on the plate using a small screwdriver DO NOT SLIDE THE END CLAMPS The reversing contactor can be slid off the rail but it 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 9A amp 9B Single phase contactors have a small jumper that is not present on the 3 phase note the 3 and 5 terminals on the reversing contactor in Figure 9A 2 Remove the electrical panel by removing the stand off screws See Figure 16 The limit switch and brake are now accessible as shown in Figure 6 3 Remove the transformer bolted to the back of the panel plate if it requires replacement 4 Refer to Figure 15 to disassemble the brake See BRAKE ADJUSTMENT on page 9 to properly set the brake 5 Refer to Figure 17 to disassemble the limit switch See LIMIT SWITCH ADJUSTMENT on page 8 to properly set the
51. the slack chain hanging from the unit may be objectionable or hazardous the use of a chain container is recommended See INSTALLATION OF CHAIN CONTAINER ASSEMBLY Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 2 Before operating the hoist be sure to observe the following a ALWAYS DISCONNECT HOIST FROM POWER SUPPLY before removing the electrical cover or when making any Retainer electrical connection in the hoist or pushbutton station Clip b The ground wire green colored of the power cable should always be connected to a suitable ground by Attac ment means of a screw or clamp An alligator clip does not make a safe ground connection Figure 1 Installing c When installing a three phase hoist make only temporary Chain Container connections at the power source Push the UP button Assembly and observe the direction of the load block If it raises the phasing is correct and permanent connections may be 4 Feed the remainder of chain into container by operating made at the power source If the load block lowers when hoist in the UP direction to the top limit This will permit the the UP button is pushed release the button immediately chain to pile freely and prevent the chain from kinking which since the limit switches will not operate to protect the hoist may occur if the chain is placed in the container by hand from over travel Reve
52. tion and the environmental conditions at least every 200 hours of run time Bearings All bearings except hook and idler sheave bearings are lubricated at the factory and should not require additional lubrication Noisy or worn bearings should be replaced Limit Switch Shaft Remove any dirt accumulation and spray with a general purpose lubricant Hook Bearing Apply a few drops of SAE 30 gear or motor oil around the edge of the bearing Idler Sheave Bearing Bushing Disassemble load block and apply a light coat of NLGI 2 grease or equivalent inside of bearing HOIST REPAIRS NOTE If you do not have an experienced mechanic to do your repair work we recommend that you send your hoist to an approved service station for repairs Use authorized repair parts only 1 For major repairs or when the hoist is to be sectioned in the suspension area it will be necessary to move the hoist to a workbench or table Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield Wisconsin 53005 TEL 800 729 3878 AWARNING Remove load and disconnect hoist from power supply before starting to do any repairs or to take any sections apart 2 For repairs which can be done by removing the electrical cover only the hoist need not be moved Lowering the hoist to a convenient working level is desirable The following repair instructions will help you in understanding repair procedures when related to

Milwaukee 9573 Use and Care Manual

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