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Americrane & Hoist Corp.

1-800-652-1932

ElufF-Ncr-tcrn
OPERATING& MAINTENANCE COFFING"
INSTRUGTIONS HOTSTS
WITH PARTS LISTS
PUBLICATION
PARTNO.EC.68O-4
ELECTRICCHAIN HOISTS

For ModelNos.
EC-0516 EC-2008
EC-0s32 EC-2012
EC-0564 EC-2016
- EC-l009 EC-4006
EC-l016 EC-4008
EC-l032 EC-6005

IMPORTANT - CAUTION
This manual contains important information for the correct installation,operation and maintenanceof the
equipmentdescribedherein.All persons involvedin such installation,operationand maintenanceshould be
thoroughly familiar with the contents. To safeguard against the possibility of personal injury or property
damage,follow the recommendationsand instructioni of this manuat anci feep it for furthei reference.
1
WARNING
The equipment shown in this manual is intended for industrial use only and should not be used to lift,
support, or otherwise transport people, or to suspend unattended toads over people.

>
"TOUFF-NORTON 1993
g|rlE L_q'!f_E,_NORTH
ALL RIGHTS
CAROL|NA, USA
RESERVED Duft-Nonton
Americrane & Hoist Corp. 1-800-652-1932
rABLEOF CONTENTS
PAGE
SECTIONI INTRODUCTION
t-l
1l

l_3
General Information
S a f e t y S r a n d a r d.s. . . . .
Hoist Construction and Features . . . . . .
l*
3
l-4 Basic Hoist Data . . 5
l-5 Applicarion Information J
t_6 Warranty....... J

SECTION II INSTALLATION
tl
Safety Notes .4
Hanging the Hoist ..4
2-t Power Supply Connection ..4
2-4 Vent Plug .. . ..4
2-5 Chain Lubrication . . . .. .4
2-6 Testing . 4
a1
Trolley lnstallation. . . . +5
2-8 C h a i n C o n t a i n e r l n s t a l l a t i o.n. . . .6

SECTIONIII OPERATION
3-l General 6
t-z Safety Notes 6
J-J Handling The Load 6
3-4 Overload Limiting Prorection . 7

SECTION IV INSPECTION
+l General ...7
+2 Frequent Inspection 7
+t Periodic Inspection ....7
u [.oad Brake Function Check . 9
+5 Chain Inspecrion 9 -l 0
+6 Hook Throal Opening l0

SECTIONV MAINTENANCE AND REPAIR


5-l General ...t0
5-2 Limit Switch Adjustment ... lG.ll
5-3 ...11
5-4
Motor Brake Adjustment
Top Suspension Removal and Replacement . . . . . ll 3
5-5 Chain Replacement ...12
5-6 Lubrication t2-t3

SECTIONVI TROUBLESHOOTING
6-l General l+15

SECTIONVII WIRING
7-l Voltage Conversion l6
11
WiringDiagrams...... l6-18

SECTION VIII ILLUSTRATEDPARTSLISTS


8-l General .19
8-2 How to Use lhe Parls List. . .19
8-3 How to Order Replacement Parts . . l9
FIGURE 8-I Basic Hoist .20
J1
FIGURE 8.2 SuspensionAssembly Kits
FIGURE 8.3A Motor Parts (Three Phase) . . . .24
RGURE 8-38 Motor Pans (Single Phase) .25
FICURE 8-4A Controller Area (SinSle Speed) 26
RGURE 84B Controllcr Area (Two Speed) .27
FIGURE 8.5 Transmission..... .28
FIGURE 8-6 ChainingParts... .30
FIGURE 8-7A Bottom Block (th & t/z-ton) . . . .32
FIGURE 8-7B B o t r o mB l o c k ( l - t o n ) . . . . . . . . 32
FIGURE 8-7C Bottom Block (Double Chain) . .32
FIGURE 8.7D Bottom Block (Triple Chain) .32
FIGURE 8-8A Standard Limit Switcb Pans. .34
FIGURE 8.88 Long Lift Limir Switch Parts . . .35
FIGURE 8.9 Motor Brake Parts . . . .J6
FIGURE 8.IOA Pushbutton (Single Speed Hoist) .38
FIGURE 8.IOB Pushbutton (Two Speed Hoist). 40
RGURE 8-II Chain Container Parts. . . . . . .42

SECTION IX DO'S AND DO NOT'S 43 *'


Americrane & Hoist Corp. 1-800-652-1932
sEcfloN I
INTRODUCTION
1-1.GeneralInformation 1-5.ApplicationInformataon
U This manual provides information for the safeoperation This hoist is intended for general industrial use in the
and maintenance of Coffingo EC-l Series Hoists. All lifting and transporting of freely suspended material
personsoperatingor maintaining thesehoistsshould be loads within its rated load. Prior to installation and
familiar with the information contained herein. Adher- operation, the user should review his application for
ence to the precautions,procedures,and maintenance abnormalenvironmentalor handlingconditionsand to
practicesdescribed should ensure long reliable opera- observethe applicablerecommendationsas follows:
tion. Suggestionsfor improvements to this manual are a. Adverse Environmental Conditions Do not use the
solicited. hoist in areascontaining flammable vapors, liquids,
1-2. Safety Standards gasesor any combustible dusts or fibers. Refer to
All personsconcernedwith the installation, operation, Article 500 of The National Electric Code. Do not
inspectionand maintenanceof thesehoists are urgedto use this hoist in highly corrosive, abrasive or wet
read American National Standard(ANSI) B30.16.That environments.Do not use this hoist in applications
Standardcontains valuable guidelinesconcerningprac- involving extended exposureto ambient tempera-
tices designedto minimize hazardsassociatedwith the turesbelow -10"F or above 130"8
useof overheadhoistingequipment.ANSI B30.16also b. Lifting of HazardousLoads This hoist is not recom-
contains detailed procedures for establishing hoist mendedfor use in lifting or transportinghazardous
inspection and maintenance programs and can be of loads or materials which could cause wide-spread
significant assistancein maintaining compliance with damageif dropped.The lifting of loadswhich could
OSHA regulations. explodeor createchemicalor radioactivecontamina-
1-3.HoistConstruction
and Features tion if dropped requiresfail-saferedundant support-
Strong,lightweightaluminum alloy die castingsprovide ing deviceswhicharenot incorporatedinto this hoist.
a compact,protectiveenclosurefor the mechanicaland c. Lifting of Guided l-oads This hoist is not recom-
clcctricalcomponentsof Coffrng' EC-l SeriesHoists. mendedfor usein the lifting ofguided loads,including
Heal treated alloy steel gearing operatesin an oil bath dumbwaitersand non-ridingelevators.Suchapplica-
1o provide the most reliable lubrication and eflective tions require additional proteclive deviceswhich are
heatdissipation. not incorporated into this hoist. Refer to your stale
EC-l Series Hoists incorporate the following and local regulationsgoverning the requirementsfor
features: clevatorand dumbwaiter installations.
a. Overloadlimiting clutch.
1-6. Warranty
b. Completely independentmechanicaland electrical
brakes. Every hoist is thoroughlyinspectedand testedprior to
shipmentfrom thelactory.Shouldany problernsdevelop.
c. Adjustablelimit swilches.
returnthe completehoist prepaidto your nearestDufl'-
d. Tough, nylon weatherproofpushbulton stations. NortonAuthorizedWarrantyRepairStation.lf inspection
e. Steelstrain cableinside pushbuttoncord. revealsthatthe problemis causedby clefectiveworkntan-
f. Transformer isolated, low-voltage pushbutton shipor material, repairswill be madewithoutchargeand
controls. the hoist will be returned,transportatic'rn prepaid.
g. Quick voltageconversionon dual-voltageunits. This warrantydoesnot apply where:( I ) deterioration is
causedby normal wear, abuse,improperor inadequate
TABLE1-1.BASICHOISTDATA power supply,eccentricor side loading, overloading.
Rrted l,ift Speed chernicalor abrasiveactions.improperrnaintenance
Model
Irad et Reted l-oed
Motor or
No. HP
0b) (ft per min) excessive heat;(2) problemsresultedfrom repairs,modi-
EC-0516 500 l6 Vt ficationsor alterationsmadeby personsotherthanfactory
EC4532 500 Ut
or Duff-NortonAuthorizedWarrantyRepairStationper-
8C4564 500 64 I

EC-1009 r000 9 Vt
sonnel;(3) the hoist has been abusedor damagedas a
EC-1016 1000 l6 y2 resultof an accident;(4) repairpartsor accessories other
EC-1032 1000 32 I
thanthosesuppliedby Duff-Nortonareusedon the hoist.
EC-2008 2000 8 Vt
Equipmentandaccessories not of the seller'smanufacture
EC-2012 2000 t2 th
EC-2016 2000 l6 I arewarrantedonly to the extentthat they arewarrantedby
EC4006 4000 6 the manufacturer.EXCEPT AS S]'ATED HEREIN.
EC4008 4000 8 I
D U F F - N O R T O NM A K E S N O O T H E R W A R R A N -
EC-6005 60m ) I TIES, EXPRESS OR IMPLIED, INCLUDING
WARRANTIES OF MERCHANTABILITY AND
1-4.Basic Hoist Data FITNESSFOR A PARTICULARPURPOSE.
Thebasichoistmodelscoveredbv thismanualarelisted
in Tablel-1.
Americrane & Hoist Corp. 1-800-652-1932
sEcroN il
INSTALLATION
2-1.SaletyNotes e. When installing a three-phasehoist, make only tem-
a. Inspectthe hoist for any evidenceof shippingdamage poraryconnectionsat the powerline. Pushthe "UP"
or loose parts. button and observethe direction of the hook. If it
b. The supporting structure and load attachingdevices raises,the phasingis correct and permanent connec-
shouldhave a load rating at leastequalto that of the tions may be madeat the powerline. If the load block
hois1. lowerswhen the "UP" button is pushed,releasethe
button immediatelysincethe limit switcheswill not
c. This hoist is not suitablefor usein uncoveredouldoor operateto protect the hoist from over-travel. Reverse
locationsor areascontainingexplosivedust, vapors the red and black wires at the power line connection
or gases. to correctthe hook direction.
d. The installation area must provide safe operating CAUTION
conditionsfor the operator,includingsufficientroom Do not changeconnectionsin the hoist or the pushbutton
for the operator and other personnelto stand clear assembly.
of the load at all times.
e. In areaswhere slack chain hanging from the hoist 2-4. Vent Plug
may createa hazard,usea chaincontainer(seeFigure This hoist has an oil-bath transmission.For shipping
2-2). purposes,a non-vented fill plug (24, Figure 8-l) was
installedat the factory.A vented plug is locatedin an
2-2. Hanging the Hoist envelopetied to one of the hoist cnd coversand must
Hook mounted hoists can be used with a variety of be installed in place of the non-ventedshipping plug
trollcysor stationaryhangers.It is recommendedthat a beforeoperatingthe hoist.
hand-gearedor motorized trollcy be used when the
pulling effort required to move thc hoist exceeds100 2-5. Chain Lubrication
poundsor when the applicationrcquiresfrequentmove- Thc hoist chain should bc liberallyoiled beforeplacing
mcnt of the hoist. thc hoist inlo operation.For lubricationinstructions,
a. Makc sure thal thc-hook latch closesafter hanging scc paragraph5-6.a.
thc hoist.
2-6. Testing
b. The standardtop hook is restrainedfrom rotationby a. Bcfore placing the hoist into operation, check for
a plate and two screws.Thc hook can be madc lo properlimit switchoperation.Pushthe "UP" butlon
swivel freclyby removingthe plate,or can be rotated and verify that the hook block stopsat least2 inches
90" and fixed in that position. from the botlom of the hoist. Run the hoist down to
c. Sce Figure 2-l for instructions on adjusting lug- ils lowerlimit. At leastl2links ofchainshouldremain
mounted plain trolleys. on the slackend. If eitherswitchis not correcl,adjusl
d. Refer to Coffrng Motorized Trolley Operatingand accordingto the procedureoutlinedin paragraph5-2.
MaintenanceInstructionsmanualfor motorizedtrol- NOTE
lcy installationinstructions. The upperand lower limit switchesare factorysetto
provide the maximum allowablehook travel. This
2-3. Power Supply Connection travel adjustmentshould not be increased.Howcver,
a. Disconnectpower beforemaking connections. the switchesmay be adjustedto stop the hook sooner
b. Voltagesuppliedto the hoist should be within plus at either end of its travel.
or minus 100/o of the voltagespecifiedfor the hoist. b. Attach a light load to the hook and check the hoist
Hoisls are laggedat the factory with a tag indicating for proper operation.The load should slop without
the vohage for which the hoist is wired. Standard noticeable drift when the pushbutton is released.
singlephasehoistsare convertiblefrom ll5 to 230 Increasethe load to nearratedload.The hoist should
volts. Standard single speed.three phase hoists are still lifl the load without hesitationand stop with no
convertible from 460 volts to 230 volts. See the more than one inch drift.
Wiring section(paragraph7-l) for voltageconversion
instructions. 2-7. Trolley Installation
c. National ElectricalCode(ANSI Cl) and localelectri- Cofling'CT Seriestrolleyscanbe mounledon American
cal codesshouldbe consultedand properdisconnects, StandardI Beamsfrom 6 to l8 incheshigh. Adjustment
branch circuit protectors,and wiring provided. for di{Ierentbeamdimensionsis accomplishedwith thft:-
proper placementof spacerwashersas describedbelow
d. Power cablesfurnished with the hoist have a green in paragraph2-7.a.
colored ground wire which must be securely con-
nected to the electricalsystemground.
Americrane & Hoist Corp. 1-800-652-1932
a. "I"-Beam Adjustment.Adjustment for "I" beam sizes The particular beam on which your hoist is to be
and tolerancesis accomplishedby locatingthe spacer installedshould be measuredand trolley spacerwash-
washersas shown in Figure 2-1. Normal placement ers adjustedas required to achievea clearanceof ln"
of washersis given in Table 2-2. Refer to Table 2-l to t/s".
for identification of part names and numbers. b. Periodic Inspection.The trolley should be inspected
BEAM MANUFACTURING TOLERANCES periodically for evidenceof excesswear or overload.
ALLOW WIDE VARIATIONS FROM HAND- Parts should be replacedas required.
BOOK FLANGE WIDTHS, AND SLIGHT
c. Lubrication. Trolley wheelsare equippedwith sealed,
CHANGES TO RECOMMENDED WASHER DIS-
lifetime lubricated, precision ball bearings which
TRIBUTION MAY BE NECESSARY TO SUIT
should not require lubrication for the normal service
SPECIFIC INSTALLATIONS.
of the trolley.

DETAIL
3-TON CT TROLLEY t1
WHEEL ASSEiIBLY I
f I 1a
\

FIGURE 2-I. COFFING CT TROLLEY

TABLE2-1. PARTSLIST FOR CT TROLLEY


INDEX PART PART NUMBERS INDEX PART PART NUMBERS
NO. NAME % TO 2-TON 3-TON NO. NAME % TO 2-TON 3-TON
t Load Pin r03Kl t03Kt 8 Axle l02Kl t02K2
z Washer(7r" Thick) H-42t1 H-42t1 9 RetainingRing Not Req. H-5530
3 Washer(.135"Thick) H-4209 H-4209 0 Bearing 500K4 500K5
4 Washer(.075' Thick) H-42r0 H-4210 I Retaining Ring H-5528 H-5529
5 Nut H-3945 H-3945 2 Nut (Axle) H-3945 H-3946
6 Side Plate 5Kl 5K2 3 Washer H-42t1 H-42t2
7 Wheel 45Kl 45K2 4 Spacer 200Kr Not Req.

TABLE2-2. TROLLEYI-BEAMADJUSTMENTDATA
Foint A Foint B Acturl hintC
l-Beam' F-lange Wsshers Between Weshers Between
Si"r & Sprcing Cleennce
width Susp. Lug & Sleeve Sideplete & Nut Susp.Lug Wheel to
Weight
.135 Thicli .075 Thick .135Thick .075 Thick to Sleeve Berm
6"-t2.5# 1.330 I 0 8 5 .135 l5
6-t7.25# 3.565 2 0 7 5 .2"1o J)

8"- I 8.4 4.000 I 6 4 .480 25


8"-23.0 4 . t 7| 2 6 J .555 l5
0'-25.4 # 4.660 6 0 J 5 .8t0 25
0'-35.0 # 4.944 7 0 z 5 .945 l8
2',-31.8# 5.000 5 4 I .965 l0
2"-35.0# 5.078 7 I 2 4 1.021 26
5'42.9 # J.500 9 0 0 5 t.215 l0
5',-50.0 # 5.640 9 I 0 4 1.290 l5
8',-54.7 # 6.000 8 I 0 1.460 -tQ7
8"-70.0 # 6.250 9 5 0 0 l.590 .lil
tAmenan
Srandard I-B€am
NOTE: All dimensions are in inchx unl6s otheryiF smificd.
Americrane & Hoist Corp. 1-800-652-1932
2-8. Ghain Container Installation completely through plate and into the opposite
a. Operate hoist in "down" direction until it is stopped housing.
by the limit switch. Disconnect the slack end of the c. Use the two hex washer head screws provided to
chain from the hoist by using a small screwdriverto fasten the two remaining hanger chains into the I
slide the spring-loadedpin to the left. At least8 inches notcheson the lower edgei of tne hoist housings. e
of chain should hang from the hoist. If less than 8
inches of slack chain is present,readjust lower limit d. Be sure the end of the chain is started into the
switch usingthe proceduresdetailedin paragraph5-2. container.Run hoist up until the hook block is even
with the bottom of the chain container.
b. Slide the spring-loadedpin asideand slip the mount-
ing arm into the slot until the pin fits through the e. Resetupper limit switch at this position (seeproce-
hole in the plate (seeFigure 2-2). Be sure pin passes dure, paragraph 5-2) to prevent the possibility of
raising a load into the chain container.

SLOT FOR
SMALL SCREWDRIVER

CHAIN
CoNTAINER--\
$
CAUTION \ \
Short edgeof chain container\
bodv must be mounted \ HEX HEAO
toward hoist (as shown).

FIGURE 2-2. CHAIN CONTAINER INSTALLATION

sEcTtoNill
OPERATION
3-1. General anytime it is moving and should be sure that the
This sectionpresentsinformation concerningthe proper load does not contact any obstructions.
operationof the Cofling'Electric Chain Hoist. It is not
h. Read ANSI 830.16 SafetyStandardfor Overhead
intended to serveas a handbook on rigging.Rigging,the
Hoists.
processof moving heavy loads using mechanical
devices,requiresspecialknowledgeand equipment. For
3-3. Handling The Load
information on the safeuseof slingsand similar riggrng
a. Align hoist directly over load. Avoid side pull.
gear, usersare urged to consult a textbook on rigging.
b. The hoist chain should not be wrappedaround the
3-2.SafetyNotes load. Use proper slings.
a. Inspect the hoist for any sign of loose, broken, or c. Be sure there are no twists in the load chain as it
malfunctioningparts(seeSectionIV). Any malfunc- entersthe hoist.
tioning hoist should be taggedas "out oforder" and
removed from serviceuntil the defect is corrected. CAUTION
This conditionshould be constantlycheckedon dou-
b. Before starting the hoist, the operator should be ble or triple chain hoists becauseit is possible for
certain that all personnelare clear. the load block to be "capsized" or flipped over one
c. Do not lift more than the rated load of the hoist. or more times, putting twist in the chain. The pres-
d. Do not lift people or loads over people. enceof twist may not be obviouswhen the hook block
e. Avoid joggrng controls or quick reversalsof sus-
is in the lowered position but can causeserious chain
binding when the hook block is in its fully raised
b"
pended loads. position.
f Do not leave a suspendedload unattended. d. Bring the hook into engagementwith the load and
g. The operator should have a clear view of the load make sure it is well seatedbefore proceedingto lift
Americrane & Hoist Corp. 1-800-652-1932
the load. On multiple reevedhoists,be surethat the run, causing overheating of both the clutch and the
load is equalizedon all supporting chains. motor. This condition should be avoided by immedi-
e. Lift the load just clear of its supports and stop the ately releasingthe "[JP" button and reducing the load
hoist to check for proper brake operation. to within the hoist load rating.
{y f. Avoid letting the hook or load swing excessively CAUTION
while moving a trolley suspendedhoist. The overloadlimiting clutch is an emergencyprotective
deviceand should not be usedto measurethe maximum
3-4.OverloadLimitingProtection load to be lifted, or to sensethe overloadimposed by a
This hoist is equippedwith a factory-calibratedoverload constrainedload. Manufacturing tolerancesrequire that
limiting clutch, which will permit the lifting of loads the clutch be set somewhatabovethe load rating of the
within its load rating, but will prevent the lifting of hoist. The fact that the hoist will pick up loads in excess
damaging overloads while the hoist is being operated. of its load rating does not in any way sanction the use
If the load being lifted exceedsthe lifting capability of of the hoist in an overloadedcondition.
the overload clutch, the hoist motor will continue to

sEcTroN
rv
INSPECTION
4-1. General
A scheduledinspection routine should be established
for this hoist basedupon severityof use and environ- dependon the anticipatedseverityofhoist use.Determi-
mental conditions.Some inspectionsshould be made nation of this period should be based on the user's
frequently (daily to monthly) and others periodically experience.It is recommendedthat the user begin with
(monthly to yearly). It is suggested that an Inspection a monthly inspection and extend the periods to quar-
and MaintenanceCheckList and an Inspector'sReport terly, semi-annually,or annually,basedon his monthly
similar to those shown in Figures4-l and 4-2 be used inspection experience.
and filed for reference.All inspectionsshould be made a. Clean hoist of any dirt or foreign material. Inspect
by a designatedinspector.Specialinspectionsshould be bottom block for accumulationof debns.
4 madeafterany significantrepairsor any situationcaus- b. Perform all frequent inspectionslisted above.
lD ing suspicionthal the hoist may have been damaged.
Any hoist which has been removed from servicefor an c. Check for loose bolts, screwsand nuts.
extendedtime should receivean inspectionasdescribed d. Checkhousings,load block, and other partsfor wear,
under PeriodicInspections.ANSI B30.16,SafetyStan- corrosion,cracksor distortion. Check for abnormal
dard for OverheadHoists,providesguidelinesfor hoist openingsbetweenhousingsections.
operationand inspection. e. Checkmotorbrakeforworn discs,oil contamination
CAUTION or excessiveclearance(seeparagraph5-3).
Any unsafecondition disclosedby any inspectionmust f. Check mechanicalload brake function (see Figure
be corrected before operation of the hoist is resumed. 4_3).
4-2.FrequentInspection g. Inspect the entire length ofchain for gouges,nicks,
a. Checkpushbuttonstation,brake,and limit switches weld spatter, corrosion, distortion and wear. See
for properoperation. CHAIN INSPECTION, paragraph4-5.
b. Check hooks for deformation, chemical damage,or h. Inspect hooks and suspensionparts for cracks,dis-
cracks.Bent hooks or hooks damagedfrom chemi- tortion or extreme wear.
cals,deformation,cracks,or having excessivethroat i. Inspecthooksfor cracksusing magneticparticle,dye
opening (see paragraph 4-6) should be replaced. penetrantor other crack detectingmethods.
Visible deformation of any hook may be evidence
j. Check limit switch set points and resel if necessary
of hoist abuseand overloadingand indicatesthat a
thorough inspectionof the completehoist shouldbe (seeparagraph5-2).
made. k. Inspectall wiring for defectiveinsulation, and check
c. Checkthat bottom hook swivelsfreely. to be sureall electricalconnectionsare tight. Check
motor reversing contactor or relay for burned
d. Checkfor missing,bent or otherwisedamagedhook contacts.
latches.
l. Inspect for oil leaks.Check oil level.
V e. Check pushbutton and power cord for cuts or other
damage. m. Inspect for missing or illegible capacity or warning
labels.
4-3.PeriodicInspection n. Inspect the supporting structure for continued abil-
The exact period for the following inspections will ity to support the hoist rated load.
Americrane & Hoist Corp. 1-800-652-1932

I N S P E C T I O&NM A I N T E N A N CCEH E C KL I S T
ELECTRIC POWERED OVERHEAD CHAINHOIST

u
T y p eo l H o r s l C a p a c r t y( T o n s ;
Localron O r g r n a l l n s t a l l a t r oO
n ate
l v l a n uaf c t ur e r M a n u fa c t u r e rs S e r a l N o

F r e q u e n c vo l l n s D e c l r o n
P o s s r b l eD e l r c r e n o e s Actron
Item Frequent Periodrc ff
Requ red
Darlv MonthlV 1 1 2 M o
O p e r a t r n gC o n t r o l s a a o A n y d e fr c r e n c yc a u s r n qr m p r o p e ro p e r a t r o ' l
L r m rS
t wrtches a a o A n y d e fr c r e n c yc a u s r n g r m p r o p e ro p e r a t r o n
a Pitlinqor delerloralton
D r s c ( M o t o r )B r a k e o a a S l i p p a g e o r e x c e s s i v ew e a r
a G l a z i n o .c o n t a m r n a t r oonr e x c e s s i v ew e a r
Load Brake o F a r l u r et o s u p p o r t l o a d w r t h d r s c b r a k e o p e n
{Mechanrcal) ( s e e p a r a g r a p h4 - 3 f )
Hooks a a a E x c e s s r v et h r o a t o p e n r n g , b e n t o r t w r s t e d. n o r e t h a n
1 Od e g r e e s ,d a m a g e d h o o k l a t c h .w e a r .c h e m r c a l
damage, worn hook bearrng
a C r a c k s( u s e d y e p e n e t r a n t m . a g n e t r cp a n r o l eo r
o t h e r s u r t a b l ed e t e c t r o nm e t h o d )
S u s p e n s r oLnu g a C r a c k s , e x c e s s r v ew e a r o r o t h e r d a m a g e w h r c h m a y
( r fu s e d ) r m p a r rt h e s t r e n g t ho f t h e l u g
a C r a c k s( u s e d y e p e n e t r a n t m , a g n e l r cp a r l r c l eo r
o t h e r s u r t a b l ed e t e c t i o nm e t h o d )
Charn o o a I n a d e q u a t eI u b f l c a t i o n ,e x c e s s r v ew e a r o r s t r e l c h
c r a c k e d ,d a m a g e d o r t w l s t e d l r n k s ,c o r r o s r o no r
f o r e r q ns u b s t a n c e
Hook and Suspensron a C r a c k s ,b e n d r n g ,s t r p p e d l h r e a d s l o o s e m o u n t r n g
Luo Connections screws
Pins,Bearings. o E x c e s s r v ew e a r .c o r r o s o n c r a c k s d i s t o r t r o n
Eushings.Shatts
C o u p l i n g sC,h a r n
Guides
N u t s . B o l t s .R r v e l s a L o o s e n e s s .s l i l p p e d a n d d a m a g e d l h r e a d s
corrosron
Sheaves a D r s t o r t r o nc, r a c k s , a n d e x c e s s r v ew e a r
B u i l d u o o f f o r e r o ns u b s t a n c e s
Housings,Load a C r a c k s d r s t o r t r o ne x c e s s i v ew e a r
Elock I n t e r n a lb u i l d u o o f f o r e i q n s u b s l a n c e s
Wrrrnoand Termrnals a F r a v r n o .d e l e c l r v eI n s u l a t r o n
ContactBlock, o L o o s e c o n n e c l r o n s ,b u r n e d o r p t t t e d c o n t a c t s
MagnelrcHorst
C o n l r o l S w r t c h ,O t h e f
E l e c t r r c aA
l oparatus
SupportingStructure a D a m a g e o r w e a r w h l c h r e s t i l c t sa b l l r t yt o s u p p o r t
(if used)
and TrolleV r m p o s e dl o a d s
N a m e p l a t e s ,D e c a l s , a , a m a g e do r r l l e g i b l e
M i s s r n gd
Warninq Labels
Transmissron a L o w L e v e l ,R e q u r r e sC h a n g i n g
Lubricant
N O T E : R e l e r t o M a r n t e n a n c ea n d I n s p e c t r o nS e c l r o n so f l h e H o r s t M a r n t e n a n c eM a n u a l l o r f u r t h e r d e t a r l s
F R E O U E N C Y O F I N S P E C T I O N:
F r e q u e n t- I n d r c a l e sr t e m s r e q u r r r n gr n s p e c l r o n sd a r l y t o m o n t h l y D a r l y I n s p e c l r o n sm a y b e p e r l o r m e d b y t n e o p e r a l o r r l
p r o p e r l yd e s r g n a t e d
P e r r o d r c- I n d i c a t e si t e m s r e q u r r r n gI n s p e c t r o nm o n t h l y t o y e a r l y I n s p e c t r o n st o b e p e r f o r m e d b y o r u n d e r l h e d r r e c t r o no f a
p r o p e r l yd e s r g n a t e dp e r s o n T h e e x a c t p e n o d o f I n s p e c t r o nw r l l d e p e n d o n f r e q u e n c y a n d t y p e o f u s a g e . D e t e r m r -
n a t i o n o f t h i s p e r i o d w i l l b e b a s e d o n t h e u s e r ' s e x p e n e n c e .l t r s r e c o m m e n d e d t h a t t h e u s e r b e g r n w a t ha m o n t h l y
i n s p e c t i o na n d e x t e n d t h e p e r i o d s t o q u a r t e r l y ,s e m i - a n n u a l l yo r a n n u a l l y b a s e d o n h r s m o n t h l y e x p e r t e n c e .

FIGURE 4-I. RECOMMENDED INSPECTION AND MAINTENANCE CHECK LIST


8
Americrane & Hoist Corp. 1-800-652-1932
INSPECTOR'S
REPORT

ITEM REMARKS(L|STDEFTCTENC|ES
AND RECOMMENDED
ACTION)

INSPECTOR'S DATE
SIGNATURE INSPECTED APPROVEOBY DATE

FIGURE4-2.RECOMMENDEDINSPECTOR'SREPORT.

4-4. Load Brake Function Check


To checkthe functioningof the mechanicalload brake,
proceedas follows:
SCREWORIVER
NO.1
a. Attacha lightloadto the hoistand lift it severalinches.
TRANSMISSIONCOVER
b. DISCONNECT HOIST FROM POWER SUPPLY
and remove short end brake cover (seeFigure 8-1,
Index No. l).
c. Refemng to Figure 4-3 (below) and Figure 8-9, place
screwdriversNo. I and No. 2 behind the plate and
arrnature assembly and prepare to pry against the
transmissioncover.
NOTE
Do not allow either screwdriverto contactbrake disc
(seeFigure8-9, Index No. 7).

d. Carefully pry open motor brake (closesolenoidgap)


>rl+-
and observeaction of load. If the load descends.the
mechanicalload brake is malfunctioningand must
be repaired.

4-5.ChainInspection
Chain inspectionand lubrication are the most important SCREWORIVER
NO.2
aspectsofhoist maintenance.Removal ofthe chain from
the hoisr usually is not necessary,but the chain should
U
be run through the hoist enoughthat every link is made
visible for inspection.
a. Checkeachlink forgouges,nicks,weld spatter,corro-
sion and distortion. FIGURE 4-3. LOAD BRAKE FUNCTION CHECK
Americrane & Hoist Corp. 1-800-652-1932
b. Inspecteachlink for wearto thediameterof thelink chain is worn lessthan l7:0/0,
checkit at severalmore
(seeFigure4-4).The nominallink diameteris 0.250 placesalong its length. If any section is worn more
inch for chainon modelsup to EC-2008and 0.281 than I t/zo/0,
the chain should be replaced.
inch for modelsEC-2012and above.If the diameter
of anylink of 0.250chainis wornto lessthan0.200,
or thediameterof anylink of 0.281chainis wornto
d. The chain used in this hoist is accuratelycalibrated
to operateover the load sprocketand is very carefully
t
lessthan0.225,theentirechainmustbe replaced. heat treated for maximum wear life and streneth.
WARNING
l. Do not weld or join hoist load chain.
2. Do not substituteanother manufacturer'schain in
this hoist.
3. Damageor wear, beyondthe stated limits, to any
WEAR IN
THESEAREAS portion of the chain requiresthat the entire length
be replaced.

4-6.HookThroatOpening
Use Table4-l (below)to checkhook throat opening.
FIGURE 4-4. TYPICAL WEAR ON LINKS

l.) Check the chain for overall wear or stretchby


selectingan unworn, unstretchedlengthof chain (at
the slackend, for example).Let the chain hangverti-
callywith a light load(about20lbs.)on rhe chainro TABLE4-1. MAXIMUMALLOWABLEHOOK
pull it taut. Use a largecaliper10measurethe outside THROATOPENING
length of a convenientnumber of links (about 12 Hoist I-oad Top Bottom
inches). Measurethe same number of links in a Reting Hook' Hoohr
(ton) (in) (in)
used sectionof chain and calculatethe percentage

u
t/q, t/t and l'/tt
I l'/rt
increasein lengthof the worn chain. 2 l'/rt I
5/,0
3 lr%: ttln
I
2.) If the lengthof the worn chain is more than l7z0lo rFigu.es gru.n
arc for hok wirh latch. Add
r/ro'
if mcasured withoui h@k latch
longerthan the unusedchain(.015"per inch of chain
measured),then the chain should be replaced.If thc

sEcTtoN
v
MAINTENANCE
AND REPAIR
5-1. General
This sectionprovidesinstructionsfor the most common
routinemaintenanceand adjustments.Major repairsare
not within the scope of this manual and should be
referredto qualified servicefacilities.
SAFETY NOTE
Always remove load and disconnecthoist from power
suppll' before removing end coversor making repairs.

5-2.LimitSwitchAdjustment
Limit switches are provided to protect the hoist
againstdamageresultingfrom overtravel.For easyiden-
tification the upper (No. 2, Figure 5-l) and lower (No.
3, Figure5-l) limit switchadjustingnuts arecoloredred
and green respectively.Each limit switch nut has ten
slots for adjustment,and the incrementof adjustment
FIGURE 5-I. LIMIT SWITCH ADJUSTMENT

10
Americrane & Hoist Corp. 1-800-652-1932
is such that one slot is equivalentto one link of chain
travel. Care should be exercisedwhen adjusting either
limit of travel. When a geared type limit switch is
furnished (long lift hoists) each adjustment is equal to
Adjustto
3 links of chain, or 30 links per revolution. give.015"-.,
iyr oaD t
T-
a. Adjusting Upper Limit (Red Nut).
l.) Carefullyraisethe load block to a point whereits
top is 2" or more from the hoist housing.
2.) DISCONNECT POWER from the hoist and
remove the short end cover.
pry the springguideplate(No.
3.) With a screwdriver,
l, Figure 5-l) out of the slots in the colored limit
FIGURE 5-2. MOTOR BRAKE ADJUSTMENT
switch nuts (Nos. 2 and 3).
4.) Turn the slotted red nut (No. 2) toward its limit a. Remove any load and DISCONNECT POWER
switch until the switch clicks. liom hoist.
5.) Releasethe springguideplateand be sureit snaps b. Remove the short end cover.
back into the slots in both nuts. Do not disturb the
c. Rcferringto Figure4-2,checkthe gapbetweenarrna-
other slotted nut if is has beenpreviouslyset.
ture (A) and frame (B). The correctgap is .015".
6.) Replacethe short end coverand reconnectpower
d. Adjust the gapby turning the threelock nuts (F) and
to the hoist.
check with a feelergaugeto be sure the gap is the
7.) Carefully raise the load block to its upper limit sameon both ends of the solenoid.
and observe10 see if it stops automaticallyat the
CAUTION
desiredpoint. Do not allow the load block to run into
Be sure the bottom of the armature does not touch
the hoist housing.The stoppingpoint should be at
the splined adapter (H). As wear occurs,the origi-
least2" below the hoist housing.
nal clearancewill be reduced.When this clearance
is gone, THE BRAKE DISCS MUST BE RE-
b. Adjusting l,ower Limit (Green Nut) PLACED.
O l.) Carefullylowerthe load block 1oa poinl whereat
leastl2 links of slackchain hanedown from the hoist e. Replaceshort end cover and reconnectpower. Ifthe
housing. brake still chattersor is hesitantto release.refer to
2.) DISCONNECT POWER from the hoist and SectionVI, Troubleshooting.
removethe short end cover.
5-4.TopSuspension
Removaland Replacement
3.) Adjust the green limit switch nut in the same
A number of diflerent top suspensionassembliesare
manner descnbedabovefor the red nut.
availableto accommodatedifferentmethodsof hanging
4.) Replacethe short end coverand reconnectpower the hoist.Ifit shouldbe necessary
to changetop suspen-
to the hoist. sions,proceedas follows:
5.) Carefullylower the load block to its lower limit a. DISCONNECT POWER from hoist and move the
and observeif it stopsautomaticallyat the desired hoist to a safe working area. If necessary,remove
level.Do no1run chain out of hoist or allow the slack trolley and/or rotate suspensionlug to gain access
end loop to becometaut againstthe hoist housing. to the socketheadcap screwsbolting the top suspen-
At least12 links of slackchain should hanefrom the sion yoke to the frame of the hoist.
hoist.
b. Remove socket head screws(1|rc"hex) and lift out
NOTE the suspensionassembly.
If upper and lower limits are not operatingsatisfac- c. Install new suspensionassemblyand tighten socket
torily, repeatadjustment. head screwsto 75 ft-lbs torque.
5-3.MotorBrakeAdiustment NOTE
When properly adjusted,the multiple disc motor brake Due to the off-centerhook or lug hole,the suspension
should release promptly, operate without noticeable yoke can be installed in the hoist in two different
chatter,and stop the load with no more than one inch ways. With the hoist level, the hook or lug must
of drift. If the hoist hesitatesto lift the load promptly always be directly over the bottom hook. Refer to
when the pushbutton is depressed,the brake should be Figure5-4for the proper yoke orientationsfor single,
adjustedper the following procedure. double and triple chain hoists.

11
Americrane & Hoist Corp. 1-800-652-1932
5-5. Chain Replacement (Old chain still in hoist) accomplishedby depressingthe pin againstthe slack
Refer to Figure 5-4,Chaining and SuspensionDiagrams end spring (29) with a small screwdriver.Remove
and proceedas follows: the soft split link (23) from the old chain and attach
the link to the new chain. Depressthe slack end pin
a. Run the load block up to its top limit.
and install the split link observingproperorientation t
b. DISCONNECT POWER from the hoist and remove of the slack end of the chain when secured.Avoid
the short end cover. twists in the chain.
c. With a screwdriver,push the springguideplate (No. k. Adjust the lower limit switch per paragraph5-2.b.
l, Figure 5-l) out of the slots in the plastic limit
switch nuts. Turn the red slotted nut (2) back to L Attach the bottom hook on single-chainedhoists to
about the center of the threaded screw. DO NOT the looseend ofthe chain. On double-chainedhoists,
DISCONNECT THE WIRES FROM THE LIMIT feed the loose end of the chain through the load
SWITCHES. block (welds of the upstanding links will be in
towardsthe sheave)and fasten the end ofthe chain
d. Removethe load hook assemblyfrom the old chain. to the dead end lug (No. 18,Figure 8-6).
NOTE
On triple chainhoists,feedthe looseend ofthe chain
through the load block (welds away from sheave),
around the idler sheavein the hoist. and to the center
of the load block.
m. Adjust the upper limit switch per paragraph5-2.a.
n. Lubricate the new chain per paragraph 5-6.a and
perform an operation test ofthe hoist.

5-6. Lubrication
Proper lubrication is necessaryfor long, trouble-free
hoist operation. Refer to the following and to Table 5-1,
Recommended Lubrication Schedule, for lubrication
points, type of lubricant,and frequencyof lubrication. 'lr.)

a. Load Chain Cleanthe load chain with a non-acid and


non-causticsolvent and coat with SAE 90 gear oil.
FIGURE 5-3. CHAINING HOIST Wipe excessoil to prevent dripping. If the hoist is
usedin an atmospherecontainingabrasivedust, the
Make a "C"-shaped chain link by grinding through chain should be cleanedand oiled more frequently.
one side of the end link of either the old or new Never apply greaseto the chain.
chain. SeeFigure 5-3.
b. GearingThe gearcaseof the hoist is filled at assembly
Hook the special"C" link to the end link of both
with 46 oz. of a gear oil containing special friction-
chainsthusjoining them. BE SURE the weldsof the reducing additives.
upstandinglinks of the new chain are out away from
the load sheave.and that proper orientation is WARNING
observed for attachment of the slack end in para- The use of gear oils other than that recommendedin
graph j. below. Table 5-l can causebrake chatter or can render the load
brake incapableof holding a load. A 46 oz.container of
NOTE this oil ls availablefrom the Duff-Norton Co. (Part No.
On triple chain hoistsbe sure all weldsare aligned
l4Jl).
like the welds on the old chain. It may be necessary
to cut a link from one or both ends of the chain to a. To check the oil level, remove the 7e"pipe plug from
accomplishthis. the side of the hoist. With the hoist hanging level,
transmissionoil should be even with the edgeof the
With the end cover o{I, connect the hoist to power
tapped plug hole.
supply. Be sure the gteen glound wire is properly
grounded. b. Thelengthof timebetweennecessary oil changeswill
dependon the severityof usethe hoist receives.In
h . Carefully jog the "lJP" button and run the joined
general,the oil shouldbe changedevery 12monlhs r
piecesof chain into the hoist until about 12 inches
of normal operation,or every 200 hours of actual 1,..1
of the new chain comes out the other side. Y
hoist on-time.Very heavyuseor operationin high
DISCONNECT POWER from the hoist. ambienttemperatures (over 105'F)will requirethat
Remove both the "C" link and the old chain from oil be changedmoreoften.An indicationof the need
the slack end pin (No. 28, Figure 8-6). This can be

12
L
Americrane & Hoist Corp. 1-800-652-1932

POWER NOTEPOSITION
CABLE OF SUSPENSION
ASSEMBLY.

POWERCAELE

ENDVIEW
OOUBLE
CHAIN
A S V I E W E OF R O M
E N DW I T HS H O R T
COVER

FIGUR-E5-4. CHAINING AND SUSPENSION DIAGRAMS

for oil replacementis load brake noise. If an erratic greasethrough the greasefitting in the bottom block
tapping sound is made when lowering a load, the oil shaft.Avoid pumping an excessive amount of grease
should be changed. into the bottom block. On triple chain hoists,use a
greasegun to lubncatethe idler sheavein the hoist
c. Limit Switch Shaft To preventrust, the threadedlimit
until freshgreasepumps from the end of the sheave
switch shaft should be given a light coat of greaseor bearing.
sprayedwith a generalpurposelubricant.
e. Hook BearingApply a fewdropsof SAE 30 oil around
d. Idler SheaveBearing(doubleand triple chain models the edgeofthe beanng.
only) Use a greasegun to put about a teaspoon of

TABLE5-1.RECOMMENDED
LUBRICATION MODELEC ELECTRICCHAINHOIST
SCHEDULE-
Type of Service And
Figure And Frequency of Lubrication
Component Type of Lubricanl
Index No.
Heavy Normal Infrequenl
Frgure 8-6, No. 7 Ilad Chain SAE90 GearOil Daily Weekly Monthly
Figure 8-5 ueanng C o f f r n gN o . H - 7 8 1 3t r a n s - At periodic inspection (see Figure {1, paragraph 5-6-2\.

I
mission oil (Kit No. l4J I
contains quantity of oil
suflicient for one oil change).
F i g u r e8 - 8 A , N o . 9 ; 'WD-40"
-imit Switch Shaft or general purpose Monthly Yearly Yearly
Figure 8-8B, No. 7 spray lubricant.
I
I Figure 8-6, No. - -oad Hook Beanng SAE30 Gearor Motor Oil WeekJy Monthly Yearly

l &No.-
Figure8-2,
Nos.t.3.4&5
lop Hook or Sus-
rnsion Lug Bearing
SAE 30 Gear or Motor Oil Monthly Yearly Yearly

iurfaces
Figure 8-7C, No. I I Idler Sheave NLGI #2 multi-purpose At periodic inspection(seeFigure 4-l).
F i g u r e8 - 7 D , N o . I I Bearing (Bushing) lithium basegrease
(Coffrne No. H-7610)
Alt ercpt rdlcr b€ann8s

dust. etc., should be lubri€ted more freeucntly.

13
Americrane & Hoist Corp. 1-800-652-1932
VI
SECTION
TROUBLESHOOTING
6-1. General electricianto do your repairwork, we recommendthat I
Use the followingtableas an aid to troubleshootyour you sendyour hoist to an approvedservicecenterfor
hoist.If you do not have an experienced machinist- repairs.

TROUBLE REMEDY

Hook Fails To Stop At End Ol Travel.


I . Limit switchesnot operating. | 1. Check adjustment.Seeparagraph5-2. Check connectionsagainst
wiring diagram. Tighten loose connectionsor replace.
2. Plastic limit switch nuts no1 moving on shaft. | 2. Check for stnpped threadsor bent nut guide.
3. Magnetic reversingswitch malfunction. | 3. Remove electricalcover and check reversingswitch

Hoist Does Not Respond To Pushbutton.


l. Power failure in supply lines. I l. Check circuit breakers,switchesand connectionsin power
I supplylines.
2. Wrongvoltageor frequency. I 2. Checkvoltageand frequencyof powersupplyagainstthe ratingon
the nameplateof the hoist.
3. Improper connectionsin hoist or pushbutton | 3. Checkall connectionsat line conneclorsand on terminal block.
station. I Check terminal block on dual-voltagehoists for prop€r
I voltageconnections.
4. Motor brake does not release. | 4. Check connectionsto the solenoid coil. Check for open or short
I circuit. Check for proper adjustment.Seeparagraph5-3.
5. Faulty magnetichoist conlrol switch. | 5. Checkcoils for open or short circuit. Checkall connectionsln
control circuit. Check for burned contacts.Replaceas needed.

Hook Does Not Stop Promptly. ,rl


l. Hoist overloaded. I L Reduceload to within rated capacity of hoist.
2. Brake not holding. | 2. Check motor brake adjustment (seeparagraph5-3) and load brake
(figure4-3).

I
l- Three-phasereversal. l. Reverse any two wires(exceptthegreengroundwire)at the power
source(seeparagraph2-3).
2 . Improper connections. 2. Checkall connectionsagainstWiring Diagram.

Hoist HesitatesTo Lift When Energized.


l. Hoist overloaded. I l.
Reduceload within rated capacity of hoist.
2. Motor brake requiresadjustmenl. I 2.
Check motor brake adjustment, seeFigure 5-3.
3. Worn overloadlimiting clutch. | 3.
Replaceclutch.
4. Low voltage. Check voltageat hoist power cord with hoist slarting. Voltage
| 4.
should be no lessthan 90% of volhge specifiedon hoist.
5. FaultySINPAC startingswitchor startcapacitor 15. Replacet-aultycomponent.
( s i n g l ep h a s eh o i s t so n l y ) .

HookRaisesButWillNot Lower.(Motornotrunning)
l. "Down" circuit open. I l. Checkcircuit for looseconnections.Check "Down" limit switch
for malfunction.
2. Broken conductor in pushbutton cable. | 2. Check eachconductor in the cable.Ifone is broken, replace
entire cable.
3. Faulty magnetichoist control switch. | 3. Check coils for open or short circuit. Check all connectionsrn i
control circuit. Check for burned contacts.Replaceas needed. ( .1
v

14
Americrane & Hoist Corp. 1-800-652-1932
TROUBLE REMEDY

HookRaisesBut Will Not LowerWhenMotorls Operating.


Consult Factory Or Authorized Duff-Norton Warranty Repair Station.

HookLowersBut Will Not Raise.


L Hoist overloaded. I l. Reduceload to within rated capacity.
2. Low voltage. | 2. Determine causeof low voltageand bring up to at least l0% of the
voltagespecifiedon hoist. Line voltageshould be measuredwhile
holding or lifting load.
3. "UP" circuit open. | 3. Checkcircuit for looseconnections.Check"UP" limit switch for
malfunction.
4. Broken conductor in pushbutton cable. | 4. Check eachconductor in the cable. lf one is broken, replace
I entire cable.
5. Faulty magnetic hoist control switch. | 5. Check coils for open or short circuit. Check all connectionsin
control circuit.
Check for burned contacts.Replaceas needed.
6. Faulty capacitor (single-phasehoists only). | 6. Check starting capacitor in motor. Replaceif necessary.
7. Worn overloadlimiting clutch. | 7. Replaceclutch.

l. Hoisl overloaded. l. Reduceload to within rated capacity of hoist.


2. Motor brake is dragging. 2. Checkfor properbrakeadjustmentor other defects.Seeparagraph5-3.
3. Low voltage. 3. Bring up voltageto plus or minus l0% of voltage specifiedon
hoist. Line voltageshould be measuredwhile hoist is lifting load.
4. Overloadlimiting clutch intermittentlyslipping. 4. Replaceclutch.

Brake "Noise". (Erratic


0 Need transmissionoil changeor
improper lubncant has beenused.
l. Changetransmissionoil. SeeTable 5-1.
Note: Hoist Warranty is void if unapproved oil is used.
Load brake malfunctionrns. 2. Check load brake operation. SeeFigure 4-3

Motor Brake Noise Or Chatter.(Whilestartinghoist)


l. Brakeneedsadjustment l. Adjust as per parag.raph5-3.
2. Low voltage. 2. Check voltageat hoist power cord with hoisr starting. Voltage
should be no lessthan 90% of the voltagespecified. I l5 volt hoists
are particularly subjectto voltagedrop problems due to their high
curent draw. Conversion to 230 volt operation is suggestedin
extreme cases.

Motor Brake "Buzz". (Anytimehoist is


l. Brakeneedsadjustment. l. Adjust as per paragraph5-3.
2. Brokenshadinecoil on brakeframc. 2. Replaceshadingcoil or completebrake frame assembl

15
Americrane & Hoist Corp. 1-800-652-1932
sEcfloN vll
WIRING
SafetyNotes c . T H R E E P H A S EH O I S T S :T r a n s f e rl e a d sT . 1 .T 5 . T 6 . T 7 .
Disconnectpowerfrom hoist beforeremovingendcovers. T U . T 9 . H 2 . H 3 . S l . a n d S 2 p e r t h e a p p r o p r i a ttee r m i n a l t
b l o c ks c h e m a t i c .
7-1. Voltage Conversion CAUTION
StandardsingJephaseunits are convertible from I l5 to Do not moveany wiresor makeany changesto the
230 volts and standardsinglespeedthree phaseunits wiring exceptat the terminalblock.
are convertiblefrom 460 to 230 volts. Conversionto
d. After converting voltage,checkfor proper phasingof
the alternatevoltagecan be accomplishedwith the fol-
three phaseunits and check for proper limit switch
lowing procedure.
operation.
a. Be sure power is disconnectedfrom hoist. Remove
long end cover. 7-2.Wring Diagrams
The wiring diagrams for standard hoist models are
b . S I N G L IP
TH A S EH O I S T S ) :r a n s - reproducedon the following pages.In addition, every
r w i t hS I N P A Cs' w i t c h T
f'crleads2, Hl. H3. T2. SI. andT3 pcr thc appropriatc hoist should have a wiring diagram locatedinside the
tcrrrrinulhlockschentatrc. lone end cover.

L1 (wxre)
telrcx) L2
NOTE:
H 1 ,C l 2,H2 Hl, C1 Diagramshownfor
6 to 32 FPM chain
H4, C2 H3 H4,C2 hoists.For EC-0564
T5' 1 modelswap locations
c2 2, s1 T2, T3 of motorleadsT5
andT8.
T4 c5 c4 T2,51 c4 t
T1 c4 c5 T3,52 c5 S2
c1
H2, H3
115V 230V

c14 c1s TO CONVERTVOLTAGE,RECONNECT


WIRESTO TERMINALBLOCKAS SHOWN

r-l MOTOR

NI DN
L.S.

GREEN
tp+-
E+
S1
S2
c21 BRAKE

r
NUT
H4

f3>L* H3
H2

H1
c20 XFMR
SINPACSWITCH

FIGURE7-I. WIRING DIAGRAM


ll5/230V,I Phase,SingleSpeedHoistwith SINPAC! switch
981EC 50

I 16
Americrane & Hoist Corp. 1-800-652-1932

REVERSING STITCH

L]L2L3

I1 . INO]C
c6 TES SPLICE CONNECTION
c5 TA c2
c5
c6 T9 c6 fIRING HARNESS
cl
cl c
A2
c2 c2
ts3
N2
r5

cr4
s2 cza I
T6. LFI
OOIN L. S
R€O NUT GREI:N NUT

NOTE.
D U A L V O L T A G EO P E R A T I O N .
SHOTN 'IRED FOR 46OV

T O C O N V E R TV O L T A G E . XFXER
f'-"i I
R E C O N N € C T O L € ^ O S M ^ R K E OT 4 , T 5 . T 6 . T 7 . I 8 I
T9.82,HJ,S , & 5 2 P E R ^ P P R O P R l A T EO I A G R ^ M
xx?

FIGURE 7-2. WIRING DIAGRAM


2301460V,3Phase, Single Speed Hoist
9E3 EC 44C

REVERS]NG SWITCH
II L2 L3

c14 C20 C15 C2t


tl tl
l"ql
tat tk4
UPLS DNLS
RED GRE€N
NUT NUT

s] s2

!l Ir.lI
q"\.P
/
I
)<'
MOTOR \
208v l
tl
BRAKE
SOLENOID
?-Ellu"
GR
--r-

\J7 al
c,'{l!
PUSH
oru
EUTTON
STATION

FIGURE 7.3. WIRING DIAGRAM


208V,3 Phase,SingleSpeedHoist
983 EC 48
17
Americrane & Hoist Corp. 1-800-652-1932

'.

wrRrN.rHARNESS

/-

ll1
TI.-l
cr4 c20 cl5 c?,

E
iFii
*l r mf -f : '{ 1 1 i
. REO GBEEN
NUT NUT
_ 1
,
sl s2
I a l
H] H2
!",!.f
G8

l**r
XFMER
aru-re
soLENoD
].t
ii;; ro
xt 6----?' x2 -l I I

"', ffIlor
PUSts
BUffON
STATION

FIGURE7-4.WIRING DIAGRAM
575V,3 Phase,SingleSpeedHoist
983 EC 45
-
SPEEOCOIJIROT

I
trt"
t EADS
L

it
L+
lr
..i! lLt
h
;lI TT TT1
iJ{
(uo,
ll
I . o *j
l'11 II
,,'
ll
i'"
rf f ll1'l lI I tl Tll

u?l ? J r ' ' | " ,). ': 'ii I,


I -a 1ay

li r i ta\
j1,.'
"i
-t lt 1 I I I f].l fl.' fr4 lir 5l
-l |14 i1t (.r5
?
l--I
f
,' lrl IL (
"" i- ;1 d-j i, -f
.+|-| i--t t*J i ^.J MOTOF
n" , ].a 'r-r
, -a I[].\.'r
r_ XMFR

t
--)
-L.ll.,
:- r..,r j I
.- a
up_ r. -as - '-oorruurrss-
uPrS
/.Yr'f\
It
t ] NEO GREEN L"l
NIjT

,:,
NUI
,'
A r NL r N E
sPLrcE
L__:
j ,{

FIGURE 7-5.WIRING DIAGRAM


230,460,575& 208V,3 Phase,TwoSpeedHoist
983EC 14r
L 18
Americrane & Hoist Corp. 1-800-652-1932
sEcTloNvill
PARTSLIST
ILLUSTRATED
8-1. General 4) If more than one part number is listed with the
The following exploded drawingsprovide a complete sameusagecode,the information under "part name"
list of partsusedin the standardEC hoistmodels(shown will determine the correct part number. This is also
in Table l-1, page3). Sinceseveraldiflerent modelsof the caseif no usagecode is listed and more than one
hoists are coveredby this manual, diflerencesmay be part number is listed for the index number.
noted betweenthe appearanceof your hoist part and
the referenceillustration.Ifthis is the case,the partslist EXAMPLE
B
will show severaldiflerent part numberswith sufficient INDEX USAGE PART PART NAME
information to allow the selectionof the correct part NO. CODE NO.
number. 4 B JF-82l -3 Transformer(Pri. 208,230/
460V Sec2a V 50/60Cy)
8-2.HowTo UseThe PartsList B JF-82r-9 Transformer(Pri. 575V Sec
a. The parts list consistsof four columnsas follows: 2a v 50/60Cy)
I ) lndex Number
2) UsageCode-This column may contain a code Parts
8-3.HowToOrderReplacement
relating to the model numbers of, or other dala When ordenngpartsor requestinginformationconcern-
relatingto the hoist in which the part is used.Usage ing your EC hoist,alwaysincludethe hoist model num-
codesare as follows: ber and serialnumber. Both numbersare permanently
stampedon the transmissionhousingcastingnear the
A- SinglePhaseHoists (SingleSpeed)
chain entrancearea. See index No. 6. Fieure 8-l and
B- Three PhaseHoists (SingJeSpeed)
illustrationbelow.
C- Three PhaseHoists (Two Speed)
D- Hoists with r/,rin. Load Chain (ModelsEC-0516.
EC-0532,EC-0s64,EC-1008,EC-1009. EC-1016,
EC-1032and EC-2008)
E- Hoistswith e/r in. Load Chain (ModelsEC-2012.
EC-2016,EC-4006.EC-4008and EC-6005)
F- SingleChain Hoisls (Models EC-0516,EC-0532.
EC-0564,EC-1009,EC-1016, EC-1032)
G- Double Chain Hoists (Models EC-2008,
EC-4006,EC-4008)
H- Single Chain Hoists (Models EC-2012,
EC_2016)
J- Triple Chain Hoists (Model EC-6005)
3) Part Number
4) In additionto basicpartname,thiscolumn contains
descriptionswhich are essentialfor choosingthe cor-
recl part number when more than one is listed.
b. How to determine proper part number:
l) Locate the index number in the corresponding
figure of the parts list.
2) If only one part number is listed for the index
number, that part number should be ordered.
3) If more than one usagecode and part number is
listed for that index number,choosethe correctusage
code by comparing the model number or electrical When ordering motor parts, please provide complete
characteristicsof your hoist with the usage codes motor nameplatedata, including motor "ref." number or
above. model number.
EXAMPLE A
;t INDEX USAGE PART
NO. CODE NO.
PART NAME
NOTE
Repair partsareavailableonly from Coffing distributors
or authorized repair facilities. It is recommended that
6 E 35Jl TransmissionHousing repair part orders be directed to the authorized repair
D 35J2 TransmissionHousing facilitv nearestvou.

19
Americrane & Hoist Corp. 1-800-652-1932

I
FIGURE8-I. BASIC HOIST
20
Americrane & Hoist Corp. 1-800-652-1932
PARTSLIST FOR BASICHOIST
INDEX USAGE PART INDEX USAGT PART PART NAME
PART NAME
NO. CODE NO. NO. CODE NO.
I 36Jr Brake Cover l0 6 7 5 J 3 8 Decal,Capacity(l Ton)
2 36J2 ElectricalCover (cont.) 675J48 Decal,Capacity(2 Ton)
J 560J4 Gasket, Brake & 6 7 5 JI r Decal,Capacity(3 Ton)
Electncal Covers ll H-4002-PFlat Washer
4 A&C 33Jl SheaveHousing t2 6 1 1t l Decal,Coffing
(Models EC-2012,
l3 H - 2 9 8 1 Screw
EC-2016,EC-4006 t4 560Js Gasket,Transmission
& EC-4008) l5 616J28 Decal. Duff Norton
B 33JI SheaveHousing
(ModelsEC-2016 l6 A 679J1 Decal, Power
& EC-4008) Requirements
B 33Jl-r SheaveHousing (llsl230v)
(ModelsEC-2012 B 67912 Decal, Power
& EC-4006) Requirements
A,B,C 33J2 SheaveHousing (2301460
v)
(Models EC-0564 A,B,C 67913 Decal, Power
& EC-I032) Requirements
A.B.C 33J2-r SheaveHousing ( 230v)
(ModelsEC-0516, B&C 679J4 Decal, Power
EC-O532. EC-1008. Requirements
EC-1016, EC-2008& (460v)
EC-1009) B&C 619J5 Decal, Power
J 33J19 SheaveHousing Requirements
(Model 6005) ( 575v)
5 34JGI TransmissionCover t7 619J9 Decal. Right
(includes2 oil seals) l8 679JI 0 Decal, trft
34JIK TransmissionCover l9 679Jtl Decal,Bottom
(older hoistsonly, 20 SuspensionAssembly
has fill plug K i t ( R e f .# 1 . 3 , 4
insidecover) & 5, Figure 8-2)
6 E 35JGI TransmissionHousing 2l 703Jl Screw(Includedin all
D 35JG2 TransmissionHousing Suspension
1 A 9 5 l Jl Power Cable AssemblyKits)
B 9 5 3 Jl Power Cable 22 H-4086-P Lock Washer
8 A&B 940JI Wiring Harness (Includedin all
C 940Jl -36 Wiring Harness Suspension
a H-2923-P Screw (slotted AssemblyKrts)
hex head) :J PushbuttonCable
H-2980-P Screw(older hoists (Ref. Figure 8-l0A
only, Phillips head) & 8-l0B)
24 H - 6 2 5 8 Fill Plug
r0 6 7 5 JI B Decal,Capacity 25 H-2910 Screw
(% Ton)
675J28 Decal,Capacity )6 s-25-l 3 lrvel Plug
(7r Ton)

21
Americrane & Hoist Corp. 1-800-652-1932

,d

'/ ./''n
fr"

FIGURE 8-2.SUSPENSIONASSEMBLY KITS


22
PARTSLIST FOR SUSPENSION ASSEMBLYKITS
INDEX INDEX JSAGE PART PART NAME
PART NAME NO. CODE NO.
NO.
F,G,H r4125 Hook AssemblyKit, 4 J 5OJG53 Trolley Lug Assembly
'. -J/ Swivel (cont.) Kit, Plain Trolley
F,G'H t4126 Hook AssemblyKit, 5 F'G,H l4J4 Trolley Lug Assembly
Risid Kit, Motorized
J 3JG23 Rigid Hook Assembly Trolley, Cross
F,G,H H-7540 Iatch Kit Mount
J H-7544 Latch Kit .: J 50JG54 Trolley Lug Assembly
Kit, MotorizedTrollel
F,G,H 50JG22 Multi-purposeLugi'fi,
Assembly
F,G,H t4J3 TrolleyLug Assembly
Kit, PlainTrolley,
ParallelMount
MotorizedTrolle

Americrane & Hoist Corp. 1-800-652-1932

(J

.J

23
Americrane & Hoist Corp. 1-800-652-1932
PARTSLIST FORTHREEPHASE.SINGLEAND TWO SPEEDMOTOR
INDEX USAGE PART PART NAME TNDEX.]SAGT PART PART NAME
NO. CODE NO. NO. CODE NO.
I B 863J201 Motor(% HP, 208V I C 873J20 l Motor(.25l.08HP
60 Hz) (cont.) 230V, 60 Hz) .{
B 863J208Motor(% HP, 208V C 873J202 M o t o r( . 5 0 / . 1 H
7P
60 Hz) 230V, 60 Hz)
B 863J209Motor(% HP. 208V Ci 873Jr 03 Motor(.75/.25HP
60 Hz) 230V, 60 Hz)
B 863J109 Motor(l HP, 208V, C 873Jl 04 M o t o r( 1 / . 3 3H P ,
60 Hz) 230V, 60 Hz)
C 8 7 3 J 2 t l Motor(.25l.08HP, CI 873J204 Motor(.25l.08HP
460 V, 60 Hz)
208V, 60 Hz)
C 873J209M o t o r( . 5 0 / . 1H 7P. C 873J205 M o t o r( . 5 0 / . 1H7P
460V, 60 Hz)
C
208V. 60 Hz)
8 7 3 Jl16 M o t o r( . 7 5 1 . 2H5P , CI 8 7 3 J1 0 7 Motor(.751.25
460V, 60 Hz)
HP
208V, 60 Hz)
C 8 7 3 J l l 5 Motor(l/.33 HP. cl 873Jl 08 M o t o r( l / . 3 3H P ,
460 V, 60 Hz)
B 863J20
208V, 60 Hz)
l Motor(rAHP,
cl 873J207 Motor(.25l.08HP
575V, 60 Hz)
B
230/460v, 60 Hz)
863J202 Motor(r/:HP,
Ci 873J208 M o t o r( . 5 0 / . 1H7P
575V, 60 Hz)
2301460 V, 60 Hz) C ] 8 7 3 Jl1I Motor(.751.25 HP
B 863J203Motor(% HP, 575V, 60 Hz)
B
2301460
863Jl 04 Motor(l HP,
v, 60 Hz) CI 8 7 3 IJl 2 M o t o r( l / . 3 3H P ,
575V, 60 Hz)
2301460 v, 60 Hz)
Contact fa( 1ory with length
B 863J204Motor(r/.r HP, 575V req urred. Thru Bolt
60 Hz) J
a
Contacl fa<tory. End Shield
B 863J205Motor(h HP, 575V +
A
N o t a v a i l a lrle separately Stator
60 Hz) 5 I500K3 Bearing
B 863J206Motor (r/.rHP, 575V 6 Contact fa<tory with complete
60 Hz)
B 8 6 3 Jr 0 8 M o t o r( l H P . 5 7 5V , Hff,,lli
eplare data for
Rotor Shaft
60 Hz) 7 H-4082-P Lock Washer

FIGURE 8-3A.MOTOR PARTS


(THREE PHASE)

I
Americrane & Hoist Corp. 1-800-652-1932

PARTSLIST FOR SINGLEPHASEHOISTMOTOR(INTERNALSWITCH)


Index Part Index Parl

rJ No. Part Name No. No. Part Name No.

I Motor, Completc: li Switch. Rrrlating JFA-11647-02


t/a HP. I l-5/230Vrlt tt6lJ20l 9 Rotor & Shaft ('()nlrct Fa!lor\
qrlh L()ntplctc
th HP, I l5/230 Volt tt6IJ202
t/c HP, I I5/230 Volt 86lJl0l lor rrarlabrltty

Nrr rratlrblc
I HP. I 15/230Volt I t 6 l J1 0 , 1 t() Stator icfrrfutcl)

2 tnd Shicld I rctorl 'fhru


lt Eolt *rth hnfth rrqurrcd
3 Switch, Stationary: tl Lock Washcr H-.1082P
I Docrr,7a& I HP JFA-1t447 tl Washcr s--l ll
I Dtrcrr, 7a & t/: HP. All l,ccson h,c0027750 | tl
Scrcw H-2118I
I
4 S c r e w( f o r a l u m i n u mc n d s h i c l d ) s-31-tt4
Washer,Shim JFA ]24
6 RctainingRing JF-5| (X)-66
1 Bcaring 5(X)Kl

,\i
W
11

6/

rJ II 7
13
\
v/ t n

PARTSLIST FOR SINGLE PHASE HOISTMOTOR(SINPAC"SWITCH)


Index Part Index Part
No. Part Name No. No. Part Namc No.

I I Motor. Complctc. t0 Stator N({ r!rrlJble


\cfJrdrr r\
t/t HP, I t 5/230 Volt I t f , l J l lI
t/z HP, I l5/2-30Volt 136lJ22l il Thru Bolt (-r)ntaLl Frrlor\ wrlh
I.n[rh Rcqurrcd

% HP, I l5/230 Volt tt6tJI 2-l l2 Lockwasher H-4082-P


I HP, ll5/230 Volt 86lJl24
L End Shicld
7 Bearing -s00K3
9 Rotor & Shaft ( 0nt.r(l I r(l0r\ qrth
(,rn\Plcla nJrIlaPlJlc
,hlr lor a\rrlrhrlir!

FIGURE 8-28. HOIST MOTOR PARTS (I PHASE)

25
Americrane & Hoist Corp. 1-800-652-1932

2 -----+

Capacitor(lndex No. 8)
and SINPACeswitch
(lndex No. 13) are used
on slnglephase
\ units only.
'8
't4'-''

Index Part lndex Parl


No. Part Name No. No. Part Name No.

I Control Panel l - 5 7 Jl A 5 Scrcw H-2751


2 ReversingContactor: 6 l-ock Washcr H-415lt
E s s e x ,2 4 V C o i l 1320JI 1 H v el c t ( - l P h a s eU n i t s ) H,4912
E s s c x ,1 2 0V C o i l rJ20J2 S c r c w( l P h a s cU n i t s ) H-2152
SquarcD. 24 V Coil It20Kl IJ C a p a c i t o rl . l 6 l - 5 9 r n l d . .
S q u a r cD . 1 2 0V C o i l lJ20K.rl7 I I 7 r o[ ) i a . JL ul0-3
2A Coil: Capacitor,4(X)-4tt0mld..
Essex,24 V u20J.r0I l r T r oD i a . J L - t it 0 - 4
E s s c x ,1 2 0V 1320J
302 C a p a c i t o r2. 3 0 n r f d . .
SquareD, 24 V lJ20K30| I I 7rr Dia. J L - t il 0 - 3
S q u a r eD , 1 2 0 V tt20K.r0l C a p a c i t o r1. 7 5 m t d . .
28 Replacement ContactKit: 2r,uro l)ia. 8l0K3
Esscx 820Jl(X) C a p a c i t o r5.3 4 n r l d . .
Squarc D tt20K3(x) 2 1 / t tD i a . 810K4
3 TerminalBlock. Capacitor.,155nrfd..
20 position 909JC2 2t/to l)ia. 8l LlK5
l0 position 909JG4 Capacitur Bracket:
6 position 909JI I rTrr Dia. ullJl
A
Transformer: 2t/to Dia. 8ilJ2
I 1 5 / 2 3 0V - 2 4 V JF-tt2I -4 l0* Splicc Conncctor H-5157
208, 230/460V - 24 V J F - 82 l - 3 ll Grommct H-7906
575V-24V J F - 8 2l - 9 l2 Scrcw H-2981-P
I 1 5 / 2 3 0V - 1 2 0 V J F - l t 2 ll-9 ll S I N P A C T {S w i t c h 839J2
208, 230/460V - 120 V JF - 8 2l l4 Cablc Tic H-9ff)6
575V-120V J F - 8 2l - 2

x Not illustrated

FIGURE8-3A.CONTROLLERAREA (SINGLESPEEDHOIST)

26
CoNTROLLERAREA PARTSLIST (TWOSPEED)
INDEX USAGT PART INDEX USAGT PART PART NAME
PART NAME
NO. CODE NO. NO. CODE NO.

J JF-82r- l 5 Transformer(208,
a
I 2 5 7J tA l ControlPanel J C
2 820Jr ReversingContactor 230/460V - 24v)
(Essex,24 V Coil) C JF-82l-l6 Transformer
82012 ReversingContactor ( 5 7 5v - 2 4 v )
(Essex,120V Coil) C J F - 8 2 1I 7- Transformer(208.
820K2 ReversingContactor 2301460 V - l20v)
(Square D, 24 V Coil) C J F - 8 2 1 - 2Transformer
0
820K317 ReversingContactor ( s 7 s v- l 2 0 v )
(Square D, 120V Coil) 4 H-2"751 Screw
2A 820J301 Coil (Essex, 24 V) 5 H-4158 Lock Washer
8201302 Coil (Essex, 120V) 6 C H -1 8 5 3 Screw
820K301Coil (Square D,24 Y) 7 C 820J3 SpeedControl Relay
820K302 Coil (Square D, 120V) (24 V Coil)
2B 820J300 Replacement Contact C 820J4 SpeedControl Relay
Kit (Essex) ( 1 2 0V C o i l )
820K300Replacement Contact 8 H-5157 SpliceConnector
Kit (Square D) 9 H-7906 Grommet
r0 H-2981-P
Screw

Americrane & Hoist Corp. 1-800-652-1932

,1
FIGURE 8-48. CONTROLLER AREA
(TWO SPEED)
Americrane & Hoist Corp. 1-800-652-1932

'l

Y**<Fi"
l".L!r& x

S/$* >

FIGURE8-5.TRANSMISSION
28
Americrane & Hoist Corp. 1-800-652-1932
PARTSLIST FORTRANSMISSION
INDEX USAGE PART INDEX USAGT PART PART NAME
PART NAME
NO. CODE NO. NO. CODE NO.

J I
2
a
J
34JGI
56rK2
TransmissionCover
Seal
MA-562 Seal
/.J
(cont.)
59lJG3
591JG4
Slip ClutchAssembly
(ModelEC-0564)
Slip ClutchAssembly
4 404J1 Output Pinion (ModelsEC-1016
5 401JG25 OutputGearAssembly & EC-2008)
580J8 BrakeDisc (all models
59lJG5 SlipClutchAssembly
6 (ModelEC-1032)
exceptEC-0564)
7 -5J6 PressurePlate
59rJG6 SlipClutchAssembly
(ModelsEC-2012
8 r30J3 Nut
9 7 J G l 5 - r Ratchet(all models & EC-4006)
59lJG7 SlipClutchAssembly
exceDt0-564) (ModelsEC-2016,
1 Jt 4 Spacer'(8C0564 only)
EC-4008& EC-6005)
l0 H-2255 Screw
59lJG20 SlipClutchAssembly
u H - 4 1 3 3 Lock Washer (ModelEC-1009)
t2 H - 5 3 8 2 Dowel Pin 24 402J1 IntermediatePinion
l3 H-2978-PScrew (ModelsEC-2012,
t4 H-5503 RetainingRing EC-4006& EC-1009)
l5 H-6258 Fill Plug,Vented 402J2 IntermediatePinion
l6 s-25-l 3 Level Plug
(ModelsEC-0516.
l7 560J5 Gasket(Ref.#14, EC-1008, EC-1016,
Figure7-l) EC-2008, EC-2016,
r8 H-6268 Drain Plug EC-4008 & EC-6005)
l9 E 35JGI TransmissionHousing 402J3 IntermediatePinion
D 35JG2 TransmissionHousine (ModelsEC-0532
20 500K7 Beanng & EC-1032)
25 H-5549 RetainingRing
2l 400JI Input Pinion (Models (ModelsEC-0516,
EC-2012, EC-2016, EC-1008, EC-10r6. I
EC-4006.EC-4008 EC-2008. EC-2016.
& EC-6005) EC-4008& EC-600s)
400J2 Input Pinion (Models H-5553 RetainingRing
EC-O516, EC-1008, (ModelsEC-2012,
EC-1016& EC-2008) EC-4006 & EC-1009)
400J3 Input Pinion (Models H-5530 RetainingRing
EC-0532& EC-I032) (ModelsEC-0532
400J4 Input Pinion & EC-1032)
(Model EC-O564)
400J9 Input Pinion
26 t 4 Jl Transmission Oil
Replacement Kit,
(Model EC-1009)
IncludesOil
22 40lJl Input Gear (Models Requiredfor One
EC-2012& EC-4006) Oil Change
40tJ2 Input Gear (Models 2tt D t 3 2 J G 2 2 SheaveShaft
EC-0516,EC-1008, Assembly
EC-1016& EC-2008) tl r 3 2 J G 2 l SheaveShaf't
40rJ3 Input Gear (Models Assembly
EC-0s32
& EC-1032) 29 500K29 Bearing
4 0l J 5 Input Gear(Models 30 H-5539 Retaining Ring
EC-2016,EC-4008 3r H-5493 Dowel Pin,
& EC-6005) Ratchet Ring
401J9 Input Gear 32 t4J2 Seal Kit, Includes
(ModelEC-1009) Three 561K2 Seals,
One MA-562 Seal
ZJ 59lJGl SlipClutchAssembly
(ModelsEC-0516 and One 560J5
Gasket
& EC-1008)
59tJG2 SlipClutchAssembly -l -) 340t7 Spring
at
(ModelEC-0532) J+ 25J2 Pawl
35 t 4 l Jl 4 Spacer

29
Americrane & Hoist Corp. 1-800-652-1932

<s
<x'
V,I

\-
-)^',--/1 8
e-< \
\\v
1s \J/
1Y
/ rr)
22 lS
n)
7*U1
fM
w

,{

44

q5
'{-t" '
:
.\iriJ
z fr.ii hi
U
\I' '2
J\'
.^\' 1
\2
,/
\" \.,

/
a-
//\' ^{"
t"
'
lr' -/ > t( ,
tl,

3.TON MODEL

FIGURE 8-6.CHAINING PARTS


30
Americrane & Hoist Corp. 1-800-652-1932
CHAININGPARTSLIST
INDEX USAGE PART PART NAME INDEX USAGE PART PART NAME
NO. CODE NO. NO. CODE NO.

J 6
7
D
E
D
s00K28
500K5
JLI98
Bearing
Bearing
Load Chain
30 500K29 Bearing (Ref. #29,
Figure 8-5)

('A in. Chain)


31 H- 5539 Retaining Ring (Ref.
#30, Figure 8-5)
E JLl9-r Load Chain JZ SheaveShaft
(eln in. Chain)
34 D t612 Sheave(th in. Chain)
l8 G 413 Dead End Lug
E l 6 JI Sheave(%zin. Chain)
19 G l 8 Jl Dead End Pin
35 D JF-250-3 Chain Guide
20 E 272J1 Chain Guide Plate (% in. Chain)
(%zin. Chain)
E IF-254-3 Chain Guide
D 272J2 Chain Guide Plate (%r in. Chain)
(% in. Chain)
36 EG,H l 0 7 J l Drive Coupling
2l t27Jl Spacer,Chain Guide J t07IG1-4 Drive Coupling
Plate
22 G H-5025-PCotter Pin
37 EG,H l 7 0 J r RetainerBlock
38 H-5382 Dowel Pin
23 H-7596 Split Chain Link 39 H l 8J8 Dead End Pin
24 E,G,H H-2978-PScrew 43 J r22JGt6 Idler Shaft
J H-2232 Screw 44 J t7014 RetainerBlock
25 H-2976-P Screw 45 J 2 5 5 K 3r Washer
26 Transmission 46 J 5 3 0 J 3 s SleeveBearing
Housing(Ref.#6, 47 281t2 Idler Sheave
J
Figure8-l ) 48 H-52t9 Grooved Pin
J
27 SheaveHousing (Ref. 49 J H - 7 8 1 8 GreaseFitting
#4, Figure8-l)
28 H-5490-P Pin, SlackEnd
29 23J2 Spring, Slack End
Americrane & Hoist Corp. 1-800-652-1932

23

25
z\- -

\\a
26

FIGURE 8-7A.BOTTOM BLOCK FIGURE 8-7B.BOTTOM BLOCK


% & %-TONHOISTS ONE-TON HOISTS

rs'o-.
//
17/
16

FIGURE 8-7C.BOTTOM BLOCK FIGURE 8.7D. BOTTOM BLOCK


DOUBLE CHAIN HOISTS TRIPLE CHAIN HOISTS
32
Americrane & Hoist Corp. 1-800-652-1932
PARTSLIST FOR BOTTOMBLOCKASSEMBLIES
INDEX USAGE PART INDEX USAGT PART
PART NAME PART NAME
NO. CODE NO. NO. CODE NO.

I 2
I F,H 3JG2OS Hook and latch

F,H H-7540
Assembly
l^atch Kit
ll G,J I6JG6
(cont.)
Sheaveand Bearing
Assembly(Models
EC-4006,EC-4008
3 F JF-20-2 Load Block Frame & EC-6005)
4 F JF-20-3 Load Block Frame t2 G 3012 Frame (Model
5 F JF-700 Screw EC-2008)
6 F 9I3JG4ASBottom Block G 30J4 Frame (Models
Assembly EC-4006& EC-4008)
8 G 9r4JG2 Bottom Block l3 G,J t22IG3 Shaft Assembly
Assembly(Model l4 G,J 255t<2 Washer
EC-2008) l5 G,J H-2403-P Screw
G 9t4IG4 Bottom Block l6 G,J H-4085-PLock Washer
Assembly(Models l7 G,J H-3473-PHex Nut
EC-4006& EC-4008)
l8 J 30J20 Frame
9 G 3KGI Hook and latch l9 J 3JGI45 Hook and latch
Assembly(Models Assembly
EC-4006& EC-4008) 20 J H-7544 Latch Kit
G 3KG6 Hook and latch 2l J l8Jl5 Dead End Pin
Assembly(Model 22 J 9t4JG23 Bottom Block
Assembly
l0 G H-7540 *l$'trflr'df1oJ 23 H 30J14 Frame
ll G I6JG7 Sheaveand Bearing 24 H l 8J8 Dead End Pin
Assembly(Model 25 H s-49-77 Screw
EC-2008) 26 H H - 4 1 3 4 Lock Washer
27 H 9 I 3 J G 3 A SBottom Block
Assembly
PARTSLIST FOR STANDARDLIMIT SWITCH
INDEX PART PART NAME INDEX PART
PART NAME
NO. NO. NO. NO.
I 9 1 8 J G 4 Limit Switch and Shaft 1 H-1402-P Screw
Assembly(Consistsof {
8 H-3944 Nut
Index Nos. 4 thru l2)
9 JF-l I 7-3 Limit Switch Shaft
A
JF900-3 Limit Switch BracketAssembly l0 JF-75r-3-GLimit Switch Nut (Green)
(IncludesIndex No. 5)
ll JF-75r-3-RLimit Switch Nut (Red)
5 JF-53r -4 Limit Switch Bushing t2 H-5520 RetainingRing
6 8l5Jr Microswitch,Limit l3 JF-343-3 Spring
I4 H - 2 9 8 1 - PScrew

Americrane & Hoist Corp. 1-800-652-1932

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FIGURE 8-8A.STANDARD LIMIT SWITCH PARTS


34
PARTSLIST FOR LONG LIFT LIMITSWITCH
INDEX PART PART NAME INDEX PART PART NAME
NO. NO. NO. NO.
I 9441G6 Long Lift Limit Switch ll H-2741-P Screw
Assembly(all itemsexcepl l2 8l5Jl Switch
No. l9) l3 H-3944 Locknut
2 t29Jl MountingPlate t4 427J1 Drive Pinion
a
J 2 5 5 K 1 6 Thrust Washer l5 258JG7 Frame and Guide Assembly
4 PB-287 Spring l6 H-1402-PScrew
5 JF-75I -3R RedNut t'l 854823 Screw
6 JF-75 1 - 3 GGreenNut l8 H-5520 Retaining Ring
7 I I 7 J G 2 Shaftand GearAssemblv 19 H - 2 9 8 1 - PMounting Screw
8 J F - 5 3 1 - 4 Bushing 20 H - 1 2 1 0 Flat Head Screw
9 258J8 End Plate 2l I l 0 J1 4 Post
l0 H - 4 1 5 8 Lock Washer

Americrane & Hoist Corp. 1-800-652-1932

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FIGURE 8-8B.LONG LIFT LIMIT SWITCH PARTS


35
Il
Americrane & Hoist Corp. 1-800-652-1932

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llf'x / 7
(32&lHPMODELS)

)o 13

(Vt &Vz HP MODELS)

FIGURE 8-9.MOTOR BRAKE PARTS


36
Americrane & Hoist Corp. 1-800-652-1932
MOTORBRAKE PARTSLIST
INDEX USAGE PART PART NAME INDEX USAGE PART PART NAME
NO. CODE NO. NO. CODE NO.
A 854JG6 Disc BrakeAssembly 4 859JG
l Plateand Stud
(Ve &thHP, Assembly
Il5/230 V Hoists) 5 29tJl BrakePlate
A 8 5 4 J G l Disc BrakeAssembly 6 JF-344 Spring
( 3 / e & lH P , l l 5 1 2 3 0 V 7 5 8 l J l A BrakeDisc
Hoists) 8 JF-7l0 Retainer
B 854JG7 Disc BrakeAssembly 9 H-3978 LockingNut
( t h& t h H P ,
l0 A JF-853- l Coil (l l5 V, 60 Hz,
230/460V Hoists)
For Brake854JG6,
B 854JG2 Disc BrakeAssembly
(3/e & | HP, 230/460V 8s4JGl)
B&C JF-853-2 Coil (230V, 60 Hz,
Hoists) For Brake854JG7,
C 854JG7 Disc BrakeAssembly
(Vq& VtHP. 230 V 854JG2)
C JF-853-3 Coil (460V, 60 Hz,
Hoists)
C 854JG2 DiscBrakeAssembly For Brake854JG8,
(3/e 854JG3)
& | HP, 230V B&C JF-853-4 Coil (575V, 60 Hz,
Hoists) For Brake854JG9,
c 854JG8 Disc BrakeAssembly 854JG4)
(t/q& t/z HP, 460 V
B&C JF-853-5 Coil (208V, 60 Hz,
Hoists)
For Brake854JG10.
C 854JG3 Disc Brake Assembly
(3/c& | HP. 460 V 854JGs)
Hoists) ll t4tJ2 Spacer(Va& VzHP
B,C 854JG9 Disc Brake Assembly modelsonly)
(th & VzHP, 575 V t2 H-2982-P Screw
Hoists) 13 t42Jl BrakeAdapter
B,C 854JG4 Disc BrakeAssembly t4 H - 5 5 0 1 RetainingRing

o B,C
(3/4& I HP. 575 V
Hoists)
854JGl 0 Disc Brake Assembly
(t/n& VzHP, 208 V
l5

r6
34JGI Transmission Cover
(Ref.#5, Figure8-l)
JF-860 ShadingCoil Element
(Must be attachedto
Hoists) framewith H-7812
B,C 854JG5 Disc Brake Assembly Adhesive)
(3/e& | HP, 208 V t1 H-78r2 Adhesive (l Oz.
Hoists) Tube)
2 8 5 7 J G l Plate and Frame l8 616J1 Decal,Load Equalizer
Assembly t9 H-4t34 Lock Washer
J 858JG
l Plate and Armature
Assembly

J
Americrane & Hoist Corp. 1-800-652-1932

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FIGURE 8-IOA.PUSHBUTTON
(SINGLE SPEEDHOISTS)
38
\
I
Americrane & Hoist Corp. 1-800-652-1932
PARTS IST FOR PI SHBUTTON (S'N
INDEX PART PART NAME PART NAME
NO. NO.
I Pushbutton & Cable PB-284-2 Pushbutton
T Assembly(Consistsof
Index Nos. 2 thru 25) 9
PB-285
PB-286
Interlock (Single speed,Red)
Boot
PB-299-68 6 ft. cable length l0 PB-287 Spring, Compression
P B - 2 9 9 -llB I I ft. cable length ll PB-288 Spring, Conical
PB-299-l6B l6 ft. cablelength t2 PB-289 Contact Plate
PBS-299*-BSpecialDrop (*Equal to l3 PB-290 Contact Plate, Common
P.B. Drop)
t4 PB-291 Washer,Contact
2 JF-761 Rubber Grommet l5 PB-301 Screw
J Pushbutton Cable l6 PB-293 Washer, Boot
Assembly: tl PB-294-I Grommet
PB-299-6 6 ft. cable length l8 PB-295 Cap, Enclosure
PB-299-ll I I ft. cable length l9 x-6477-l "O" Ring
PB-299-16 l6 ft. cablelength 20 H-7851 Rubber Seal
PBS-299*- SpecialDrop (*Equal to 2l H-2991 Screw
P.B. Drop) 22 H-2992 Screw
4 534K978 PushbuttonAssembly 23 H-2993 Screw
(Consistsof Index Nos.
24 PB-296 Warning Tag
5 thru 25) 25 H-4160 Lock Washer
5 PB-282-4 Enclosure
6 PB-298 Cover

39
Americrane & Hoist Corp. 1-800-652-1932

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FIGURE 8-IOB.PUSHBUTTON (TWO SPEED HOIST).


40
Americrane & Hoist Corp. 1-800-652-1932
PARTS ST FOR PUSHBUTTON Hoists)
INDEX PART INDEX PART PART NAME
PART NAME
NO. NO. NO. NO.
I Pushbutton& Cable 9 PB-286 Boot
Assembly(Consistsof l0 PB-287 Spring, Compression
Index Nos. 2 thru 30) ll PB-288 Spring,Conical
534JG4-6 6 ft. cable length t2 PB-289 Contact Plate
534JG4-l l I I ft. cable length l3 PB-290 Contact Plate,Common
5 3 4 J G 4 - 1 6l6 ft. cablelength l4 PB-29r Washer,Contact
534JG4-* SpecialDrop (*Equalto
P.B.Drop) l5 H -1 8 5 2 - P Screw
t6 PB-293 Washer,Boot
2 JF-76I Rubber Grommet t7 PB-294-l Grommet
3 PushbuttonCable l8 PB-29-5 Cap, Enclosure
Assembly: l9 x-6471-l "O" Ring
PB-300-6 6 ft. cable length 20 H - 7 8 5 1 Rubber Seal
PB-300-ll I I ft. cable length zl H-2925 Screw(Enclosure)
PB-300-
r 6 l6 ft. cablelength 22 H-2992 Screw(Cap)
PBS-300-* SpecialDrop (*Equalto 23 H-2993 Screw(Plates)
P.B.Drop) 24 PB-296 Warning Tag
4 534JG4 PushbuttonAssembly 25 H-4160 Lock Washer
(Consistsof Index Nos.
26 PB-308 2-SpeedAdapter
5 thru 3l ) 2 1 7 5 5 Jl InsulatingBushing
5 PB-282-4 Enclosure
PB-29tt 2 8 344J5 Spring. Lower
6 C'over 29 2 0 r Jl Contact Button
l PB-284-22Pushbutton
8 PB-2tt5-
I Interlock (Two-speed.Black) 30 200Jr 6 Bushing
3l IF-940-42 JumperWire

;4'

41
Americrane & Hoist Corp. 1-800-652-1932
CHAINCONTAINERPARTSLIST
INDEX PART PART NAME INDEX PART PART NAME
NO. NO. NO. NO.
I 9 2 7 J G t 1Chain Container Kit (20 feet 2 927Jt7 Container(20 feet chain max.)
chain max.)
921JGt8Chain ContainerKit (25 feet
927Jt8
927J19
Container(25 feet chain max.)
Container(35 feet chain max.)
h
chain max.) 927120 Container(50 feet chain max.)
9 2 t I G t 9 Chain ContainerKit (35 feet J 26tJ3 Mounting Arm
chain max.) ^
.+ 53J4 Chain Section
927JG20Chain ContainerKit (50 feet H-7929
5 Split Link
chain max.)
6 H-2349 Screw

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FIGURE 8-TI.CHAIN CONTAINER PARTS


42
Americrane & Hoist Corp. 1-800-652-1932
SECTIONIX
DO'S AND DO NOT'S
Electricand Air PoweredHoists 18. DO apply lubricantto the wire rope or load chain
\. rhe following warnings and operating practices have as recommendedby the hoist manufacturer.
u6ssn taken from American National (Safety)Standard 19. DO NOT lift more than rated load.
ANSI 830.16and are intendedto avoid unsafehoisting
practiceswhich might leadto personalinjury or property 20. DO NOT use the hoist load limitine device to
damage. measurethe load.
Theserecommendationsapply to all electncand air 21. DO NOT use damagedhoist or hoist that is not
poweredhoistsfor vertical lifting serviceinvolving mate- working correctly.
rial handlingof freelysuspendedunguidedloads. 22. DO NOT usethe hoist with twisted,kinked, dam-
agedor worn wire rope or chain.
WARNING: TO AVOID INJURY
23. DO NOT lift a load unlesswire rope is properly
I . DO readANSI B30.l6 SafetyStandardfor Overhead seatedin its groove(s)or unless chain is properly
Hoists and Hoist Manufacturer'sOperating and seatedin chain wheel(s)or sprocket(s).
MaintenanceInstructions.
24. DO NOT use load rope or load chain as a sling or
2. DO be familiar with hoist operatingcontrols,proce- wrap rope or chain around the load.
durcs and warnings.
25. DO NOT lift a load if any binding preventsequal
3. DO make sure hook travel is in the samedirection loadingon all supportingropesor chains.
as shown on controls.
26. DO NOT apply the load to the tip of the hook.
4. DO make sure hoist limit switches function
properly. 21. DO NOT operate unless load is centeredunder
hoist.
5. DO maintain firm footing when operatinghoist.
28. DO NOT allow your attention to be diverted from
6. DO make sure that load slingsor other approved operatingthe hoist.
sling attachmentsare properly sizedand seatedin
the hook saddle. 29. DO NOT operatethe hoist beyond limits of load
rope or load chain travel.
7. DO makesurethat the hook latch,if used,is closed
and not supportingany part ofthe load. 30. DO NOT use limit switchesas routine operating
stops unless recommended.They are emergency
8. DO make sure that load is free to move and will devicesonly.
clearall obstructions.
31. DO NOT use hoist to lift, support or transport
9. DO take up slackcarefully,checkload balance,lift people.
a few inchesand check load holding action before
contlnulng. 32. DO NOT lift loadsover people.
10. DO avoid swingingof load or load hook. 33. DO NOT leavea suspendedload unattendedunless
specificprecautionshave been taken.
I l. DO make sure that all personsstay clear of the
suspendedload. 34. DO NOT allow sharp contact between two hoists
or betweenhoist and obstructions.
12. DO warn personnelof an approachingload.
35. DO NOT allow the rope, chain or hook to be used
13. DO protect wire rope and load chain from weld as a ground for welding.
spatteror other damagingcontaminants.
36. DO NOT allow the rope,chain or hook to be touched
14. DO promptly report any malfunction,unusualper- by a live welding electrode.
formance,or damageof the hoist.
37. DO NOT remove or obscurethe warningson the
I 5. DO inspecthoist regularly,replacedamagedor worn hoist.
parts, and keep appropriate records of main-
tenance. 38. DO NOT adjust or repair a hoist unlessqualified
to perform hoist maintenance.
16. DO use the hoist manufacturer'srecommended
parts when repairinga hoist. 39. DO NOT attemptto lengthenthe load ropeorchain
or repair damagedload rope or chain.
17. DO use hook latcheswhereverpossible.

43
I
DUFF.NORTONHAS ALL YOUNEEDTO
HANDLEA VARIETYOF TOUGHINDUSTRIAL,
MAINTENANCE AND CONSTRUCTION t'
LIFTINGJOBS.
Coffing(-'is America'sfirstnamein quality, productcatalogis availablefrom your localCoffing
industrialhoistingequipment.Nowhereelsecan you hoistdistributor,Duff-NortonDistrictSalesManaqer,
find sucha broadrangeof hoistswith suchconsistent or by writingdirectlyto Duff-Norton.
Ask for
high-qualityconstructionand durability.
A detarled Catalog201,it includes:

CoffingroElectric Chain Colf ing''r Electric Wire Coffing'' Hand Chain Coffingr"'Lever Hoists.
Hoists Rope Hoists. Hoists.
Load ratingsfrom % to 5 Lowheadroomunitswith Designedfor lightweight A varietyof mechanisms
lons. More standard load ratingsfrom % to 3 a n d l o n gl i f ew i t hm i n i m u m and rated loads from % to
featuresthan any tons.Choiceof rigidhookor mainlenance. Ootronal 15tons;in 36 modelslor
comparablehoist-Two- lug suspensions, plusplain. capacitylimiteravailablein bothconventional and
speed optionsavailable;47 gearedor motorizedtrolleys somemodels.99 modelsin specialpurpose
modelsto choose. Singleor two speedoptions ratedfoadstrom:/z lo 25 applicalions.
and varietyof standard[fts. tons.
35 models.

WARNING: The hoistingequipmentdescribedin this manualis intendedfor industrialuse only


and should noi be used to lift, support, or otherwise transport people,or lift loads over people.

AVAILABLE
FROMYOURLOCAL
DUFFNORTON
LYNX@
COFFING@/DUFF
HOISTDISTRIBUTOR: Duff-Nonton
P . O .B o x 7 0 1 0
Charlotte, NC 28241-7010

CustomerService(800)477-5003
PartsService(800) 477-5004
FAX (704)588-8466

Duff-NortonManufactures: EC 680-4
Duff-NortonActuatorsi!'. MechanicalJacks . RotaryUnions . Coffing'ur
Hoists . Duff Lynxo Hoists Printedln USA
Yale.oHoists,Shop King Hoists . LittleMulec'Productsand AmericanLifts 500 10/93