3.0 manual de op y mantto de polipastos

NEKOTEC ~ MANUFACTURA

MANUAL DE OPERACiN Y MANTENIMIENTO DE POLIPASTOS

OPERADORA CICSA, SA DE CV

OT 129/2010

POLs 16t, 12t, 10t, 5t, 2t (JACK UP)

MANUAL DE OPERACiN Y MANTENIMIENTO

SECCION # 3

NEKOTEC

~ MANUFACTURA



OT - 129/2010

PO,Ls 16t, 12t, 10t, 5t, 2t (JACK UP)

MANUAL DE POLIPASTO MANUAL CHESTER 1442-12SR


SECCION # 3

SECTION 825

Rev.1-09

ZLP-ZLG Series

Parts and Instruction Manual Low Headroom

CHESTER

Users should refer to ASME B30.16 Safety Standard and ASME HST-2M Performance Standard for Manual Chain Hoists for specific requirements regarding safety practices far the installation, maintenance, and operation of this equipment.

P.O. Box 449 7573 Sto Rt. 45

Lisbon, Ohio 44432 Phone (330) 424-7248 FAX (330) 424-3126

---------_.-----------------~

-------_._-~--

RECOMMENDED PRACTICES

HAND CHAIN MANUALL y OPERATED CHAIN HOISTS

Beca.u~ the manufucturer has no direct control over the host and itN operation, conformance v.ith gocrl safety pmcti.ce is the responsibilityofthe user and operatingpersonne1. ANSI/ ASME B30.16 has been u~ as a guiie in preparing this list ofSHAlL's and SHALL NOTs. Ask )'Our supervisor for a ropy. Each is identified according to ANSI NEMA Z535.4 with either the sgnal word CAlmON or WARNING to indicate the degree of seriousness.

WARNING Improper operacion of a hoist can creare apotentiallyhazardous situation which, if not avoided, could result in litigation or senous .i!:ili!!Y. To avoid such a potentially hazardous situation, the operator shall:

k NOT operate a malfunctioning or unusually performing hoist. 1: NOT operare the hoist until you have moroughly read and

undemood me manufactureI's Operating and Mairnenance

lnstructions or Manuals.

1:. NOT operate a hoist which has been modified without the manufactureI's approval orcettification to be in conformity'Wit:h appIicable OSHA regs.

.:i: NOT Iift or pul! more [han rated load for me hoist 2: NOT use darnaged hoist or hoist that is working properly. Z, NOT use hoist 'Wit:h twisted, kinked, darnaged, or wom load chain. lh NOT use the hoist to Iift, support, or transport people. 2, NOT lift loads over people and make sure all personnel remain

clear of the supported load.

10. NOT an:empt te lengthen the load chain or repair damaged load

chain.

11. Protect the hoist's load chain from weld spIan:er or other

damaging contaminantS.

12. NOT use load chain as a sling or -wrap load chain around load. 13. NOT applythe loadtothe tip of the hookortothe hooklatch. 14. NOT apply load unless load chain is properlyseated in the chain

wheel(s) or sprocket(s).

15. NOT apply load if bearing prevents equ.alloading on allload

supporting chains.

16. NOT operare beyond the limits of me load chain traveL 17. NOT Ieave load supported bythe hoist unattended unless specific

precautions have been talren.

18. NOT allowthe chain or hook to be used as an electrical or

'Wl:lding ground.

19. NOT allowthe chain or hookto be touched bya live

welding eIectrode.

20. NOT remove or obscure the warnings on me hoist. 21. NOT operate a hoist which has Not been securely attached to a

suitable support 22. NOT operare ahoist unless load slings or other approved single

attachments are properlysized and seared in the hook saddle. 23. NOT operare a hoist when it is restricted from fOmllng a straight

line from hook to hook in the direction of loading. 24. NOT lift loads that are Not balanced and that me holding action is

Not secure, taking up sIack carefully. 25. NOT operare ahoist unIess all persons are and remain clear of me

supported load. 26. Reportma.lfunctions orunusual perrormances of ahoist, afterit

has been shut down until repai.red. 27. NOT operare a hoist on which the safety placareis or decals are

missing or illegible. 28. Be familiar 'With ooeratine contrels. orocedures. and warnine.s.

CAUTION

Improper operacion of a hoist can creare a potentia1lyhazardous situation whicb, if not avoided, could result in minor or moderare injury. To avoid such a porentially hazardous situation, the operaror shal1

1. 1vfaintain a firm footing or be othet'Wise secured when opeIlltng

the hoist

2. ClJ.eck brake function byrensioning the hoist prior to each lift or

pulling operation.

3. Use hook latches. Latches are te 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 s'Winging the load or hook 7. Inspect the hoist regularly, replace darnaged or wom parts, and

keep appropriate records of maintenance. 8. Use the hoist manufactureI's recommended parts when repairing

the unit. 9. Lubricare load chain per hoist manufacturer's recommendations. 10. NOT use the hoist load limiting or w.uning device to measure

load. 11. NOT operare except 'With manual power 12. NOT pennit more than one operaror to pull on a single hand chain

at the same time. More than one operator is likely to cause hoist overload.

13. NOT allowyour an:enrion [O be diverted from operating the hoist. 14. NOT allowthe hoist ro be subjected to sharp contact 'Wit:h other

hoists, structures, or objectS through misuse. 15. NOT adjust or repair the hoist unIess qualifJed 10 perform suro

adjustments or repairs.

DISCLAIMER

Under no cin:urnstances does the hoist manufacturer assume any liability for the use of these voluntaty recommendations, and no w.u-rantywhatsoever is made in connection 'Wit:h them. The recommendations do not take precedence over existing plant safety rules and regulations, or OSHA regulations. lt is me user's, inrent to absolve and protect the hoist manufactu.rer frem anyand allliability, in tort or other'Wise.

EKOTEC

~ MANUFACTURA



OT - 129/2010

POLs 16t, 12t, 10t, 5t, 2t (.JACK UP)

MANUAL DE POLIPASTO MANUAL CHESTER 130-1 OSR


SECCION # 3

FAX

i

@

CHESTER HOIST. INe. PHONE (216) 4247248

The sQuipment iIIu$rrated and described in thi$ bulletin i$ designed far manual operaton only and is not ro be power driven, nor ;$ ir witable far lifting people.

, , "-../

IMPORTANT PZ482 Keep

10r Futura

Reference

Service Instructions and Parts List

SPUR GEARED HOIS1, EXTENDED HANDWHEEL HOIST, and TWIN HUUK HUISl

SECTION ZMS-80-R-03HOOK SUSPENDED,

EXTENDED HANDWHEEL,

TWIN HOOKS and

ARMY TYPE HOISTS

SERVICE INSTRUCTIONS ANO MAINTENANCE MANUAL

OPERATING INSTRUCTIONS A Lockout/Tagout policy and procedure shall be implementad by the O\'II'ner or user of all hoists. MAKE A COMPLETE INSPECTION of the host at regular and frequent ntervals. See ASME 830.16 tor inspection criteria and record keepng requrements.

LUBRICATE AS RECOMMENDED, as often as may be necess8ry. AVOIO OVERLOAOING and mpacting, Use only with loads withn the rated hoist capacity, and avoid sudden stops and jerkng in raising or lowering. 80th are dangerous and destructive, and wll shorten ths workng life of the hoist.

LUBRICATING THE HOIST

Ordnarily only the load chain will require any perodc lubricaton. Chester Zephyr hosts have besn thoroughly lubricated and tested when they leave the factory. NormaHy, factory lubrication withn the completely enclosed covers will

last throughout the working life of the hoist. However. the lubricant will melt and escape if the hoist is subjected to very high temperaturas. Should this happen the lubrlcation must be renewed as recommended below.

(1) BRAKE (4) LOAD CHAIN Useful load chain life can be apprecab!y

with lubrication of the hoist that the brake It should be immedately noted in connection

ncreased by mmersng chain in oi! at frequent requires none at any time. lt is advisable, intervals. Unlubricated chain wears rapidly though, to coat the square thread HghUy with from friction wlth the pocket wheel as well as bearing grease at reassembly. with its own inks. Immerse in container of oil

with an E.P. additive as often as necessary or (2) NEEDLE BEARINGS swab with ol! soaked rag. Wipe off excess oL

This will mantain the charn in a lubricated and Lubricate with an NLGI Grade 2. complex rust free condition.Iithum based grease wth E.P. additve after

prolonged use or at reassembly. 4f (ji! i~ objectioHable, 01 1"I0t !,reaticel, a bORO ~dll)t:rtSan~lj~~$-mW ~~1tt~~:I( . " .~t " d~. ':;1,., , -. . ;t ~~ j.. ~",l' ik~, ~,N,JtJPhl4'(3) GEARS e, ~s'~r~tUse NLGI Grade 2. complex lithum basad

grease wth E.P. additive. Lubricate gears after prolonged use or at reassembly.

Cansult your local 011 dealef in regard to recommended gra s~.. . , .... ~.. . ~_CAUTION: MAKE NEEDED REPLACEMENTS I ME'mA17i!~, " ; ' ;~Mt, . ...- " -I'm:CHI:i, '

/. :.;;~(rr~c [:-j e~ p ~~:r1; Ft~j 00t/J }rv'V t~fAr:;..\I"A C~ . .\ _ -~~':::::t:,JtiV . J f~r:;::C;HAZAOO ~~.c.atOn~......_ c7faL~91/0 If hooks are badly stretched or worn, raplace with new ones.

Obviously worn or stretched chan should also be replaced immediate!y. Do not anneal Chester Zephry load chain. It has been heat treated and will not work~harden. Do not use hoist f the load chain is fouled by rust or other foregn substances. Chester load chan will wear wel! if kept lubricated. Replace tt1e load sheave when both ends of oach pocket

become excessrll 'FINo. .'. .

wear, reverse the load sheave. If load sheave is replaced,

do not use stretched or badly worn chan in new load sheave

pockets.

Replace i3ny badly worn or damaged brake assembly

\'\>'ashers, pawl or pawl spring. Adjust check washer No. 925

if substantially greater trian j/ ncll throwis measured.

ASSEMBLY PROCEDURE

Reassembling the Zephyr Host Mechanisrn after complete tear-down.

.A.ssemble ball bearings No. 960 in nterna! gear trame No. Assernble bearngs No. 922 in gear-and-pinon No. 927 .

920-G and handwheel trame No. 920-H. Place load shaft No. Assemble gear-and-pinion insde pinion caga No. 921 and

974 In internal gear frarne bearing. with smal! splined end place cotter in axles No. 919,

toward Interna! goaL

CHESTER HOIST USBON, OHIO U.S.A. 44432 PHONE (330) 424-7248 FAX (330) 424-3126

Assemble bearng No, 906 in pinion cage bearng block No, 959, and press pinion cage bearing block into pinlon caga. Assemble pinion cage complete with gears on splined .!oad shaft. Une up the set-serew hole n pinion caga with hole in load shaft.

Now, time tha gears. Locate punch marks on gears as shown in Fg. 2, Theses marks must be drect!y opposte each other as indcated, for proper timng.

FIG.2

Aftar gears are property installed, press pinion caga wlth gaars completely anto the load shaft, and secure with squarehead setscrew and lock nut Assemble load sheave No. 929 on load shaft No. 974 with combination stripper and load chan guide No. 90S. Align stripper with studs on intemal gear frame and press on as one assembly, Spacing 01 studs assuras loeation, Next, assemble pawl spring No. 910 and pawl No, 923 on handwheel trame stud and fasten wth pawl retaining snap ring.

Assemble handwheel trame ta internal gear trame, and nM stall top hook No. 913 before pressngframe ovar separator studs. Fasten with tour nuts and lock washers, making sure the tal! of the pawl spring No. 910 is anohored under the nearest separator stud nut

Run spindle No. 918 through load shaft. Spindla wHl tall in place and may be turned easly if gears are propery timad, lf spindle cannot be turned, or locks, gears are out of time and tMe timing will have to be repeatad, Procesd with assembling the brake parts. Place one brake diso No, 934 ovar the threaded end of the spndle No. 918 ano follow with the ratchet No. 935 and another brake dise No. 934. Ft the end of tha pawl nto the ratehat teeth.

Rotate handwhesl and nut clockwse on spindle and tghten. Assemble check washer No. 925 on splined hub of part No. 916 makng sure that lug on splined rng is 1/.1neh mnimum to right of hole in spndle. lnsert drive corter pino Try handwheel ralease, and if It releases hard, ncrease the gap between drtve pn and check washer lug by cne tooth. Keep tne gap to a mnimum. Handwheel nut No. 916 must not Hghten against the drive pin when releasing. Assemble bearing No. 903 in handwheel cover No< 968. Assemble hand cnain No. 937 n handwheel cover. Assemble handwhee! caver to trame. and fasten with four round head screws and lock washers. Reeve the hand chaln on handwheel with the welds up in ths grooves. Apply and clase open link, Now, reeve load ehain in load shsave! again with the side opposite wetd of each link riding in the groova. First and last links of chan must be in vertical positon. Test reeving by pulling on hend chaio. Excessive hand chaln pull will indicate load chal n ls not properly set in load sheave pockets.

Remedy by load chain off and reeving agan. Continuad hand chain pulling will cause ehain to ball, with sorous damage to chain and cover. Finally, tastan dead end af load chain to combination stripper and dead support No. 905 with bolt flut and lockwasher. Lubricate gears as recommended on page 1, and assemble gear covar No, 930 on nternal gear trame. Fasten with four round head serews afld ock washers,

NOTE: Ahoist in whch load suspensiQf1 parts have been mered, load tested at 100% of ratea capacity per ASME 830.16,

OOS ANO OONITS FOR SAFE OPERATION

DO'S READ ASME B30.16 SAFETY STANDARD FOR OVERHEAD HOISTS 1. CHECK lubricant before operating the hoist 2. EXAMINE hoist before each shift. CHECK for darnaged

hooks or chains, also make sure the host IS properly secured. Make sure your hoist is kept cleafl and well lubricated.

3, CHECK daily the chain for improper seating, twistlng, kinking, wear or other defects befan, the hoist If these are not checked, the chain may under a norma! load.

4, BE SURE fhere are no objects in the way of a load or hook when maving the host on the troHey.

5. MAKE SURE l load clears neighborng stock piles or machinery when raising or lowlring the load.

6. CENTER hoist unit over the load before lifting. 7. AVOID of load or load nook when traveling tha

hoist 8, PROPERLy secura outdoor hoist when unattendad. 9. KEEP load block above head level when not in use,

10. BE SURE the s properly seated in the saddle of the hook, Tip foading leads to and possble falure, Hook !atch should not any part of the load.

11. DO lift a load only a few nehes check load balance and brake operaton befare proceE~ajrlO

DON1TS 1. NEVER lift a load with hoist untll al! personal are clear. 2. DO NOT allow any unqualified personnel to operate hoist.

3, AVOIO consions or bumpng 01 hoists.

4, DO NOT transport load over personneL

S, NEVER carry personnel on the hoak or the load.

6. DO NOT operate hoist if you are not physically ft to do so. 7. NEVER pick up a load beyond the capacity appearing

on tila hosL 8, DO NOT tamper with any parts of (he host unless you

are a qualified mainlenance man, 9, NEVER use the hoist cha.n as a slng.

10, DO NOT use chain as ground ter welding, NEVER touch fue weiding electrode to tlle chain.

11 DO NOT divert attention from load while operatng hoist 12, DO NOT llave a load suspended in the ar at the afld

of a work shitt, or far extended periods of time and DO NOT leave a load unattended during regular working hours,

13> DO NOT tp O "polnf' load a hook,

14,DO NOT aparate a hoist in oeed of adjustment or repair.

15. DO NOT operate a hand host wth power or rnore than

one operator. 16. DO NOT operate a host that has been tagged out of

servjce,

CHESTER HOIST LlSBON, OHIO U.S.A. 44432 PHONE (330) 424..7248 FAX (330) 424..3126

PRECISION BEARING TROLLEY . ~ SERVICE INSTRUCTIONS ANO PARTS LIST

SECTION O1T12, P01

CAUTION: THE EQUIPMENT ILLUSTRATED AND DESCRIBED IN THIS BULLETiN IS DESIGNED FOR MANUAL OPERATION ONL y AND IS NOT TO BE POWER DRIVEN, NOR IS IT SUITABLE FOR TRANSPORTING PERSONS!

This trolley is a relatively simple mechanism requiring comparatively little care, maintenance, inspection and lubrication. The following information is provided to assist in installing and maintaining this equipment. INSTALLATION Sliding the trolley over the open end of the runway beam is the simplest way to install this unit. If an open beam end is not available, one side plate can be removed and the unit can be reassembled on the beam. Always verify the trolley is adjusted properly to fit the beam. See the adjustment instruc'tions below. Always run the unit along the entire length of the runway beam to verify proper operation and clearances.

GENERAL MAINTENANCE Thorough inspection is recommended at regular intervals. The frequency of inspection must be determined by the user, since application factors such as duty cycle and ambient conditions will dictate the maintenance requirements of the unit. When inspections are made, the entire trolley should be inspected for wear, or for damage such as may bo sustained through severe overloading or impact with other objects. Replace all damaged parts immediately. Check trolley motion along the runway beam, to verify proper operation.

LUBRICATING THE TROLLEY 4 thru 12 ton Trolleys are built with sealed, precision tapered roller bearings that are factory lubricated. Grease fittings are provided on the back side of the trolley wheels and a small amount of lithium based NLGI Grade 2 grease can be added periodically to insure proper lubrication is maintained. Periodic lubrication of the trolley drive shaft support block and the handwheel guard is recommended. A small amount of lithium based NLGI Grade 2 grease should be applied through the grease fittings provided.

WARNING: DO NOT operate the trolley unless you are physically fit and trained to do so. . DO NOT transport loads over people.

4 THRU 12 TON

..,

.4 v A ~t 1:,J !

PLAIN TROLLEY GEARED TROLLEY

ADJUSTMENT INSTRUCTIONS: Beam flange width plus 1/16" running clearance on each side of the flange is the correct trolley setting. Move the spacing washers to the inside or outside of the plates as required.

~-t-l/16"

SPACING 'w'ASHERS

MAINTAIN CLEVIS IN CENTER OF TROLLEY

LOAD

WARNING:

DO fit al! open beam ends with trolley stops.

DO make sure there are no objects in the way of the

moving load.

DO NOT leave a load unattended.

NEVER allow a load to swing off center.

NEVER lift an off center load.

r----- --.-------~-.----DO NQ-T~~~'l:A*'en~ f!,..'OOi..p~d~~t~ " ,~ ~~7 1rf ~ ~'1;~."~ ~ jJ;~ ~l. Jtl ~k.~~~~' time. ... ;: NEVE l.~;iTErolley ber-r-(it~~~~~~~ . tJ~ rI~r~ I R;:H';~;O

~k~-~~,,_~, ~-t(~oi,i(\~ ~:\~,U~ ~". : , ;.: :\t l r':~:C~~~

4 THRU 12 'TON CAPACITY PT TROLLEY PARTS LIS-r

C-1Z91D 5/15

ITEM b ITEM 4 TON 5 ANO 6 TON BTON 10 ANO 12 TON NO. ESCRIPTION PARTNO QTY PARTNO QTY PARTNO QTY PARTNO QTY

1 HANO CHAIN C937 ?(O) C937 ?(O) C937 ?(O) C937 ?(O) 1 CONNECTING LINK C937L 1(0) C937L 1(0) C937L 1(0) C937L 1(0) 2 HANOWHEEL C9120-0100P1 1(0) C9120-0100P1 1(0) C9120-0150P1 1(0) C9120-0150P1 1(0) 3 HANDWHL GUARO C9121-0100P1 1(0) C9121-0100P1 1(0) C9121-0150P1 1(0) C9121-0150P1 1(0) 4 SNAP RING (EXT) 5100-87 1(0} 5100-87 1(0) 5100-87 1(0) 5100-87 1(0) 5 KEY 13-.25-1.50 1(0) 13-.25-1.50 1(0) 13-.25-1.50 1(0) 13-.25-1.50 1(0)

I

6 SUPPORT 8LOCK C906AP1 1(0) 6AP1 1(0) C9106-0150P1 1(0) C9106-0150P1 1(0) 7 LOCKWASHER 1-.31 2(0) 1-.31 2(0) 1-.50 2(0) 1-.50 2(0) 8 CAP SCREW 14-.31-1.00 2(0) 14-.31-1.00 2(0) 14-.50-1.25 2(0) 14-.50-1.25 2(0) 9 SETSCREW 58-.25-.87 1(0) 58-.25-.87 1(0) 58-.37-1.25 1(0) 58-.37-1.25 1(0) 10 GREASE FITTING 17438 6(4) 17438 6(4) 1743B 6(4) 1743B 6(4) 11 PLN SIDE PLATE C42921 1 C42921 1 C42923 1 C42923 1 12 GRD SIDE PLATE C42921G 1 C42921G 1 C42923G 1 C42923G 1

!

13 CLEVIS C42926P6 1 C42926P7 1 C42926P8 1 C42926P9 1 I 14 EQUILlZING PIN C42927P4 1 C42927P4 1 C42927P5 1 C42927P5 1 15 ORIVE SHAFT C154A0150 1{O) C154A0150 1{O) ~4A0800 I 1(0) C154A0800 1(0) 16 PLAINWHEEL C37003-1 2(4) C37003-1 2(4) 7005-1 2(4) C37005-1 2(4) 17 GEARED WHEEL C37003-1G 2(0) C37003-1G 2(0) C37005-1G 2(0) C37005-1G 2(0) 18 AXLE C9110-0300 4 C9110-0300 4 C9110-0800 4 C9110-0800 4 19 ADJUSTING NUT C9112-0300 4 C9112-0300 4 C9112-0800 4 C9112-0800 4 20 NUT 96-1.00-2 4 96-1.00-2 4 100-1.25-2 4 100-1.25-2 4 22 BEARING C9116-0300 8 C9116-0300 8 l ,ln H'\-I 800 8 C9116-0800 8 23 BEARING CUP C9117-0300 8 C9117-0300 8 C9117-0800 8 C9117-0800 8 24 LOCKWASHER 1-1.00 4 1-1.00 4 1-1.25 4 1-1.25 4 25 WHL SPACER(THK) C9303-0200 4 C9303-0200 4 C9303-0400 4 C9303-0400 4 26 WHL SPACER(THN) C9303A0200 4 C9303A0200 4 C9303A0400 4 C9303A0400 4 27 COTTERPIN 128-.15-1.75 4 128-.15-1.75 4 135-.18-1.75 4 135-.18-1.75 4 28 WASHER C99911 47 C99911 47 C99907 36 C99907 36 29 COTTER PIN 128-.50-3.00 2 128-.50-3.00 2 128-.50-3.00 2 128-.50-3.00 2 31 SERIAL NO TAG SNT-PTG(P) 1 SNT-PTG(P) 1 SNT-PTG(P) 1 SNT-PTG(P) 1 32 RIVETS 142-4-.25 2 142-4-.25 2 142-4-.25 2 142-4-.25 2

NOTE: PARTS ILLUSTRATED FOR STANDARD UNITS ONLY. ALWAYS SPECIFY SERIAL NUMBER ANO CAPACITY WHEN ORDERING. QUANTITIES SHOWN FOR GEARED UNITS. PLAIN QUANTITIES ARE SHOWN IN BRACKETS ().

CHESTER HOIST, P.O. BOX 449, LISBON, OHIO 44432 PHONE: (330)424-7248 FAX: (330)424-3126 WEB: CHESTERHOIST.COM

)


HAND UlAIN MANUALLY OPERATED UlAIN HOISTS

Becaus:: the manufact:urerhas 00 direct control over the hoistand its opem.ti:m. corrli:mJance with goocl sai:typractice is the responstbiliWoftheuserand operatingpersonnel. ANSIASME B30.16 has been used asaguXfe in preparing this HstofSHAIL's and SHAIL NOT's. Ask your supervisor rOl' a copy. Each is identified acoording ro ANSI NEMA Z535.4 with either the signa!word CAlmON or WARNING ro indicare the degree of seriousness.

WARNING Improper operm of a hoist can creare apotemially hazan:Ious siruation v.hrh. if J1Qt avoidcd, coukIresult in Iiigation orserious !!l!!:I.To avoid such apcxem:iallyhazardous si:uation, tbe operaror shaIl:

k NOT operare a maIfunctioning or unusually pertorming hoist. 1. Maintain a finn footing or be a:berv.ise ~ vAlen operating 1, NOT oper.ll't! the ~ unta }W Jm.e thomughly m:d and !he boist

tmdemood tbe ~s Operaring and ~ 2. Oleck br* function by tellSioning tbe hoist prior ro e:d! lft oc Insouctlons or Manuals. pulIing operar:on.

i. NOT oper.II't! a hoist ~ has been modified wibout tbe 3. U;e hooklarches. Utcbe$ are to reuin slings, chains. etC. onder rnanufaaurer's approval or cmifx::ation ro be in confor:mity wiIh sJack condi:ions only.

applicable OSHA regs. 4. MaIrt: sure the hook_hes are closed and not supporting any

pans of ihe load. ~ NOTl.L1e damaged hoist or boist that is working properly. 5. MaIrt: SUR! ihe load is free 10 move and wiII cbr all obstructions. lo NOT l.L1e hoist wiIh ~ kinb:d. ciunaged, or 'WOl1lload chain. 6. Avoid ~ the load or hook. ~ NOT use the hoist lO Iift, supporc.. Oftr.lllSport people. 7. Impea: tbe hoist reguIarly, repb::e dasruIged orwom pans, and

2. NOT Iift oc puU mOl\: than raed load for tbe hoist

2. NOT Iih Ioads OVI:I' peopIe and. makc sure all personnel remain kcep appropriate recoo:ls of mallteoance. clear of the su~ load. 8. U;e ihe hoist manufllCtll:l'et"s recotTlIllended parts vAlen repairing

10. NOT mempt ro Iengthen the Iood chain or repardarna&ed Iood me unit. chain. 9. Lubric:ate load cm per boist manufacturer's recommend:aton.

11. Prctect the ~'s Iood cmfrom weld splaueror otber 10. NOT use ihe hoist Iood Iimitiog or w.uniDg device 10 measure damaging contatninants. load.

U. NOT use load chain as a sling or wrap Iood cm around load. 11. NOT operare except with manual ~

11 NOT applythe Iood ro the tip of the hoak or ro the hoaklatch. 12. NOT pennit more than one operntor ro pul! on a single hand chain

14. NOT applyIood unbs Ioodchain is properly scated in the chain lit the same time. More tban one operator is liIrely to cause hoist

~I(s) or sprocket(s). averload. 15. NOT apply load if bearing prevem:s equaI Ioadint: on allload 11 NOT allow}Wrmellton to be diVl:IT.Cd from operaring tbe hoist.

supponing chains. M, NOT allowtbe hoist ro be subj:aed 10 sbaIp coma:t wiIh other 16. NOT operae beyond the Iirnirs of me load chain U'ilVeL hoists, structures, or objects through misuse. 17. NOT leave Iood supported bythe hoist UIlaIIeIlded unIess speciflC 12, NOT adjust or repar the hoist unless qualifled lO pertorm such

precautons bave been w.:n. adjustments or re~. 18. NOT aIIowtbe cbain or hookro be used as an electrical or

~lding ground. 19. NOT allowthe chain Of hook w be rouched bya live

wclding eIectrode. 20. NOT remove or obscure the w.unings on the hoist. DISCLAIMER 21. NOT opeme a hoist.wich has Not been securely attached lo a

sWtable suppolt Unde:r no circuInstu:K:ef, does the host manufa:rurer assume any liabilityforthe l.L1e o these volunwyrecOIIllllo:ndaons, and no

22. NOT operare a hoist unbs Iood slings orother approved s. macbmem:s are properlysized and seato:! in ihe hooksaddle.

w.urantywbatsoever is made incOlllltCton wiIh thern.. The23. NOT oper.II't! a host ~ it is rest:ted from forming a stn1ight recommendations do not talle precedence over exsting plantI.ine from hook 10 book in the direction of Ioading. safetyrules and regulaom, orOSHA regulations. It is iheuser's,

24. NOT Iih Ioads that are Not baIanced and tbal: the holding a=tion is iment toabsolve and protect che hoist manufaaurer fran any and Not secure, taking up s.Iack carefully. alIliabi1ity, in ton or otherwise.

NOT operare aboist unIess all pel'SOllS are and remain clear ofme supported load.

26. Repon malfunaions orUllllSll4i perfonnancts of a host. after i: has been shut dO\'\'Il until repaired.

27. NOT operae ahoist on wbich die safety plaanls or cIec:ak are missing or illegible.

28. Be familiar with ooeratlllt corurols. Drocedures, and ~

CAUTION

NEKOTEC

,., MANUFACTURA



OT 129/2010

POLs 16t, 12t, 10t, 5t, 2t (.JACK UP)

MANUAL DE POLIPASTO MANUAL CHESTER 1442~5SR


SECCION # 3

SECTIONZLP-ZLG Series 825

Rev.1-09Parts and Instruction Manual Low Headroom

CHESTER

Users should refer to ASME B30.16 Safety Standard and ASME HST-2M Performance Standard for Manual Chain Hoists for specific requirements regarding safety practices for the installation, maintenance. and operation of this equipment.

CHESTER HOIST P.O. Box 449

7573 Sto Rt. 45

Usbon, Ohio 44432

Phone(330)424-7248

FAX (330) 424-3126


HAND OiAIN MANUALLY OPERATED OiAIN HOISTS

Because t:be manufact:urer has no d.irect rontrol CJIII'!l' the hoistand ita ope.ratim, conbmanre with. goo:i satetypractice is the respmsibilityoftheuser and o.peratingpet'QUlel. ANSI/ASME B30.16 has been used as a gui:::le inpre:ming this list ofSHAIL's and SHAILNOTs. Ask your supervisor for a copy. Each is identified according to ANSI NEMA Z535.4 with either the signal word CAt.mON or WARNING to indicare the degree ofseriousness.

WARNING Improper opem:ion o ahoist can creare apotentiallyhazanloos situation v.m:h. jf nlX avoided, coukf n:suk in Iitigation orscrious ~. To avoid 5UCh apotemially ha:z.a:rdous sI:uation, tire oper.ttor shall:

l. NOT operare a malfunction.rlg or unusuaIly pertonning hoist. 1. Maintain a film fotting or be ahe~ secured when ope~ ,1 NOT opet;JtL' che hoist um:l }UU have thorou;bly read and tbe hoist

undemood lhe ~s Oper.uing and ~ 2. Cck ~ function by rensioning the hoist prior ro eac:h lift or Insouctions or Manuals. pulling oper.aton.

1: NOT oper.e a hoist v.m:h has been mOOifJCd without che 3. Use hook Iatt:bes. I..atches are tO retain sliDgs, chains. etc. tmder manufaauret's approval or cmifaOOn ro be in confonnity wiI:h slack conditions oDly. applicable OiHA regs. 4. MW SIIJ'e tbe hooklatrbes are closed and llOI: supporting any

parts of the load.~ NOT lift or puI1 more than r:ated load fonhe hoist

., NOTuse d.amaged hoist or boist that is working properly. 5. MW SUte tbe load is free 10 move and wilI dear aII obstructions.

Z NOT use hoist "I'irh twisted, kin!rl:d, damaged, oc wom load chain. 6. Avod swinging the load or hook.

' NOT use the hoist 10 Ift,. suppon, or tr.Ul$port people. 7. Inspea the hoist reguIarly, replace damagcd orv.um pan:s, and

!. NOT Iift loads over people and make SIIJ'e aII personnel m:nain keep appropriate records of maintenanu.

clear of the supponed load. 8. Use che hoist lll3I!U&a:urer's recanunended parts v.nen repairing 10. NOT an.empt te lengtben che load chain or repair damaged load tbe unir.

chain. 9. Lubricare load chain per hoist manufacturer's recommendations. 11. PIttI.:Ct the hoist's loadchain fmm ~ splatteroraher 10. NOT use the hoist load limitiog oc warning device to measure

~gcoouunWanu. load. 12. NOT use load chain as a sling oc wrap load chain around load. 11. NOT oper:ate except wir.h manual power 13. NOT applythe load ro che t%> o the hoak.arrothe hookl:atch. 12. ~ Il'IOI'e than one operlll'Or ro puI1 00 a single hand cbain 14. NOT applyload unless load chain is properlyseared in the chain al the Sarn! time. More than OIJe operaror is likely to cause hoist

wl=1(s) oc sprocket(s). overload 15. NOT apply load if bearing prevem:s equalloading on aII10ad .u. NOT aIIow}UUf at.te1ltoo to be diverted fmm operating the hoist.

supporting chains. 14. NOT aIIowthe hoist ro be subjea.ed ro sharp coma::t widl aher 16. NOT oper:ate beyond tbe limir:s of tbe load chain tIaveL hoisu. structures, oc objec:ts through misuse. 17. NOT leave load supported brthe hoist UIlattended un.Iess specif.: Th NOT adjust orrepair the hoist unless qualifJCd 10 perlorm such

precautions have beeo taken. adjustmellts or repairs. 18. NOT aIIowtbe chain or hook ro be used as an electrix:al or

welding ground. 19. NOT aIIowthe cbain or hook ro be toucbed bya live

welding elect:rode. 20. NOT remove or obscuce the wamings on the hoist. DISCLAIMER 21. NOT oper.ae a hoist v.m:h has Not beeo securely attached to a

suitable suppott 22 NOT operate a hoist unless load slings or tther approved single Under!lO cin::umstances does the hoist manuflCtllrerassume any

liablityforthe use of these volumaryrec~ns, and noattachmelltS are propedysi?ed and seared in the hook saddle. wammtywhatsoever is made inconnection widl them. The23. NOT 0per.R a boist v.m ir is restricted fmm forrning a straigbt recommendations do ntt take precedence over existiDg plantline fmm hook to hook in the direction of looding. safety rules and regulations, or OiHA reguhu:ions. It is the users,

24. NOT Iift loads that are Not babnced and tbat the holding a:tion is mm to ab.sohr and protect the hoist manufactwttfrom any and Not secure. taking up slack carefuJly. allliablity, in ton or otbeme.

25. NOT oper:ate a hoist unless aII persons are and remain clear of the supported load.

26. Repon malfunctions or UI1USIl'a! perf~ o almt, after ir has been shut d

NEKOTEC

~ MANUFACTURA



OT129/2010




SECCION # 3

SECTIONZLP-ZLG Series 825

Rev.1-09Parts and Instruction Manual Low Headroom

CHESTER

Users should refer to ASME 830.16 Satety Standard and ASME HST-2M Performance Standard tor Manual Chain Hosts for specific requirements regarding safety practices for the instaliation, main1enance, and operaton of this equipment.

CHESTER HOIST P.O. Box449 7573 St. Rt. 45

Lisbon, Ohio 44432 'C Phone (330) 424-7248

FAX {330} 424-3126


HAND CHAIN MANUALLY OPERATED CHAIN HOISTS

Beca:use !he manufacturer has no direct rontrol aver the h.oist and its operation, conb:mance with good safetypractice is therespmsbilityoftheuserand operatingpersonneL ANSI/ASMEB30.16 has been used asaguK:ie in preparing this Jist ofSHAU.:s and SHAIL Nars. Ask your SUpeMsor ror a copy. Each is identified according ro ANSI NEMA Z535.4 with either the signa! \"IIOI'd CAlTIlON orWARNING ro india:\te the degree ofseriousness.

WARNING Improper ope.rarion o ahost can 0= aporemial\y hazardous situation v.:h. jfnat avQided, cooH JmIIt in litigaIioo orserious ~.To avoMi such apotemially bazaRlous m.ation, tbe operator shall:

k NOT operare a rnalfunctioning oc un\l$Ually perlorming hoist 1. Maincain a finn footing or be otherwse secured -wben opel1lting J.. NaT ope~ tbe bo$: um:l }'CU have thoroughly =d aod me hoist

undemood tbe ~s Opeming aod MainrenaDce 2.

NEKOTEC

..... MANUFACTURA



OT - 129/2010




SECCION # 3

SECTION ZMS-80-R-03 HOOK SUSPENDED,

EXTENDED HANDWHEEL,

TWIN HOOKS and

ARMY TYPE HOISTS

SERVICE INSTRUCTIONS ANO MAINTENANCE MANUAL

OPERATING INSTRUCTIONS A LockoutfTagout policy and procedure shall be implemented by the owner or user of all hoists. MAKE A COMPLETE INSPECTION of the hoist at regular and frequent inteNals. See ASME 830.16 for inspection criteria and record keeping requirements. LU8RICATE AS RECOMMENDED, as often as may be necessary. AVOIO OVERLOAOING and impacting. Use only with loads within the rated hoist capacity, and avoid sudden stops and jerking in raising or lowering. 80th are dangerous and destructive, and will shorten the working life of the hoist.

LUBRICATING THE HOIST

Ordinarily only the load chain will require any periodic lubrication. Chester Zephyr hoists have been thoroughly lubricated and tested when they leave the factory. Normally, factory lubrication within the completely enclosed covers will

last throughout the working life of the hoist. However, the lubricant will melt and escape if the hoist is subjected to very high temperatures. Should this happen the lubrication must be renewed as recommended below.

(1) BRAKE (4) LOAD CHAlN It should be immediately noted in connection Useful load chain life can be appreciably with lubrication of the hoist that the brake increased by immersing chain in oil at frequent requires none at any time. It is advisable, inteNals. Unlubricated chain wears rapidly though, to coat the square thread lightly with from friction with the pocket wheel as well as bearing grease at reassembly. with its own links. Immerse in container of oil

with an E.P. additive as often as necessary or (2) NEEDLE BEARINGS swab with oil soaked rag. Wipe off excess oil.

This will maintain the chain in a lubricated and Lubricate with an NLGI Grade 2, complex rust free condition. lithium based grease with E.P. additive after

prolonged use or at reassembly. If oil is objectionable, or not practical, a bonde hr~!JLgJ--I)__pow Molykote M-~8 m~~__

(3) GEARS b " ,~,-:-:: ' .' \, :\~ ~" ,~ , t t 1 :t:. j ~ "'..,1 ~~ ~' ;t\~' ~ s: -.\.' ~ '-t' ~.~ - , ~ ~ ~ ( ji 4 -.. Use NLGI Grad 2, complex lithium based 1 ~

I

Assemble bearing No. 906 in pinion cage bearing block No. 959, and press pinion cage bearing block into pinion cage. Assemble pinion cage complete with gears on splined load shaft. Line up the set~screw hole in pinion cage with hole in load shaft. Now, time the gears. Locate punch marks on gears as shown in Fig. 2. Theses marks must be directly opposite each other as indicated, tor proper timing.

FIG.2

After gears are properly installed, press pinion cage with gears completely onto the load shaft, and secure with square~ head setscrew and lock nut. Assemble load sheave No. 929 on load shaft No. 974 with combination stripper and load chain guide No. 905. Align stripper with studs on internal gear frame and press on as one assembly. Spacing of studs assures location. Next, assemble pawl spring No. 910 and pawl No. 923 on handwheel trame stud and fasten with pawl retaining snap ringo Assemble handwheel trame to internal gear frame, and in~ stall top hook No. 913 before pressing 'frame over separator studs. Fasten with tour nuts and lock washers, making sure the tail of the pawl spring No. 910 is anchored under the nearest separator stud nut.

Run spindle No. 918 through load shaft. Spindle will fall in place and may be turned easily if gears are properly timed. If spindle cannot be turned, or locks, gears are out of time and the timing operation will have to be repeated. Proceed with assembling the brake parts. Place one brake " disc No. 934 over the threaded end of the spindle No. 918 ,,' and follow with the ratchet No. 935 and another brake disc No. 934. Fit the end of the pawl into the ratchet teeth. Rotate handwheel and nut clockwise on spindle and tighten. Assemble check washer No. 925 on splined hub of part No. 916 making sure that lug on splined ring is 1/4 inch minimum to right of hole in spindle. Insert drive cotter pino Try handwheel release, and it it releases hard, increase the gap between drive pin and check washer lug by one tooth. Keep the gap to a minimum. Handwheel nut No. 916 must not tighten against the drive pin when releasing. Assemble bearing No. 903 in handwheel cover No. 968. Assemble hand chain No. 937 in handwheel cover.

Assemble handwheel cover to frame, and fasten with four round head screws and lock washers. Reeve the hand chain on handwheel with the welds up in the grooves. Apply and elose open link. Now, reeve load chain in load sheave, again with the side opposite weld of each link riding in the groove. First and last links df chain must be in vertical position. Test reeving by pulling on hand chain. Excessive hand chain pull will indicate load chain is not properly set in load sheave pockets. Remedy by backing load chain off and reeving again. Con~ tinued hand chain pulling will cause chain to ball, with serious damage to chain and cover. Final/y, fasten dead end of load chain to combination stripper and dead support No. 905 with bolt nut and lockwasher. ) Lubricate gears as recommended on page 1, and assemble gear cover No. 930 on internal gear frame. Fasten with four round head screws and lock washers.

NO TE: Ahost in whch load suspension parts have been altered, replaced or repaired should be load tested at 100% of rated capacity per ASME 830. 16.

005 ANO 00N1TS FOR SAFE OPERATION

DOIS READ ASME B30.16 SAFETY STANDARD FOR OVERHEAD HOISTS 1. CHECK lubricant before operating the hoist. 2. EXAMINE hoist before each shift. CHECK for damaged

hooks or chains, also make sure the hoist is properly secured. Make sure your hoist is kept clean and well lubricated.

3. CHECK daily the chain for improper seating, twisting, kinking, wear or other defects before operating the hoist. If these are not checked, the chain may break under a normal load.

4. BE SURE there are no objects in the way of a load or hook when moving the hoist on the trolley.

5. MAKE SURE a load clears neighboring stock piles or machinery when raising or lowering the load.

6. CENTER hoist unit over the load befo re Iifting. 7. AVOIO swinging of load or load hook when traveling the

hoist. 8. PROPERLY secure outdoor hoist when unattended. 9. KEEP load block above head level when not in use. 10. BE SURE the sling is properly seated in the saddle of

the hook. Tip loading leads to spreading and possible failure. Hook latch should not support any part of the load.

11. DO lift a load only a few inches then check load balance and brake operation before proceeding.

DONITS 1. NEVER lift a load with hoist until all personal are clear. 2. DO NOT allow any unqualified personnel to operate hoist. 3. AVOID collisions or bumping of hoists. 4. DO NOT transport load over personnel. 5. NEVER carry personnel on the hook or the load. 6. DO NOT operate hoist if you are not physically tit to do so. 7. NEVER pick up a load beyond the capacity appearing

on the hoist. 8. DO NOT tamper with any parts of the hoist unless you

are a qualified maintenance mano 9. NEVER use the hoist chain as a sling. 10. DO NOT use chain as ground for welding. NEVER touch

the welding electrode to the chain. 11. DO NOT divert attention from load while operating hoist. 12. DO NOT leave a load suspended in the air at the end

of a work shift, or for extended periods of time and DO NOT leave a load unatlended during regular working hours.

13. DO NOT tip or "point" load a hook. 14. DO NOT operate a hoist in need of adjustment or repair. 15. DO NOT operate a hand hoist with power or more than

one operator. 16. DO NOT operate a hoist that has been tagged out of

service.

CHESTER HOIST LlSBON, OHIO U.S.A. 44432 PHONE (330) 424-7248 FAX (330) 424-3126

ZS-4L LH/Z

Service Instructions and Parts List

SWIVEL TRUCK LOW HEADROOM TROLLEY HOISTS

GENERAL RECOMMENDATIONS Read the ASME B30.16 Safety Standard for Overhead Hoists. This equipment is not designed or suitable for lifting or lowering persons. A LockoutITagout policy and procedure shall be implemented by the owner or user of all hoists. Make a complete inspection ofthe hoist at regular and frequent intervals. See ASME 830.16 for inspection criteria and record keeping requirements. Avold overloadlng and impacting. Use only with loads within the rated capacity, and avoid sudden stops and jerking in raising or lowering. 80th are dangerous and destructive and will shorten the working life of the hoist.

OPERATING THE HOIST OPERATING ACTION: Raising or lowering a load is accomplished by gear reduclion. To raise, the operator pulls on the right hand chain to rotate the hand wheel. The hand wheel then transmits the pull through the spindle, which is actually a driving pinjon, to the two cluster gears (gear & pinion). These gears with their integral pinions are mounted and revolve on fixed axles carried by the pinion cage. The pinion cage receives rotary motion from the meshlng of the two cluster gears (gear and pinion) with the intemal gear, which is part of the intemal gear frame. The hollow load shaft is attached to the pinion cage through splines cut on the load shaft and is anchored with a setscrew and lock nut. The load shaft then transmits rotary motion djrectly to the load sheaves mounted directly on the load shaft. The load sheaves pick up and carry the load chain, thereby completing the transmission of hand chain pul! to the load chain. LOAD LOCKING ACTION: There is an intermedjate action in the hoist before the load lifts. When the hand wheel advances on the screw thread on the spindle, it clamps the brake discs and the ratchet tig htly between the hand wheel and the spindle f1ange, which causes all four parts to operate as a single unit when litting. The spindle by means of its driving pinion, transmits the pull on the hand chain into the gear reduction. When the operator stops pullng on the hand chain, the load, in attempting to run down, causes the ratchet disc to engage a pawl, and the hand wheel and disc hub advancing on the screw threads tightens on the brake disc to prevent the load from descending. A sfight pull by the operator on the left hand chain releases the pressure on the brake

discs, permitting the brake to become a friction clutch enabling the load to descend slowly. TRAVERSING THE HOIST: Motion along the beam on hand geared units is accomplished by imparting movement to the geared trolley wheels through the trolley hand chain and hand wheel. A trolley drive shaft connects the trolley drive pinions and the trolley hand chain wheel; then a pull on the trolley hand chain gives motion to the trolley hoist. Motion along the beam on plain units consists of shoving the load or g rabbing the load chains and walking under the runway beam.

TROLLEY BRAKES: These hoists can be equipped with track clamps with a chain actuated hand wheel. This assembly consists of steel shoas with a serrated face to grip the toe of the runway beam. These shoes are actuated through a trae k clamp screw that has a left and right hand thread on the same shaft. The shaft is causad to rotate by a track clamp hand wheel that carries a special hand chain. A pull on the hand chain thus causes the shoes to engage or back away from the toe of the monorail.

MAlNTENANCE PROCEDURE LUBRICATION BRAKE: It should be immediately noted in connection with lubrication of the hoist that the brake requires none at any time. However, while it is preferable not to lubricate it, the brake will operate efficiently regardless of lubrication on its surfaces. It is advisable, though, to clean the brake surfaces in the course of each inspection. BALL ANO NEEDLE BEARINGS: Lubricate with a good grade of lithium base grease recommended for a~ti-fiction ge~~h}g5..., . ' X!m8t. ..1~ .~:S;T.,~~~,~" .. , " .'- ~~'. '. . ~PP~ ~ . : " worklng penetratron 2&5 295, ( ,):N'L.~.!~ - . . . " . . :' .~ .... Note : LUbricali~~ .~nd M~~i~t~~~~~e~ ';i;> ,~. ; 01~ \.. ~ ", u i Procedures c~~~~ oJl, 'back paWr l, ;;~ t ~()

I~J;/";LCi R::CIiAzADO l~~-:. ;t.~- ;2r{~

/~o ..-..,,~59

.51 ""itI.1I1O;.::::";;1-IIll-f-r-tJ:\..- 5 8 52~W~W~

---57

1,'-"""--56 CHAIN OPERATEO "rRACK CLAMP

1'1 ~!II 64 ~-= ....1. 67.......,~.~~~J~~'\

/. . I 65/ \...::..... 66

On sorne capacities iterns 10 and 11 are cornbined into one piece REEVEDSOTTOM BLOCK 1~-2-3-4 TON ONLY

REF NO.

PART NO. DESCRIPTION

QUANTITIES PER CAPACITY IN TONS ~&~ 1 1 ~&2 3&4 5&6

1 9620-G Internal Gear Frame 1 1 1 1 1 2 921 PinionCage 1 1 1 1 1 3 930 Gear Cover 1 1 1 1 1 4 919 Gear and Pinion Shaft 2 2 2 2 2 5 959 Pinion Cage Bearing Block w/bushing 1 1 1 1 1 6 906 Bronze Bushing for 959 1 1 1 1 1 7 9618 Spindle 1 1 1 1 1 8 922 Needle Bearing For Gear and Pinion 4 4 4 4 4 9 927 Gear and Pinion 2 2 2 2 2 10 9629 Load Sheave 2 2 2 2 2 11 9674 Splined Load Shaft 1 1 1 1 1 12 9624 Stripper 2 2 2 2 2 13 960 Load Shaft Bearing 2 2 2 2 2 14 934 Brake Disc (Pair) 1 1 1 1 1 15 916 Handwheel Threaded Insert 1 1 1 1 1 16 928 Handwheel 1 1 1 1 1 17 925 Adjustable Check Ring 1 1 1 1 1 18 903 Bronze Bushing in Handwheel Cover 1 1 1 1 1 19 909 CotterPin 1 1 1 1 1 20 907 Ratchet Bushing for 935 Ratchet 1 1 1 1 1

OROERING INFORMATION ANO PARTS LlST Recommended Procedure for Ordering Parts: To insure prompt service, each repair parts purchase order must include the following information: 1. Quantity required 2. Part No. (see Parts List) 3. Description (~ee parts Life) 4. Hoist capacity 5. Hoist serial no. 6. Your complete address, and complete address

of shipping destination

32~__[E~~~~11 33

.1----40

41

If this nameplate has been removed or defaced, give size and type of I-beam on which the hoist operates.' If in doubt about any required parts information, return the part or parts to be replaced to the factory, transportation prepaid. Attach a tag to each part, giving as much information as available, your complete name and address, and your purchase order number. The serial number of each hoist may be found on the small aluminum nameplate mounted on its side plate.

62- 62A-62B

REF PART QUANTITIES PER CAPACITY IN TONS NO. NO. DESCRIPTION ~&~ 1 1%&2 3&4 5&6 21 968 Handwheel Cover with 903 Bushing 1 1 I 1 1 22 935 Ratchet with 907 Bushing 1 1 1 1 1 23 908 Pawl Snap Rng 1 1 I 1 1 24 923 Pawl 1 I 1 1 1 25 910 Pawl Spring 1 1 1 1 l 26 9620-H Handwheel Side Frame l 1 1 1 1 27 9685 HoistFrame 1 1 1 1 1 28 9605 Chain Guide 4 4 4 4 4 29 906-A Handwheel Shaft Support (Long) 1 1 1 1 1 30 9120 Trolley Handwheel l 1 1 J 1 31 9187 Trolley Orive Shaft Snap Rng 1 I 1 1 1 32 9611 Trolley Orive Shaft 1 1 1 1 1 33 9121 Trolley Handwheel Swingng Guard 1 1 1 1 1 34 937 Trolley Drive Hand Chain (SpecifY drop) 1 1 1 ] I 35 %52-1 Bottom Crosshead (Unreeved) 1 1

- -.

36 9640 Boltom Load Hoolc and NUI 1 1 1 1 37 91tA I Pinion Gear 2 2 2 2 2 38 %58 Swivel Bolt and Nut 2 2 2 2 2 39 %81 Cross Piccc Bushing or Bearing 2 2 2 2 2 40 937 Host Hand Chain (SpecifY drop) ] 1 ] 1 ] 4] 914 Hand Chain Guide R 2 2 2 2 42 906-B Handwheel Shaft S1!PPOrt (Short) 1 1 1 1 43 9108 Geared Trolley Wheel 2 2 2 2 2 44 9683-G Geared Trolley Side PIste 2 2 2 2 2 4S 9293 Dead End Bale

-2 2 2

46 9689 Dead End Stud -

2 2 2 47 9]09 Plain Trolley Wheel, Geared unit Qty. ( ) 4(2) 4(2) 4(2) 4(2) 4(2) 48 938 Load Chain (Specify lift) 2 2 2 2 2 49 9683 Plan Trolley Side Plate, Geared unit Qty. ( ) 4(2) 4(2) 4(2) 4(2} 4(2) 50 9153 Track Clamp Side Plate (Optional) 2 2 2 2 2 51 906-B Track Clamp Screw Support (Short) I 1 I 1 1 52 9152 Track Clamp Guide Pin 1 1 1 1 1 53 9151 Track Clamp Screw t=+=F 1 1 1 1 54 9682 Cross Piece (Specify track size) 2 2 2 2 55 9150 Track Clamp Jaw Pair (LH and RH) 1 1 1 1 56 937 Track Clamp Hand Chain (S~ drop)

=l 1 1 1 1 1 57 9121 Track Clamp Handwheel Swinging Guard 1 ] 1 1 1 58 9187 Track Clamp Screw Snap Ring 1 1 1 1 1 59 9120 Track Clamp Handwheel I 1 1 1 1 60 906-A Track Clamp Screw Support (Long) 1 1 1 1 1 61 9110 Wheel A.xle with Spacer(s) 4 4 4 4 4 62 9107 Wheel Ball Bearing 8 8 8 . -62A 9116 Tapered Bearing Cone . .

-8 8

62B 9117 Tapered Bearing Cup . -

. 8 8 63 9112 Bearing Adjustment Nut

- - -4 4

64 9688 Bottom Block Sheave Guard - -

2 2 2 65 HIL Hocle Latch 1 I 1 1 1 66 9656 Idler Sbeave witb Bushing - - 2 2 2 67 9125 Busbing for 9656

- -2 2 2

68 9652-2 Bottom Crosshead (Reeved) -

1 I I SPEC~FASTENERS(NOTILLUSTRATED) 998 Gear (930) and Handwheel (968) Cover Screw I 8 8 8 8 8 999 Hand Chain Guide (914) Screw 8 8 8 8 8

.

CHAIN SPECIFICATIONS For parts Contact: Chester Holst Phone : (330) 424-7248 I~~~~~g~ ~ Fax: (330)424-7248 E-mail: [email protected]

Useand Part Chaln Size Description No. (wlre dla.) C W R L Gauge Length NetWelght HANDCHAIN C-937 %" .378 .878 1.048 1.548 19links: 20.406" .50 Ibs/ft. LOAD CHAIN: % thru 2 Ton C-38-1/2 9/32" .313 .876 .794 1.357 25 IInks: 19.925" .75Ibs/ft. 3 thru 6 Ton C381/2A 9/32" .313 .876 .794 1.357 25 links: 19.925" .75Ibs/ft.

LUBRICATION (continued from front pagel GEARS: Use a high-grade non-corrosive extreme pressure lithium base grease, NLGI No. 2.

LOAD CHAIN: The usable life of a load chain can be appreciably increased by lubricating the chain at frequent intervals. Unlubricated chain wears rapidly from friction with the pocket wheel as well as with its own inter-links. Thoroughly clean chain with an oil solvent and relubricate by dipping in light oil (S.A. E. 10 or 20). Wipe off excess 011 before reapplying chaln to the hoist.

TROLLEY WHEELS: 8all check hydraulic grease fittings are provided on each trolley wheel or axle. Lubricate with a good grade of lithium base grease, NLGI No. 2.

(*) NLGI - National Lubricating Grease Institute RE-ASSEMBLY: Should it ever become necessary to dismantle the hoist, extreme care must be exercised in reassembling the cluster gears in the internal gear frame. Punch marks on the pinion gears must be nearest to and in a direct lne with each other to mesh properly in this planetary gear system.

INSPECTING THE HOIST

MAKE A COMPLETE INSPECTION of the hoist at regular and frequent intervals. See ASME 830.16 tor inspection criteria and record keeping requirements.

1. Inspect bottom hook tor excessive wear or opening. Examine the bolt attaching the load chain to the bottom block or top dead and shackle for damage or loosened locking nut. It hooks appear to be badly stretched or worn, replace with new ones.

2. Examine the load chain for excessive wear, particularly at its inter-link contacting points. Measure the pitch or gauge length of the chain, and compare with the standard dimensions as shown aboye. An increase in pitch will indicate that the

chain has been elongated or that excessive wear has taken place. Elongation generally causes harmful wear on the pockets of the load sheave. Load shave pockets should be examined for wear and improper engagement with the load chaln. Any tendency of the load chain to ride up out of sheave pockets while under rated load will indicate faulty chain engagement. Replace obviolJsly worn or stretched chain. Do not anneal load chain furnished with or for this hoist. It has been heat-treated and will not work-harden. It will wear well if kept well lubricated. Replace the load sheave when its pockets become excessively worn. If the sheave is replaced, do not use stretched or badly worn chain and risk damaging the new sheave pockets.

3. Test the brake mechanism, by operating the hoist under load, to determine if the brake is holding the load at all positions. If the brake falls to hold properly, brake parts should be disassembled and thoroughly cleaned. Check tor excess wear or other damage, then reassemble and again test under load. Replace brake assembly washers, pawl or pawl spring if badly worn or damaged.

4. Remov~ the gear cover and inspect all gearing. Check all gear teeth for excess wear or other damage.

5. Inspect trolley wheels, visually, tor damage or wear. Push-pull and hand-geared trolleys should also be checked tor proper ease of traverse along the supporting track.

CAUTION: Make'all necessary replacements immediately

NOTE: A hoist in which load suspension parts have been altered, replace or repaired should be load tested at 100% ot rated capacity per ASME 830.16.

DO'S AND DON'TS FOR SAFE OPERATION

DO'S Read ASME B30.16 safety standard for overhead hoists 1. CHECK lubricant befo re operating the hoist 2. EXAMINE hoist befo re each shift. CHECK for damaged

hooks or chains, also make sure the hoist is properly secured. Make sure your hoist is kept elean and well lubricated.

3. CHECK daily the chain for improper seating, twisting, kinking, wear or other defects befo re operating the hoist. If these are not checked, the chain may break under a normal load.

4. BE SURE there are no objects in the way of a load or hook when moving the hoist on the trolley.

5. MAKE SURE a load clears neighboring stockpiles or machinery when raising or lowering the load.

6. CENTER hoist unit over the load before lifting. 7. AVOIO swinging of load or load hook when traveling the

hoist. 8. PROPERLy secure outdoor hoist when unattended. 9. KEEP load block aboye head level when not in use. 10. BE SURE the sling is properly seated in the saddle of the

hook. Tip loading leads to spreading and possible failure. Hook latch should not support any part of the load.

11. DO lift a load only a few inches then check load balance and brake operation before proceeding.

DON'TS 1. NEVER lift a load with noist until all personnel are clear. 2. DO NOT allow any unqualified personnel to operate hoisl.

See ASME B30.16 for operation training requrements. 3. AVOIO collisions or bumping of hoists. 4. DO NOT transport load over personnel. 5. NEVER carry personnel on the hook or the load. 6. DO NOT operate hoist if you are not physically fit to do so. 7. NEVER pick up a load beyond the capacity appearing on

the hoist. 8. DO NOT tamper with any parts of the hoist unless you are

a qualified maintenance mano 9. NEVER use the hoist chain as a sling. 10. DO NOT use chan as ground forwelding. NEVER touch

the welding electrode to the chain. 11. DO NOT divert attention from load while operating hoist. 12. DO NOT leave a load suspended in the air at the end of a

work shift. or for extended periods of time and DO NOT leave a load unattended during regular working hours.

13. DO NOT tip or "point" load a hook. 14. DO NOT operate a hoist in need of adjustrnent or repaid. 15. DO NOT operate a hand hoist with power or more than

one operator. 16. DO NOT operate a hoist that has been tagged out of

service.


RAND CHAIN MANUALLY OPERATED CHAIN HOISTS

Because fue manufacturerhas no dire:ct wntrol ove!' the hoist and fu; operation, ronfi::mlance with ~ safetypIadice is the respansibilityofthe user and opemtingpersormel. ANSI!ASME B30.16 has been used asa gui:le in preparing this list of SHAIL's and SHAU.. Nars. Ask your supervisor for a copy. Each is dentified. according to ANSI NEMA Z535.4 with eifuer the signal-worrl CAUTION or WARNING to indicate the degree ofseriousness.

WARNING CAUTION Improper operntion of a hoist can 0= aporentiallyh:mu:dous Improper open!I:On of ahoist can cn:ar.e aporentially hazan:lous situation wbi:h, if no!: avoidcd, coukI R:SUlt in litigarion arserious situzDn wbi:h, if no!: avoided, caJld l'e!>1I Il mnor or modmre !!!!!!. To avoid such apoteatiallyhazardous situation, th: injury. To avoid sucb a potentially hazardous situation, th: ope.ratorshall: opu.ttor sball:

b NOT operare a malfunctioning or UIlllSU2y perfomng hoist. 1. Maintain a firm foa:ing or be ~rwise secured when operating 1, NOT operate th: hois\: umil. ~ bave thoroughly mad and the boist

wtdemood tbe manuf~ Opellltllg and Mainrenance 2. Oleck b~ funaion by~!:he hois!: priorto each!ift or Instructions or Manuals. puIIing operntion.

i. NOT operate a hoist vmi=b has bemmodified withOUl: tbe 3. USe hooHm:hes. U!u:hes are to reWn slings, chains, etc.. I.ll1.der manuf'actun:r's approval or c:.ertifation 10 be in confOllIlir:ywith sladt condirions oo1y.

applicable OSHA regs. 4. Mal: SUII: the hooklar:cbes are closed and not supponing any

parts of me load 2, NOT use damaged hoist or boist tbat is working properly. 5. MaR SUII: the load is free to move and wiIl dear all ohstructions. Z NOTuse boist with twisted, kinked,damaged, arwom load chain. 6. Avoid sv.1ngllg the load oc hook.

2: NOT lift arpull more t.ban nu:ed load fortbe hoist

1: NOT use the hoist lO lift, suppon, ortlllllSport people. 7. Inspecr th: hoist regularly, n:p!ace damaged orworn parts, and 2., NOT Iift 10ads CIVI:!' people and make sure aH pe:!SO!lIlI:In:main mp appropriate records of maintenance.

clear of the supporred load. 8. USe !:he boist manufacturer's recommended parts v.ben n:pairing 10. NOT atrempt 10 Iengthen tbe load chain or repair damaged load me UDit.

chain. 9. 1.ubricate load chain per hoist manufacturer's n:commendmions. 11. P=tbe hoist's load chain from _Idsplatreroraher 10.NOT use !:he hoist load limiting orwaming device to measun:

damaging contaminants. load. 12. NOT use load chain as a sling or wrap load chain around load 11. NOT oper:tte except with manual po\\eT 13. NOT applythe load to tbe tip o tbe hoak or to tbe hoaklatch. 12. NOT pel'lIli: more tban eme opernror to pul! on a singk- hand chain 14. NOT applyload unless load chain is properly seated in the chain al tbe same time. More t.ban eme operarar s likdy to cause hoist

wheel(s) or sprock&(s). overioad. 15. NOT apply load if bearing pn:vents equalloading on aH load 11 NOT allow y:.ur attellton ro be diverted from opellltllg the hoist.

supporting chains. li. NOT albwthe hoist to be subjea.ed ro sbarp CO!l!aCt with orher 16. NOT ope= beJOOd rbe Iimirs oi tbe bad chain traveL hoists. st:roctureS, or objectS tbrough misuse. 17. NOT 1eave load suppom:d bytbe hois\:l.lIl1IIrended unless specifK: 12. NOT adjust or repairtbe bois!: unless qualifred to perfonn such

pn:cautions bave \:leen tak.:ll. adjusanents or repairs. 18. NOT allowde chain or bookto be used as an eko!ctrical oc

\\elding grouncl. 19. NOT allowtbe cbain orhook lO be touehed bya live

-welding eb::trode. 20. NOT n:move orobscUl1: the wamings on the hoist. DISCLAIMER 21. NOT operare a hoist which has Na! been securely maebed lO a

suitable suppon ~ NOT opentte a hoist unless load slings or ~er approved sIlg.!e Uncieron cirrumstances does tbe boist manufacrurerassume any

liabilityforthe use of these volumaryrec~ndations, and nomacbments are properlysiz.ed mi seared in tbe hooksaddle. warr.mrywb.atsoever is madc Il COIIll/.'.Cton with th:m Then, NOT operare a hoist MJen ir is restxi::ted from forming asr.. recornmendations do not tm precedence over existing plantline from hook to hook in me direaion of loading. safety rules and n:guIacions, or OSHl\. regulacions. It s the user's,

24. NOT Iift Ioads that are Not baIm:ed and rhat tbe holding a::tion is ntellt to absolve and prcxect the hoist manufacturer from any and Not secUl1:, taking up slack carefully. aHlability, in ton or otbel'Wise.

25. NOT operate a hoist unless all persons are and rernaIl dear of the supponed load.

26. Repon rn:!lfunctions orunusual perfOfIl)21lCes of a boist, alter it has been shut dov.n W1tiJ repaired.

27. NOT operatf a hoist on which. the safety placards or decals are missllg or iIlegible.

28. Be familiar with oocratinl: controls. Drocedures. and v.at"l'l.Iles.

3.0 manual de op y mantto de polipastos

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