r
INSTRUCTION,
MAINTENANCE
and
PARTS MANUAL
CAPACITY: FROM lOt TO 5 TON
Caution -
Important
If nol properly installed, operated and maintained, the use of all mechanical
equipment presents the possibility of personal injury or property domage. Before hoi.t use, all person. who will instoll, operate Or maintain should read
this mClnual thoroughly. For safe, dependable and economical performance,
follow all instructions and recommendations contained herein. It i, 0110 im·
portant 10 retoin this manual for future use.
1ST
DIVISION COLUMBUS M CK INNON CORPORATION
TONAWANDA , NEW YORK 14150 U .S .A .
MANUAL NO. 8lG
83876
PRICE $2.50
=
DO'S AND DON'TS
DO' S -
Sale Operation of Hoists
Th~ followin& .'. Do's and Don'l s lor safe operat ion 01
OIIerhud hoists . raking precedence Over any specil ic .ule
listed ha,e, however, is the most importa nt rule 01 all, USE
COMMON SE NSE. A few mInute'S spent readi"ll these n.~s
un rna"" an Opel.tor aware 01 danae,ous pu'ctice'S 10 avoid
.nd ore<aul ,ons t o la ke 10. his own sa fely lind the sa fely of
Olhers. Frequent examin ations and period ic Inspect Ions 01
thl! equipment IS well IS • cons<;ienl ious observallce 0 1
safety ruin may save lives n 00,,11 on \,me aoo rnO<ley.
DON'TS I. NEVER lilt
ciea ••
Of
HOISTS
tra nsport . load until ,II personnel Ire
2. DO NOT allow an y unqualified personnel to o pe,a te
hoi!!.
3 . N EVE R pick up • load beyond
capacity appearina on
t he holst . Overloadmg can be cau$e<l by ,erklng I f ..,II
11.,
as by stat ic overload.
4. NEVER carry personnel on t he hook or I he load.
S. 00 NOT operate hoist II you are not physltilly l it .
6. 00 NOT operlte hoist to e>ctreme lim,ts 01 thllun or rope.
7. AVOID sharp contact between two hoists. between holst
a nd end post. and hookS and holst body.
00 NOT tamper wit h any parts 01 the hoist .
9. N EVER use the hoist rope or thain lIS a slong.
10. 00 NOT divert attent ion from load while ope rat ing holst .
1]. N EVER leave a su spended load un.tt ended.
12. 00 NOT atten'pt to lengthen 10lld tha,n. or to repaIr
damaged load chain.
13. 00 NOT uSi tha,n or rope IS ground for weld,ng.
N EVER touch II live welding electrode to I he chaon or
rope.
a.
HOISTS
I. READ and follow manul acturer's inst ruction. instal lat ,on
and maonl enance ma nuals. When repair ing or maint ain·
inS II hoist. use only mlnul&cturer's recommended
parts lind materials.
2. READ and follow 1111 instru ction and wa rnins in formltion
on or attaChed 10 a hoisl .
3. REMOVE the hoist lrom Hrvice lind thoroolj:hly inspect
and repa" ;os necessary if unusu.' performance or vrSUIII
defect s (such U Pf<;ulilr no,", je. ky operations. 0'
travel in improper diret tlon or ol)viously d.maged pIIrts)
/I re noticed.
4. ESTABLISH a regular schedule 01 Inspection and mllin·
tIIin records l or 1111 hoISts wIt h special atten l ,on s,ven to
hoo ~s. ropes. ch.rns. bra kes and hmit SWItches.
5. CHEC K ope,a l ion of b" kes for ucessive d,ift .
6. CH EC K operation of limit sw'tches.
7 . CHECK lor dllmased hooks. ropes Or thllin.
a. KEE P 1000d cha,n or rope etean lind _II lubf,cal ed.
9 CH ECK I he wire rope Or chain l or improper seatong.
twisti ng . kon kins. wear or Ol her defec ts before operating
t he hoists.
10. CH ECK lor broken wires In wire rope. T_lve ,an60mly
d"I "bul ed broken wi.es in one rope lay Or lou r broken
wires in one sl rand in one fOpe lay are su ffic,enl cause
for replacement .
1 ] . MAKE SU RE I load etnrs neighbo, ing stock pries. rna·
chinery. or othe, obstructions when ' aislng, ~"ng.
Or I rllvelina the 1000d.
12. CE NTE R hoist over t he load befo re opera l ong.
13. AVOID swinging ol lOlld or load hoo k when travelong the
horst.
14. BE SURE the 10lld attachment is p4"ope"y Hated in Ihe
sa ddle of t he hook. Balance 1000d prope"Y before han·
dling. Avoid t ip loadin, .
15. PU LL in a stra ight line. SO that neil her r.orst body no,
load chilrn Or rope are .",IId around In object.
]6 . MA KE SURE yoo la ke up stack slowly.
17. ON LEVER OPERATED HOISTS, always "'eue h.ndle
g ,ad ually when und er IolId to ,void fl ying handle.
CONTENTS
Pilge No.
SECTION A - INSTALLATION
All Hoist s
Lug Suspension
Hook Suspension
All Trolleys
Plain and Geared Trolleys
Motor Driven Trolleys
Current Collectors and Wiring
Ad justable Screw Limit Switch
..
).4
5
••
,•
' ·B
B
SECTION B - OPERATION
General
Operat ing Instructions
Safety Procedures
SECTION C - MAINTENANCE
... .
Genera l
•
Periodic Inspect ion and
Maintenance Procedure
Hoist Lubrication
Trolley Lubrication
Adjustments
SECTION 0 - TROUBLE SHOOTING
Procedure
Wiring Diagrams
Open and Short Circuit s
Electrica l Data
..
B·9
9
9
.. .
10
10· 11
II
12
12·16
16·19
20·24
24
25
SECTION E - REPAIR PARTS LIST
Ordering Instructions
Hois t Arrangement
Reeving Components Two·Part Rope Hois t
Reeving Components Four·Part Rope Hoist
Reeving Components Six· Part Rope Hoist
Control End Components
Hoist Frame & Motor·Brake Components
Gearing End Components
Electric Brake &
Wea the rp roo f Brake Housing
Upper Limit Switch
Adj ustable Screw Limit Switch
Hoi st Motor
Plain & Geared Trolleys
Motor Dri ven Trolleys
Trolley Motor
Motor Driven Trolley Motor Brake
Contactors
Control Station s
Hook & Lug Suspensions
Current Collectors
Page No.
2.
2.
27·28
27·28
27·28
27 ·28
27·28
27·28
27·28
27·28
27·28
27 ·28
29·30
29·30
29·30
29·30
3 1·33
33·37
3B
39·41
1
Enclosed Conductor System
Current Collectors
co.. 1(1
co .. T
'\
' 00 S
•
co .. "
.,, ----(co .. 6
co .. •
"
601[
101T
&01f
•
60' P' - - < --l
co ..
601 ~
' ~' -,
•
"iiP
8
co .. a -
"",..,..,
iii
~l
,~ .
•
•
601 Ie
! 6 0111 5
_
&01 8 C
I
•
co .. s :
co .. 2
co .. ,
cOM "
co .. 2
"
· NUMBER looE
NUMBER 70E
COLLECTOR ASSEM BLY PARTS LIST
COLLECTOR ASSEMBLY PARTS LIST
Part
No.
No.
Req'd.
- IOOE
601 BC
601 BS
601 P
60 1 E
601 Y
60 1 AD
100 S
100 Y
100 Z
COM 1
COM 2
COM 3
COM 4
COM 5
COM 6
COM 7
COM 8
COM 9
COM 10
COM II
3
1
I
1
1
1
2
1
1
I
1
I
1
2
3
1
1
2
2
I
1
p,rt
Part Name
Collector Assembly
Clamp only
Swivel only
Post
Standard Arm
Yoke
Case Half
Shoe
Shoe Clip
Spr ing
% - 16HexNut
% Lockwa sher
%-16xl'l2Bolt
'14 - 20 x 1 Machine Screw
% -20 Hex Nut
% Lockwa sher
'14 - 20 )( Ih Bolt
% x 1l,4 Roll Pin
Dot Faste ner
No.6 Non·lnsulated Terminal
Ih Retaining Ring
No,
No,
Req'd.
70 E
3
60 1 BC
601 BS
I
I
I
I
I
60 1 p
60lE
701 Y
707
70 S
100 Z
COM 1
COM 2
COM 3
COM 5
COM 6
COM 7
COM 8
COM 10
COM 11
2
I
I
I
I
I
I
I
I
2
I
I
Part Name
Collec tor Assembly
Ctamp only
Swivel only
Post
Standa rd Arm
Yoke
Case Half
Shoe
Spr ing
% - 16 Hex Nut
% Lockwasher
16x 1'12 Bolt
1/ 4 20 Hex Nut
II. Lockwas her
l,4 - 20 x 1
12 Bol t
'I. )( 1l,4 Roll Pin
No. 6 Non·lnsulated Terminal
li z Retaining Ring
% -
- ASSEMBLIES DISCONTI NUED. INDIVIDUAL COMPONENTS AVAILABLE FOR REPAIRS ONLY.
40
REFER TO PAGE 26 FOR ORDERING INSTRUCTIONS
Current Collectors
*wtt£fl COlI£CTOI FOIl ....u CO'P£. WIRE
CONDUCTOI: snTfM
* SttO£ COUKTOI K>It ,.-.U CO'PU WIle
CONDUCTOI SYSTfM
Wl-I"--+
~,.
COU KTOR BR.-.CUT &
, .... fO R , ... RE COPPER
WIRE ... NO ~ lOS E O
CONOIJCTOR SYSTfM
,
-'"
- ASSEMBLIES DISCONTINUED. INDIVIDUAL COMPONENTS AVAILABLE FOR
REPAIR S ONLY. REfER TO PAGE 41 FOR MOUNTING INSTRUCTIONS.
-- INDIVIDUAL PART NOT AVAILABLE. CONTACT fACTORY f OR REPLACEMENT.
Parts Li st
No.
K"
No.
Req'd.
· WS·723
I
· WS·724
I
WS·725
WS·726
2
WS·727
2
WS·728
WS·729
2
WS·730
·WS·732
1
WS·733
WS·734
WS·735
I
I
3
I
I
2
Part Name
Shoe Collector Assembly (Items
WS·725 Thru WS·730 & Three
WS·732; Specify Size of
I·Beam & Capaci ty of Hoist)
Wheel Collector Assembly (Items
WS·725 Thru WS·730 & Three
WS·750; Speci fy Size 01
I·Beam & Capaci ty of Hoist)
Collec tor Bar Bracket
Collector Bar Bracket Attaching
Screw
Collector Bar Bracket Att aching
Screw Lockwa sh er
Collector Bar Bracket Set Screw
Collector Bar (Speci fy Whether for
Shoe or Wh eel Collec tor. Size
01 I·Beam & Capaci ty 01 Hoist)
Collec tor Bar Insulator
Shoe Collector (Items WS·733
Thru WS·738)
Collector Shoe
Collec tor Shoe Clamp Screw
Washer
Collector Shoe Clamp Screw
Lockwasher
K"
No.
WS·736
WS·737
WS·73B
· WS·750
WS·751
WS·752
WS·7 53
WS·754
WS·755
WS·756
WS·7S7
" WS·758
WS·7 59
WS·760
WS·761
WS·762
WS·763
WS·764
WS·765
WS·766
WS·767
WS·768
WS·769
No.
Req 'd.
2
I
I
3
I
I
I
I
I
I
I
I
I
I
I
I
1
1
3
3
3
I
I
Part Name
Collec tor Shoe Clamp Screw Nut
Coll ector Shoe Clamp Screw
Collector Shoe Cotter Pin
Wheel Collector (I tems WS·75 1
Thru WS·769)
Clamp Bearing and Rivet
Clamp
Clamp Screw
Clamp Screw lockwasher
Clevis Pin & Rivet
Collar & Rivet
Rivet
Harp
Harp Pin, Washer & Co tterpin
Spring
Wheel
Wheel Pin
Wheel Pin Cotter Pin
Copper Shunt
Shunt and Terminal Screw
Shunt and Term inal Screw
Lockwasher
Shun t and Term inal Screw Washer
Harp Pin Washer
Harp Pin Coller Pin
REFER TO PAGE 26 FOR ORDERING IN STRU CTION S
"
Hook and Lug Suspension
Parts List
K.y
No.
No.
Req'd .
WS-269
2
WS·325
I
WS·326
2
WS·326
2
WS·327
WS·328
4
4
WS·329
WS·329
4
2
WS·330
WS·330
WS·335
76
36
I
WS·336
I
WS·345
1
WS·346
1
WS·355
I
WS·356
WS-357
WS·358
WS·359
WS·360
WS·361
1
2
4
2
2
2
'11.3 TON HOO K SUSPENSION
5 TON HOOK SUSPENSION
W$'UO~
rJ;t;~'\: J
~
?"'r"
W$·121
I
W$.3l1>
(f OR $ 101-1 SUSPENSION
O NlY )
W$·321
Part Name
La tch Kil (% ·3 Ton iF Latch Kit.
S Ton .:::8 Lalch Kit). Specify
Hook Size (Not Shown)
Lug Suspension - 1f:·3 Ton Unil s
(Ilems WS·326 Thru WS·328 &
WS·330)
Hoist Suspension Boll
(Speci fy Lenglh of Boll)
Hoist Suspen sion Pin
(5 Ton Hook Suspension)
Hoist Suspension Bol t Nut
Hoist Suspension Bolt Nul
Cotler Pin
Hoist Suspension Pin Cotler Pin
Idler Sh ea ve Housing Support Pin
Cotter Pin
Spacer Washer - % ·3 Ton Uni ts
Spacer Washer - 5 Ton Unit s
lug Suspension - 5 Ton Units
(ltems WS·326 Th ru WS·330 &
WS·336)
Idler Sheave Housing Support Pin
(Specil y Length of Pin). For
other type Pin see Page 28.
Hook Suspension - %·3 Ton Units
(I te ms WS·326 Thr u WS·328 &
WS·346)
Upper Hooks and Channel
Assembly
Hook Suspension - 5 Ton Units
(I te ms WS·326. WS·329.
WS·336 & WS·356 Thr u
WS·36 1)
Hook Suspension Channel
U pper Hook-Latchlok
Upper Hook Wa sher
Upper Hook Nut
Upper Hook Nut Pin
Idler Sheave Housing Support Pin
Wa sher
'11·5 TON lUG SUSPENSION
REFER TO PAGE 26 FOR ORDERING IN STRUCTIONS
38
Push Button Stations
Series 0
.-8unON ~TA T IO N FOR
SINGLE SPEED HOIST WIT H
SINGLE SPEED TROLLn
.... ·1"
' .8U1TON STATION fOR
SINGLE Sf'HO twiST
Parts List
"Y
No.
WS·64
WS·68
No.
Req'd.
2
WS·69
WS·90
WS·783
WS·784
WS·785
I
I
I
WS·785
I
WS·786
WS·786
I
I
Part Name
Push Button Chain Atta ching link
Push Button ChaIn
(Speci fy Length Req·d.)
Push Button Cable
(Specify length Req·d.)
Push Button Cable Clip
(Speci fy No. Req·d .)
Push Button Chain Cfip
Push Button Bo)!. Connector
2·Push Button Station
(Specify Button Mark ings
Req 'd.) (Items WS·786 Thru
WS·789. WS·793 & WS·830)
4·Push Bu tton Stal ion
(Items WS·786 Thru WS·789,
WS·793 , WS·81S. WS·816,
WS·830 Thru WS·834)
Cover (For 2·Button Station)
Cover With Name Pla tes
(For 4·Bu1lOn Station)
"Y
No.
No.
Req 'd .
Part Name
WS·787
I
So.
WS·788 4 or 6 Cover Attaching Screw
WS·789 4 or 6 Cover Attaching Screw
lockwa sher
WS·790
I
Cover Gasket
(For Weatherproof Station)
WS· 793 l or 2 Switch Unit (Specify Button
Markings Req'd.;
State Whether for " Hoist "
or ··Trolley")
WS·815
2
Name Pla te (Specify Markin gs
Req·d .)
WS·8 16
4
Name Plate Drive Screw
WS·830 1 or 2 liner
WS·83 1
Switch Allaching Screw
8
WS·832
Switch Attaching Screw
8
lockwas her
WS·833
I
External Ground Screw Wash er
E)!.ternal Ground Sc rew
I
WS·834
REfER TO PAGE 26 fOR ORDERING INSTRUCTIONS
87
-------------------------------.
Control Station - Hoist Trolley Combi nation
o
;
~{ii
I I
o
."
No.
WS·774
Parts list
No.
Req 'd.
Part Name
I
ContrOl Station Parts Kit
consi sts of:
2-Terminal Atta ching Screw
I-Strain Cable Attaching Screw
1-5train Cable Atta ching Screw
."
No.
W5 -776
W5 -777
No.
Req 'd .
W5·778
I
I
I
WS -78 1
I
8-Swilch leaf Spring
s.
1
Control Stalion Switch Kit
consists of:
8 Switch
I-Jumper
2-Jumper
Ga sket
Cover Assembly (Decal &
Rocke r Included)
Control Sta tion Kit consists of:
l---Control Station Chain Clip
2---Chain Clip Atta ch ing Screw
4 -Pin Retainer Screw
W5·775
Case
I-Grommet
Washer
2-Switch Mount ing Pin
4-Terminal
Part Name
WS·785
6
I
Cover Screw
Cont rol Station (I tems WS·774
Ihfu WS·778 & WS·781)
REFER TO PAGE 26 FOR ORDERING INSTRUCTIONS
Control Station - Two Speed Hoist
Parts Li st
K.,
N• .
WS-77-4
W S-711
N• .
bq'd.
I
PClft HClm.
Conlrol SICIlian PClrts Kil
conlilll of,
I - Spr ing
I - SItClin Cobl. Alloc hing Screw
I _ StrClin Cobl. AIIClch ing Screw
Walher
2- Switch Allochi ng Pin
I _ Sliding Com
2_ Spring End Suppor t
J - Swilch Moun ting PICl t. & Rocker
Anembly Alloch ing Scre w
I _ Swi tc h Moun l; ng Plate & Rocke r
A..embly
I - Com Return Spring
K.,
N• .
N• •
Req'd.
WS-77S
I
WS-776
I
WS·777
WS·778
I
WS.781
I
WS·78S
I
I
PClrt HClm.
Conlrol Siolion Switch Kil
COnlilh of,
3- Sw itch
2- lnlulCltor
I - Jumper
Cal.
Ga.k.t
Cover Anem b ly (Decal & Rock..
Incl ud ed )
Control Stotion Kil
consists of:
I -Gro mmel
I - Con lrol SIOlion ChCl in Cli p
2- Choln Cli p Attaching Screw
6- Cover Attaching Screw
Cont,ol Station (Item s WS·77-4 .h~
WS·778 & WS.781 )
REFER TO PAGE 26 FOR ORDERING INSTRUCTIONS
ws·m
S5
Control Station - Single Speed Hoist
Parts list
K.y
No.
leq'd.
WS-7H
1
WS-7 / S
Ko,
No.
Port Nom .
No.
bq'd .
Con trol Station Porh Kit
consists of:
l - Stro;n Coble Allochin; Screw
I - Strai n Cable Atlachlftll Screw
Walher
2_ Sw itch Mounting Pin
3-Pin & Jumper Reta iner Screw
2- Switch leof Sprin;
Control Station Sw ikh Kit
consisls of:
2_ Switch
I - Jumper
WS-776
WS-777
No.
1
WS-778
,
,
,
WS-781
,
WS-78S
,
Port Nam.
C(II'
GOlket
Cover Assem bly (Decal & Rocker
Included)
Con1rol Stot;on Kit
(on,i.h of,
I-Grommet
l -Control Station Choin Cl ip
2-Cho in Clip AHo(hing $cr_
.4-Cover AHachiftli Screw
Control Stalion (Items WS-77.4 Ihrv
WS-778 , & WS-781 )
W$ .71'
, _ws.n.
,
•
•
••
Parts List
K.y Ho.
...
K.y No.
Part Nom.
No. Required
$ohn-.,
C_...;".
_ .. C_ _
WS·61 0
WS-6 11
WS-612
WS-61 3
WS·6U
WS ·615
WS-6 16
WS-61 7
WS·618
WS· 6 19
WS·620
WS ·621
WS·6 22
WS·623
WS·62A
I
I
,,
,
0o. 1
I
I
I
I
,,
0
0
oOr 2
6
o or A
,,
0
I
I
•
2
,
WS·625
WS-62 6
,,
3 or A
0
Speed Sele eling CO"Iottor
Bock ' la te , Sid. Ploles
and Scr,w I
Coil
Yoke Spring , Right Ha nd
WS-627
WS-628
WS-629
WS-6JO
Yo ke Sprin g , Left Hand
WS-631
Te rmi nal Block Kit
(Blo.:k, Terminals &
Scr,wl)
lI: oc:h. Arm With Brocke,
Mec ha nical Int • • loc k
N. C. ConTact Ki t
N. O. Con tact Kit
Du m my Con toci Kil
Sial ionary COn lacl Block
Uppe r and Low er Movable
Can lo ci Blocks and
Sc rew (WS-6 A2)
Mova ble COn loe! Block
A$$8mbly Screw
Mova ble Con ioci Block
An embly Screw
l ockwolher
Con nector
WS·632
WS-633
WS·63"
..,
WS·635
WS·636
WS·637
WS·638
WS·639
WS·6AO
WS-6AI
WS-6A2
WS·6A3
WS·6AA
Part Nom•
hi",' •
C_.....
( _ _ <I. .
R. v. rsing Co n 'ocior
I
I
.........
No. Requ ired
•• ,,
,
•
, ,
,,• ,,
,, ,
•
0
8
I
I
8
•
8
0
J6
J6
I
JO
8
,
I
,
,
I
•
Coil It" " ;n,,
Yoke Tru nnion , Screw and
lockwosh'r
Jump.r
Stat ionary Contoct Block
Anoth '''g S,:rew
Arma ture
Wi" R,lo in,r
Co nlo"or Attoching Screw
Contador Allo chi ng Screw
WCllh • •
Grommet, lo,g.
Fi e ld With Brock.1I &
Shodi ng Coill
Field Allo chi n; Screw,
Wa l her and Nul
G rammel,lmoll
lIeinforcln; Bar
Qu ic k Conn"'l Term inal
Qu ic k Con nee! Terminal
Screw
Movable ContOe! Block
Screw
Yoke
Shod in; Call
REFER TO PAGE 26 FOR ORDER ING INST RU CTION S
Push Button Stations
,
W$.11'
WfA1H[".OOf
nAIION )
2 ·8U TTON STAT ION
FOR TWO SPEED HOIST
A. BUTTON STATION FO il :::::;:;;
SINGLE OR TWO SPEE D HOIST
WIT H SINGLE OR TWO SP EE D TIiOllEY
Series R
..,
No.
Parts List
No .
Req 'd .
Part Name
Bo~
WS ·784
I
Pu s h Button
WS ·785
I
2 ·P ush Button S tat io n
DiscontinUed - Control
S tat ion Pa ge 35 will be
fu rn ished
WS·785
I
4 ·Pu s h Button S ta l ion
Discont inued - Control
S ta l ion Page 36 w ill be
furnished
Con nect o r
ALSO , IN DIVID UAL COMPONENTS FO il THE SE
STAT IONS Ail E NOT AVA ILAB LE .
Contactor Type BW
\-_ W~2 1
WS·61'
REVERSING CONT ACTOR
SPEED SELECTING CONT ACTOR
32
Contactoy Type 0
Parts List
'·r
N •.
WS-64S
N• •
Req'd.
,
PClFt Nom.
Co"IOClO' (Item, Ws..646 Thru
WS-066)
WS-646
WS'~I~
WS·047
WS·6of8
WS·6A9
w>~
WS-6S0
WS-6S1
WS-6S2
WS-6SJ
W5·6S"
WS-6SS
W5-6S6
WS-6S7
WS-658
WS-659
o
WS-660
WS-661
WS-662
WS--60J
WS-66"
WS-66S
~WS._
WS-666
WS-667
WS·668
2
,
12
12
,,
,,
,
2
,
2
2
•
•,
Con tact Bloc:k Scre ..... With
Lockwolher
Conlocl Block With Stolionory
ConrQc! Screwl & l ockwolh.,.
Stgl;onary Con tad Screw
Siotionory Contact Scre .....
l ockwolher
COniOtl Co"i'r
Moyoble Conlocl
Conloc t Spring Retoine.
Contact Spring
Ba.e With BUlhinll1
Mechonical Interlock
Interlock Latch
Coil WOlh.r
MO'4il"el Coil
Coil Term inal Scre ..... With
Loc.kwo,h. r
Slip-o" ConnKlor
Coil J umper
2
2
2
,
Armatu •• With lockwolher & Nul
A,malur, SlolI.d NUl
Armatur. Nullockwo,h,r
Balfam Pial,
2
80llam Plo'e Scre ..... With
,
,
Lockwo. her
Electrlcol Interlock Auembly
(N.C. Conloel.)
COn lo~1 Kit (Items WS·6"8, WS-6049,
WS·6S1 & WS·653)
AOJUSTMENT
If ormOI.." e ,olenold Is removed, It
should be odjulted when rOOllem bled by sc rew ing
ormolure within 15/ 6" of mognet co,o and locking
with .Ialled nu l to 20 In .-Ibl. tarq..,e.
REFER TO PAGE 26 FOR ORDERING IN STRUCTI ONS
31
SECTION E - REPAIR PARTS LIST
Ordering Instructions
The following informatio n must accomp.... ny all
corres pondence or repair pa r ts orders:
I) Hoist Model Nu mber.
2) Serial Number of Hoist a nd/ or Motor
Driven Trolley_
3) Voltage. P hase. Hertz.
This infor ma tion is stam ped on the hoist name
plate. Hoist ser ial nu mber is also stamped on
cont rol end of right suspension lug.
T he MOlor Driven Trolley ser ial number is
st a mped on end of mot or side frame.
When or deri ng hoist and /or trolley motor
pll rt." gh'e the motor name pla te da ta in addition
to t he above.
For parts orders s pecify:
I) Qua ntity desired.
2) Key nu mber of part.
3) Part name.
NOTE: When ordering repiaee ment parts. it is
s uggested t hai the indh'id ual also consider the need (i f he has not done so
a lready) for s uch items as gaskets. oil
seals. faste ners. etc. These it ems rna)' be
da maged or lost du ring the di saSSt mbl ~'
or rna)' be jus t unfit for futu re sen 'ice
bf,Cause of deteriorlltion from age or
sen 'ice cond itions.
Hoist Arrangement
A
a
C
o
26
_
-
Ree,,;ng Component.
Con!rol End Componen!1
Hoil! F.ome & Mo! o.· a.ake Com ponents
Georing End Componen!1
Electrical Data
.....--
,,......,. ,
M01015
."
,~.
»0/ _ 3.$0
H• • ,
•
St ...;...
19/ 14 ,$
~
f~.l"'"
' .111.1
".
1 ' ·14
12 ·fj
~"
".,
" ·n
»o/ .060-UO
•
_.I n
" .~
"."
" .U
12."
n·T.
17·"
2'JtJ/ 0I60.3·'"
•
" ·n
, ·n
6.lll
10.61,-,
11 ·T4
nn
~"
".,
230/ 460.) .60
..,
T7 . I'
.0/ 11
n /6
11·19
fl · T'
u·u
1).16
n ·TI
2/ .• 7
2'/' .'
6/'.2
\010_)
12 •.s/ 6.'
)/ 2.6
..,
f2.l)
Tl1 . rll
TJ1 ·tl3
l12" '3
1:10-1·60
0160-1·60
'I'
11 / H
" , ,. "
1 .5/ 1.0
• . 1/ • .0
TlI ·tll
112·113
"
n ·n
n ·n
u
"
"fI :·n
n
'"
1M3
..,
111 ·T12
TlI ·Tll
Tl 2·T13
J1/ 1).,
...,/ 1.5
0160-3-60
7.2/ 6
n ·n
11.S
l loT3
12.1')
,.
TlI ·1I2
111 ·113
Tt 2·Tll
."
......
."
11.7
MAIC.I COil
U
'
( Oh~. ,
~"''''''Y '
.,1--,.,
,. ...... c........
•••
,
"
~
~
looiot.~ c .
•••
..,
OJ
,_.
D.C.
tOIl...)
4....., •.)
•
,~,
17.2
•W
•••
' 6 • 17
'I · "
•»
-
D.C. .....t ••••
I .. ~.
.....
CONTACIOIl
I, ... C_.<I..
II· T1
Il' ·flt
TII· I Il
fl2 ·Tll
' .llS.'
37/ 1' .5
6 /1 .))
.060-)·60
2loO/ 060 10 1 U
TIl ·T12
111 .111
In·lIl
l2.T)
u
Tll ·113
t 12·ll1
u
...
1' .11
lI·n
12·n
TlI ·rn
nAHSfOitMEI
1I·11
TMl
n ·n
"
l ion
111 ·T12
...
"
(010 ... )
U ·TJ
u
U
1I·n
, • .• / 12
7.t21
"
ll · n
II . Tl
l l .n
' .. I ....
11."11.6
74/ 27
U / I..5
2:)0.)·60
TlI .Tl2
2/.'7
_fl .n
O. C.
•• tiot ••••
~
(AM,,,)
..,
12·13
460-3·60
......
M. , .
,~.
u
•••
Tn ·Tll
TI2·TIl
,-
C~ ......
MOIOttS
2)0.)·" ,
'1·19
17.19
2:10-3·60
..........
D. C.
'"
'"
N• . - I C.. _,
D.C. _ _ _ e.
t.....,•.)
4010.,0\
••
~
••
,~
25
....-..
..·......-_._..
·•_.·._ou
-...... 10 ._
!ROLLEY MOTOR
- - - -;::.:::.::;:~::.:;..:~-
--:,
:-
I
.__... - ,.
,
-
<.....<t ..
--- t--_ " _"
" ",,' -C ' .
,
,,I
To Detect Open and Short Circuits
In Electrical Components
Open ci rcuits in t he coils of electrical components may be detected by isolating the coil and
checking for conti nuity with ~In ohmmeter or with
t he oomponenl in series with n light or bell circuit.
Shorted turns afC indicated by a current draw
substantiall y abo ve normal (connect ammeter in
series with suspected element and impose normal
24
voltage) or D.C. resis tnncc su bstantiall y below
normal. The current method is re<:ommendcd for
coils with \'cry low D.C. res istance.
Motor current draw in the stator should be
measu red with the molor running. Brake and contnctor coil current should be metlSured wi th the
core iron in operaling poaition.
•
-
"
'
.
•
•
,
....
.....
..
,,.."...,-•...
..-.,........ ".....
.....
-
, .. u _
..
-...-.
_
~
"
," .
• •
..
,.;".;~;-
,
---- . --.....
.,- _
._.
•••
• ••
• ."
......
•
I
.-
-
•. - ---
0---- --- --
••
-.-...
.,-,-
• ".
••"
••
• ••
•
__-_
- - _.-..-_- .. .......
..............- . . •
......
....
..... . t....... __ ,
,
----. ------~
23
-.-
(
\
'.
I
,,-----_. __ .If
•
..
·..· .....-_..
·
.~.
.......
""'......'.....
. -~
.."..,..
' ~ 'fo
.- .-
.... _,. _
.
M
. . . .. . . . . .
_
.
.-
_.
~. "
•
_. __ .._- _.-.- ....
_._--- --------.
__
.....
-.
:::···.r"::::::::::::"::::::::~:::
---------R' ............... _ _ •
""""".... . '.
.:;::.:;::::--, ......,. . .....,....._.
~------­
-,,...----. ...... •
•
""', ... ,,,....
-.-" ..,
.·........
...
..
·,, ......
.
.
..."-..
,...
21
NOTE:
UNIT.
i,
...._ _._-"..
....... ."'..
•
.. "'- - . at .......
·...... .
..·· .- ..
-.-• - ·..-.•
,
. ~.
"
.. ......
~
--. ... ...
,. ,'~ '
R."" •~ .
,- ,."
M""'''"
< ~'M'M_
. ," , ~ . , ~
,
'W'
.:.~ '~~;.~.. -==~::::;:=.--. -.......-.-.-.--..-..-...... . ./'
.., ......__ .
_.. _...... _- •.....--... •,•..•.-_.
--,
•
•• •• •,•••
.
•,-.
,..... ",,'" " ..
,,,
•_
20
M M' ... .. M _
_
••
•
•
•
M . .. .
Motor Driven Trolley
19) Trolley does not
a) No voltage at motor
()pen circuit. grounded or faulty connection m
hois t wiring.
b) Phase failure
See Item l b.
,) ()pen control eiJ"(';uit
See Item Ie.
d) Low voltage
See Item Ie.
.) Wrong voltage or
See Item Id.
operate in eit her
direction
frequency
20) T rolley operates in a) Open control ciJ"(';uit
one direction only
a) Excessive load
21) T rolley operates
sluggishly
b) Low voltage
,) Unbalanced cur rent
In the phases
d) Brake draggi ng
22) Trolley motor
See Item l c.
See Ttem I g.
See Item Ie.
See Item l b.
See Page 12.
See Item 8.
overheats
19
10) Hoist will not
operate at fast
speed in either
direction
b) Phase failure
See Item lb.
a) Open circuit
See Item 9a.
b) Open speed
selecting---contr ol
eireuit
Open or shorted winding in speed selecting contador coil. Loose ronnection or broken wi r e in
circuit. Mechanical binding in contactor. Control
station contact:! not making or opening.
See Item lb.
See Item Gb .
.
,) Phase failure
II) Hook will not raise
) Excessive load
at slow speed
b) Phase fa il ure
See Item lb.
,) Open speed select ing
See Item 9a.
control circuit
') Brake not releasing
.) Open hoisting circuit
12) Hook will not lowe r .) Phase failure
at slow apeed
13)
REMEDY
CAUSE MAY BE
IF
,) Brake not releasing
See Page 12.
See Item 11 .
I') Hook will not lower
See Item 12 .
at fast speed
.) Phase reve rsal
Wiring reconnected improperly. Intercha nge two
leads of motor winding that is out of phase at the
speed selecting contactor.
.) Slow acting brake
See Page 12.
b) Upper limit switch
not wor k ing
See Page 12.
proper direction at
one speed-wr ong
direction at other
16) Hook fai ls to stop
at upper limit
See Item lb.
See Item 9a.
at fast speed
"....
Open or defective t hermnl switch. Replace switch.
b) Open circuit
Hook will not raise
15) Hook moves in
See Page 12.
Hoist Equipped with Adjustable Screw Limit Switch
17) Hook fails to stop
a) Shaft not rotating
Dr ive pin or gear key damaged or omitted: gears
damaged. Install or replace as necessary.
b) Nut not movi ng
Guide screw damaged or missing; shaft or nut
t hreads damaged. Install or replace all necessary.
at either or both
ends of travel
along shaft
18) Hook stopping
point varies
18
c) Switches not opening
circuit
Check for electrical continuity and mechanicnl
operation.
a) Not holding
adjustment
See Ite m 17.
b) Brake not holding
See Page 12.
•
IF
CAUSE MAY BE
0) Phase failure
d) Monitor relay
not energized
.) Monitor switch
tripped
4) Hook ra ises but
REMEDY
Check continuity. repai r or replace defective part.
Check operation of upper limit switch (see Page
12) and adjustable screw limit switch (P age 12).
See Item lb.
See Page 8. (60 FPM unit.! only).
Lower load to floor to reset switch.
.) Open lo .....ering circuit
Open or shorted winding in revening contactor
coil; loose connection or broken wi re in lowering
circuit; control station con tach not making. Check
oontinuity and repair or replace defective part.
Check operation of adjustable screw limit switch
Page 12.
a) Phase failu re
See Item lb.
6) Hook does not
stop promptly
.) Brake slipping
See Page 12.
b) Excessive load
Reduce loading to the capacity limit of hoist as
indicated on the identification plate.
7) Hoist operates
,) Excessive load
See Ite m 6b.
Low voltage
See Item Ie.
will not lower
5) Hook lowen when
hoist control i8
operated
sluggishly
b)
8) Motor overheats
c) Phase failu re or
unbalanced current
in the phases
See Item lb.
d ) Brake dragging
See Page 12.
a) Excessive load
See Item 6b.
b) Low voltage
See Item Ie.
c) E:d reme external
heati ng
Abo"e an ambie nt temperatu re of 104"F ., the
frequency of hoist operation must be limited to
avoid overheating of motor. Special provisions
should be made to ventilate the S]lIIce or sh ield the
hoist fr om radiation.
d) Frequent starting
or reversing
Excessive inchi ng, jogging or plugging should be
avoided since this type of ope ration will d rastically
sh orten the life of motor and contactor and cause
excessive wear on the brake.
e) Phase fail ure
See Item lb.
f) Brake dragging
See Page 12.
Two Speed Hoist
-
9) Hoist will not
ope rate at alow
speed in either
direction
a) Open ci rcuit
Open or sho rted moto r winding, loose or b roken
wire in circuit. Speed selecting contactor atuck in
opposite speed mode. Replace motor, r epair wire
and/or repa ir speed selecting contactor .
17
.... " .
K"
WS· l94 t:. 2
WS· I95 • 1
WS·I95 t:. 2
,,
WS· L95 1J. I
WS· I95 !
WS· I95 '
WS·I96
WS·197
WS·198
WS· I99
ws·",
WS·220
1
1
1
1
1
1
Req'd.
P¥l Name
Hook Bkx;k Sheave Bear;na Wawr
Hook Bkx:k SheaYe ~ Ring
Hook Bled Sheave Snap Rinl
Idler She.iwe Soap Rina
Hook Blotk sne_ Snap R""
Idler Sheave Snap Ring
L _ Hook-----l.alchlok
lOW1.'t' Hook Nut Washer
Lower Hook Nul
l.ow<!r Hook Nut Pin
tower Hook Thrust Bearing
WS·22l
WS·222
,
WS·230
1
1
1
1
1
WS·234
WS·24S
WS ·246
WS·24 7
WS ·248
m ·249
WS·250
WS·251
WS·252
WS·253
WS·254
WS·255
WS·256
WS·269
WS·270
1
1
,,
,
,
,
,,
,,
1
,
1
1
WS·271
WS·280
1
1
WS·28!
1
WS·282
1
WS·'"
WS·' "
1
1
1
WS·' "
1
1
1
1
1
WS·28S
WS·287
WS·""
WS·' "
,,
,,
,
,,
,
WS·310
1
WS·3 11
WS.J 12
1
1
WS·289
WS·290 t
WS·29 1 t
WS·292 t
WS·293
1'0'5·294
WS·295
WS·'"
WS·297
1
WS·193 Thru WS-I96 , WS·198
Thru WS·200, WS·22l & WS ·222)
Hook Block Cenw CoYer
Hook Block Shea ..... Sh;III Snap R'n.
Idler Sheave A.sembly (llems WS· 191.
WS· 193. WS· 195 & WS·23 1 Thru
WS·234)
Id .... Sheave Sh;!It K~r PI;Ite
Idler Sheaw! Sh;!1t Keeper Plate Sc,",
Idle< Sheave Shalt K~r PI;Ite
Screw lockwnher
Idler SheltVe Sha lt
Hook BIoc~ Assembly (Items WS · I 90.
WS·19 1. WS·193. WS· \95.
WS·I96. WS·l98 Th",
WS ·246 Thru WS·256)
Hook Block Side Plate
Hook Bloc k Shea ... e ShaH Nut
Hook Bloc k Sheave Shalt Nul
l oc kwasher
Hook Block Sheave Bea"ng
Space< (End)
Hook Block Sheave Bea.ing
Space' (Center)
Hook Block Trunnion
Hook Bklck Bolt and Nul
Hoole Block Bott lockwnher
Hook Bklck Spacer
Hook Block Capac,ty PI;Ile
Lower Hook Sleeve
Lalth Kit-Spec.ify Hook Size (not $hOwn)
Idle. Sheave Housing Anemb/y
(Items WS· 19!. WS· 193 . WS· 195,
WS·23l Thru WS ·234 & WS·271)
Idle. Shea ... e Hous,na
Upper Limit Switch (Items WS ·2a l &
WS·293 Tllm WS·297)
Upper Lim it Switch Sub·Assembly
(Items WS·282. WS·284 Thru
WS·289 )
Limi t Switch HouSIng With !Hoar ing
and B.xket
limit Switch Housing Sea. inlil
limit Switch cam Sh;!1t
limIt SWItch Cam Sh;!tt
Ret urn Spring
Urnlt Switch Spring ReUoinet Screw
Um.t Switch Atm
Lim, t SWItch Attn Pin
Limit SWItch Housing Plulil
Umit SWItch Bl"lKket
limit Switch 8'acket Sc.ew
LimIt Switch B.acket Screw loc kwJsher
Limit Switch Bracket Insulatins Shield
limit Switch
Limit SwitCh AUaching Screw
li mit Switch Attaching Sc. ew
lockwasher
limit Switch Attaching Screw Nut
limit S"""h Weight Screw
limit Switch Weiaht Screw lockwashe.
lim,t SWItch Weight Sub·Assembly
(Items WS.J!! Thru WS·3 1 S)
limit Switch Open Link
Limit Switch Weight Chain
• for 2 Piort Rape
t:. For 4 Pa.t Rope
~ f or 6 Piort Rope
t Discontinued - For Repai rs Only
m·200.
Pari Name
WS-JIJ
WS·JI4
WS·3 IS
1
1
Limit Switch Weight Ring
limit Switch Sc<ew Eyebolt
Limit Switch Weilht
WS>3'
1
Idle<
Hou:.ing Support Pin
(Pin shown i$ lor a hoi~1 with
Motor Drive!> Trolley. f or ottle'
WS·451
WS-452
1
1
1
Power c.bIoI
Power Cable Connector
sne-
t)'l)e pinl see p;oge 38)
WS ·501
Monitor Switch As$CtTIbiy. (Includes
W$· 126. WS·504, WS -505a r.d
Hook Block Assembly Items WS·I86,
WS-IS7. WS·189. WS·191.
WS·'"
K"
....
,,
Req' d.
WS·5(6)
WS·502
1
Mountin~ate
WS·
SA ( Includes WS ·126.
. WS ·50S and WS·5(6)
Replacement ollhi. PI.I requires the Re-Calibration
01 the Monitor switch ass..m~. Reier to page 12.
NOTE: Micro Switch is Spec~ and Should Not
Be Substit uted.
1
Monitor Relay (Inc:~ J umpef$)
60 fPM Units Only.
Slipper
1
""50<
Slipper $prine
WS·505
1
1
Jumper HarMSs - Numbered 2 1 & 22
WS""
WS·525
1
Motor (Frame & Stator. Sh;!11 & Rotor.
Items WS·S27 and WS·S29 Thru
WS·S37)
1
F....... & Stator
(Order Motor WS·525)
Shalt
& Rotor (Order Motor WS·S25)
1
1
End Bell and Plug
WS ·S28
Mounting Bolt and Lockwasher
WS ·S29
Mounting Bolt loc kwasher
WS·530
WS·S3!
1
Bearing
WS· S32
1
Be"ring S""p Ring
!Hoaring Rttainer
WS·S33
1
Searina Retainer Screw
WS ·534
Searinlil Retaine. Screw l ockwa.ner
WS·S35
TI\emIIII O<oerload Switch
1
1
End Bell [xpanlion Plug
WS·537
Electric: lIfilke (Items WS·546
1
Th.u WS·554)
B,.ke
BaM! Plate With St uds
1
WS·' "
B.a~e f riction Disc
WS·547
B. ah Intermediate Plate
1
Brah Armat u.e With Plate &
WS·549
1
Shading Coils
1
Br<1Ih
Coil
WS ·550
Brah Coil Retainer St rap
WS·5S!
1
Brake Field With Plate
WS·552
1
WS ·S53
Br~ke SPrln~
Brake St ud u t
WS ·S54
WS·SSS
Shadinlil Coil
Adjustable Sc. ew Limit Switch
WS ·S75
1
(Items WS·55 see page 27. WS·S76
Th", WS·594)
l imit SWItch Brxket With Bushing
WS·S76
1
l imit SWItch IIfxket Bushing
WS·5 71
1
limit SMtch Shaol!
1
WS ·578
limit SWItch Sklft Nut
WS·S79
limit Switch Gear
1
WS""
limit Switch Gear Key
WS·581
1
Orum CoYe. Bushina
1
WS·582
limit SWItch Drive Pinion Wit h Pin
1
WS'"'
Drum Shaft Dr"e Pin
1
WS'"'
limi t Switch Orivll Pinion
WS·58S
1
AUxhing Sc rew
WS"'" 1 Li mit Switch Guide Screw
limit Switch Guide Sc rew loc kwasher
1
WS ·SS7
" ,. " ,
limit Switch
Limit
Switch Attaching Screw
WS""
limit
Switch Attachina Sc.ew
WS·S90
l oc kwa$her
Umit
Switch Attachina Screw Nut
WS ·59!
Umit Switch e..cket Attaching Screw
WS·592
limit
Switch Bl"lKket AttilChina
WS·S93
Sc rew l ockwashet
Jumper Wire
R_.si~taetor
WS-6l0
1
St: eed Se tinlil Contactor
1
WS·611
WS. .,
Trolley R8't8fsina Contactor
1
Control Station
WS·785
1
""""
,,
,,
"",,.
"",,,
"',..
,
,,
,
,
,,
,
,,
,
,
""",
REFER TO PAGE 26 FOR ORDERING INSTRUCTIONS
,
-
...'"
ws·'
WS,
WS<
WS·'
WS8
WS·'
8
...
WS· IO
WS· II
WS·1l
WS·14
WS·15
WS·16
WS, I7
WS· IS
WS· 19
WS ·20
WS·21
WS ·22
WS·"
WS40
WS,41
WS·42
WS·43
WS4>
WS.,
WS ...
WS·49
•
WS·"
WS·S l
WS,52
WS·"
WS·"
WS·55
WS·"
WS·57
WS."
WS"
WS·60
WS·6 1
WS·"
WS.,
WS·"
WS·65
WS. .
WS.,
WS . .
WS. .
WS·70
WS·1l
WS·]2
WS·]3
WS·74
WS"
WS·"
WS"'
WS·"
WS·92
WS·93
WS·"
WS·95
WS·"
WS·97
WS·98
,
••,
,,
•,,
,
,,
,
,,
,
,•,
,,
•,
,,
,,
,
....
....
'"
ws·"
,,
,
R'eq 'd,
~'d,
,
ws.
,,
,,
,,
,
,
" ,
,
,,,
,,
,,
,,
,
,•,
ws·.. ,
,
,
WS...
,
•,,
,,
,,
WS·'
WS·'
•
,
..,,
Meteor Hoist Series SA
Parts l ist
PulN_
eo. ..,
Gear Houloinll
Gear HouloinS Covet Dowell
Gear Houloilll
G;uket
Gu, Hoon.i"l CoYer Suew - I \(oM 41;.
Gu, Houlol"l CoYe, Screw - I 'h" 41;.
Gur Houloina
Oil Fil", Plua:
Oil level Plua
Oil Drain PIu~
Motor Shillt '1Seiol
Motor Shalt e.. Bearing
Pr~ lntennediate Ge:a, & Pinion Ball
SNri"l
Secondlry Inle. ",ediale Gear & Pinion Elan
BYrina - Covet End
Second3oryln\e1 medi.al" Ge:ar & Pinion
!Hon SNri", - Houloin& End
Drum Shilfl Ball BY,i. .
Motor Pinion
Pr~ Inl.... mediate Gear & Pinion
Sec
ry Intermediate Gea, & Pinion
Drum Gea,
Motor Pinion Key
Motor ShlIt SnIp Ri"l
Drum Shill! Snap RinK
WI , nlnll label
Frlme With Motor Cove, Pins
(IrocluOes WS ·39)
F,am, Sc,ew
Fr.me Serew Loc kwasrn.r
MotOl' Cover
Motor Cover Pin
Motor eo.er Clamp Screw
Motor eo.e, Clamp Screw Lockwasher
Drum Shroud
Drum Shroud AlIachin& Screw
Drum Shalt Oil Seiol
Gear Housinll Dowel ()'Ring
Gear Houloin& Dowel
Drum With R""" Arochor tn..eo1 & Screw
R""" Anchor In..ert
R""" Anc;hor InMo1 Screw
Drum CoYer (Spi!Ci~ if unit is equipped
wilh screw limits)
Drum eo.er Screw
Drum Ccwer Screw lockw3.sher
Drum SNft Ball BYrin&
Drum Cc ,., SnIp Rin.s
!ioillldefltilication PIIte
ldentilicalion Plate Attaching Scr_
Wirin.s Conduit
Pleklnc Rin,
Control StatlOll Chain Attaching Link
Cont,oI StatlOll Chain Attachi"l Screw
Control Station Chain AttKhing Screw
lockwuner
Control Statlotl Ctwoin Attaching Screw Nut
Conltol Station Chain (Specify l ength
Req·d .)
ConI,oI Station Cord (Specify Length
Req'd.)
Motor Brlke Hub Snap Rinll- Inbo»rd
Motor Brake Hub
otor Brak, Hub Snap Rinll_
Outbo».d
Motor B,ake AlI..:hing Screw
Lockwa$l\er
Motor Bfake Attachi n!\, Sc.ew
Cable Return Rinll Wit Screws and
Lockwashers (Not Shown)
Cable Retufn Ring Screw (Not S""",,n)
Cloble Relu rn Rinll Set Sc.ew (Not S""",,n)
Control Station Cable Clip (Speci~
Number Req'd.)
Brlke & Houloin& AII..:hing Screw
Brlke !HoM P\;ole Gasket
(WeitherPfool !ioisl Only)
Brlke Houloinll Gasket
Bflke HouloinS
B'.... Hous.in& Piog
Brake Housinj CoollOt Gaske t
Brake Housinll CoYe,
CoY",
WS, IOO
WS·II I
WS·112
PI<1 NMI,
8
8
Switch
WS·1I2
WS·1I3
WS·1I4
WS·1I5
WS-1I6
WS·116
WS·1I7
WS· IIS
WS·1I 9
WS·I20
WS·121
WS·122
WS·123
WS· 124
WS·125
,,
,,
,
••
,
,,
,,,
,
,,,
,,
,
••
••
,
,
,
,,
,,
"', ,,,
,
,,
,,
,,,
,,
,
,,
,,
t:. ,
,,
WS· I26
WS·127
WS·I28
WS·I29
WS· I30
WS·131
WS·132
WS·133
WS·IJ4
WS·135
Spacer
Mounti nll Sc rew
Mountinll Screw Nut
Mountln& Sc rew
WS· I36
Screw With
WS· l lS
WS· I39
WS·I40
WS·141
..
WS·1 42
WS·l.t3
WS· 145
WS·I 46
WS· I48
WS·149
WS·151
WS· I53
\YS. I60
WS·1 61
WS·162
WS·I77
WS·1S3
WS·l84
WS· IS5
WS · l86
WS·IS7
WS·t88
WS·I89 •
WS· I89
WS ·I90
WS·191·
WS·191 t:.
WS·191 0.
WS·191 ~
WS·19P
WS·192
WS·193·
WS- 193 0.
WS·193 0.
WS·193 %
WS·193 1
WS- 194 •
,,
,
2
I
,
,,
,
2
I
,
,
"
20
Black. 4V. " 1..1.
,
Lockwasne,
WS· I86
l~
,
, I
~;
i! ,... . ..I'
~
.", ,• ~~ •
.r -,
,
~I
,,
, I,
-,'
•
'f-!:
p; ~~ !! d
,
-
Ii,
,
- --
-
,I
,,--
II.I
Ii
•i
i
' 7• -'
,
.ii- .i @;";
<+.<-
't'"
l' \
-'\.0
i , r
i
II
;
@
.
Ko,
N •.
WS-454
N• .
Req' d.
1
K.,
Part Name
Con ta ctor 80)(, Cover, Gasket and
N •.
WS·675
N•.
Req'd.
1
Screws
WS·456
WS-457
3
3
WS-4 58
2
WS-4 70
1
1
WS·471
Contaclof Boll. Attaching Screw
Contactor Box Attaching Screw
loc kwashe r
Contactor Box Cover Attaching
Screw
Power Cable (To Line)
Power Cable
(Contacl or Box to Hoist)
Conlrol Slation Cord
WS·472
WS·473
WS·474
(Spedly Length Req'd.)
3
3
WS·475
WS·476
WS·477
WS· 478
3
WS·479
WS·480
2
2
WS-4 82
1
WS·483
1
WS·484 ·
1
WS·48S ·
1
1
2
2
WS·488
1
WS·489
WS·490
4
WS·491
WS·492
1
1
2
WS·493
WS·494
WS·495
WS·496
WS-497
2
2
2
2
WS·64S
1
1
WS·678
WS·679
WS·680
WS·681
WS·682
Sha lt and Rotor
(Order Molor W5·675)
1
1
1
1
1
1
1
End Bell ( Pulley End)
WS·683
WS-684
Lockwa sher
Contactor Att aching Screw Nul
Tran sformer
Tran sformer Attaching Screw
Tran sformer Atta chi ng Screw
lockwasher
Tran sformer Attaching Screw Nut
Power Cable Connector , O·Ring,
and locknut
Control Stat ion Cord Connector,
O·Ring, and locknut
Control Sta tion Cord Connector,
O. Rin~, and lockn ut
Plug and ody
(Power Cabl e to Hoist)
Plug and Bod~
(Control tation Cord to
Hoist)
Control Stat ion Cord
(Con tactor BOll 10 Hoist)
Con t rol Station Cable Connector
Transformer l ead Connector
(460 Volt Unit Dnlt
Control Station Ch ain yebolt
Con trol Slation Chain Eyebolt
Washer
Control Stat ion Chain Eyebolt Nut
Ground Screw
Ground Screw lockwasher
Ground Screw Nut
Motor lead Connector
(I Req'd. for 230V. Unit)
(3 Req'd . for 460V. Unit)
Trolley Reversin g Contactor
WS·685
WS·686
WS·687
WS·688
WS·700
4
4
4
WS·701
1
WS·702
WS·703
WS·704
WS·705
WS·706
WS·707
1
1
1
1
1
1
WS·708
WS·709
WS·710
WS·711
WS·785
2
Note: The Terminll Box and anoc il t,d parts shown on the
opposile PlIie 11 mount ing on s ide of motO!', piuS t he IIdd i·
lion,1 con t.ol PlItt, ,hown mount ing on Cont rol P,nel are
for I Hoist w,th Slngl' Spee-d Trolley.
REfER TO PAGE 26 fOR ORDERING INSTRUCTION S
Mol or and Pin (Frame & Stator,
Shaft & Rotor, Items WS-678
Thru WS·688 & W5·41S)
Frame and Stator
(Order Motor W5·67S)
1
Contaclor Attaching Screw
Contaclor Attaching Screw
.Oiscont in ued lor .ePII lrs on ly.
Part Name
Spring Wa sher
Bearin g (Pulley End)
End Bell ( Brake End)
Bearing (Brake End)
Snap Ring
Bearing Cap
1
Bearin, Cap Screw
Motor hru Bolt With lockwa sher
Molor Thru Bolt l ockwa sher
Brake lead Grommel
Trolley Motor Brake (Items WS·430
Thru WS· 433, WS, 435,
WS· 436 & WS·70 1)
Electr ic Brake
(Item s WS·702 Thru WS·710)
Brake Ba se Plate With Studs
Brake fr iction Di sc
Brake Ar mature With Plate
Brake Coil
Brake Coil Reta iner Strap
Brake f ield Wi th Plate and
Shading Coils
Brake Spring
Brake Spacer Wa sher
Brake Stud Nut
Shading Coil
Control Station (See Pa ge 36)
WS·784
1
Push Bullon BOll Connector
WS·785
1
2·Push Bulton Stal ion
Di scontinued - Control
Station Pa ge 35 will be
furn ished
WS·785
1
4 ,Pu sh Button Stat ion
Di scontinued _ Control
Station Pa ge 36 will be
furnished
1
1
10
2
2
-
K.,
N•.
WS·64
,
Plain, Geared and Motor Driven Trolleys
Paris List
N•.
Req 'd.
Part Name
2
Control Station Chain Attach ing
Link
ContrOl Station Chain
(Specify Length Req'd.)
Control Stat ion Cord Clip
(Specify No. Req 'd.)
WS·68
WS·90
WS·153
W$·326
W5·327
WS·328
WS·330
WS·330
WS·330
WS·3 70
WS·37 1
WS·372
WS·373
WS·374
WS·375
WS·376
WS·377
WS·378
WS·379
WS·380
WS·381
3
2
4
4
52
3'
32
4
8
8
8
4
4
4
2
4
I
I
I
WS·382
'"
ws
WS·383
WS·384
WS·385
WS·386
WS·387
WS·388
WS·389
WS·390
WS·391
WS·392
WS·393
WS·394
WS·395
WS·396
WS·397
WS·398
WS·399
WS·400
I
2
3
3
I
I
I
2
2
I
I
I
I
I
I
I
I
K.,
N• .
WS·401
I
I
I
I
I
I
Hoist Suspension Bolt
Hoist Suspension Boll Nut
Hoist Suspension Bolt Nul
Cotter Pin
Spacer Washer
2
I
WS·410
I
WS·411
WS·412
WS·413
WS·414
WS·415
WS·416
WS·417
WS·418
WS·419
WS-420
WS·421
WS·422
WS·423
WS·4 24
WS·425
WSA30
WS·43 1
WS·432
WS·433
WS·434
1
WS·435
WS·436
WS·437
WS·438
WS·439
WS·440
WS·441
WS·441
Part Name
Idler Sheave Housing Support Pin
Keeper Plale Screw Lockwasher
(For 5 Ton Capaci ty Only)
Trackwheel Pinion Spacer Wa sher
(3 Ton Only-Specify No.
WS·402
Contaclor Jumpe r
(For ljz ·2 Ton Capacity)
Spacer Washer
(For 3 Ton Capacity)
Spacer Washer
(For 5 Ton Capaci ty)
Trackwheel With Bearing Cups
Tra ckwheel Bearing Cup
Trackwheel Bearing Cone
Trackwheel Bearing Seal Washer
T rackwheel Stud
Trackwheel Stud Collar
Trackwheel Stud Nut
Trackwheel Gear And Pins
Trackwheel Gear Pin
T ra ckwheel Gear Pinion
Trackwheel Pinion Key
Geared Side Frame (Does Not
Include Wheels)
Plain Side Frame (Does Not
Include Wheel s)
1 Req·d. for Geared & Motor
Driven Trolleys
2 Req·d. for Plain Trolley
Handwheel Bracket With Bushings
Handwheel Bracket Bushing
Handwheel Bracket Screw
lockwasher
Handwheel Bracket Screw
Handwheel Shaft
Hand Chain Wheel Key
Hand Chain Wheel
Handwheel Shaft Nut lockwasher
Handwheel Shaft Nut
Hand Chain Guide
Chain Guide Screw
Chain Guide Screw Wa sher
Chain Guide Screw Nut lockwasher
Chain Guide Screw Nut
Hand Chain And Connecti ng link
(Speci fy length Req'd.)
Hand Chain Connecting link
Idler Sheave Housing Support
Pin Keepe r Plate ( For 5 Ton
Capacity Doly)
Idler Sheave Housing Support
Pin Keeper Plate Screw
( For 5 Ton Capacity Only)
N•.
Req' d.
I
I
I
I
I
I
I
I
I
I
I
4
4
I
I
I
2
2
2
1
3
3
I
3
3
I
I
WS·442
WS·443
WS·444
WS·445
I
I
I
I
WS·446
WS·447
2
2
WS·448
2
WSA50
WS·4S1
WS·4 53
I
I
I
Req'd.) (Not Shown)
Trackwheel Pinion Shaft
T rackwheel Pinion Lockwasher
Trackwheel Pinion Nul
Trackwheel Pinion Spacer
Pinion Bearing Sleeve
Pinion Shaft Ball Bearing
Intermediate Shaft Ball Bearing
(Side Frame End)
Intermediate Shaft Ball Bearing
(Motor End)
Driven Gea r
Intermediate Pinion
Intermediate Gear
Motor Pinion And Pin
Motor Pinion Pin
Driven Gear Key
Pinion Bearing Spacer
Intermediate Bearing Spacer
Intermediate Pinion Nut
Intermediate Pinion Nut lockwasher
Gear Housing
Gear Housing Gasket
Gea r Housing Screw
Gear Housing Screw lockwasher
Motor End Bell Gasket
Brake Hub
Brake Hub Snap Ring
Brake Attaching Screw
Brake Attaching Screw lockwasher
Brake or Motor Cover Gasket
(Weatherproof Units Only)
Brake Cover
Brake Cover Screw
Brake Cover Screw lockwasher
Motor End Cover
Motor End Cover Screw
Motor End Cover Screw l ockwasher
Terminal Box
Terminal Box. Cover & Gasket
(Wea therproof Unit Only)
(Not Shown)
Terminal Box Cover
Te rminal Board
Terminal Box Attaching Screw
Terminal Box Atta ching Screw
lockwasher
Terminal Board Spacer
Terminal Box & Board Atta ching
Screw
Terminal Box & Board Attachi ng
Screw lockwasher
Power Cable Connector
Power Cable
Junction Box Gasket
,
t
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4<r-.'
1-1
METEOR HOIST MONITOR 10EN TIFICATION COLOR COOE
MOOEl
.,-------+
SECTION D - TROUBLE SHOOTING
All Hoists
IF
1) Hook does not
raise or lower
a) No voltage at
hoist
b) P hase failu r e
(Single phasing)
c) Open co nt rol ci r cuit
d) Wrong voltage or
f requency
e) Low voltage
[) Brake not releasing
g) Excessive load
2) Hook moves in th e
wrong di r ection
UNIT RATING
MIN IMUM VOLTAGE
208·240/ 3 / 60
440-460 13160
18'
".
Branch li ne overloaded. install separate line to
hoist or use proper wire size for branch line.
Open or IIho r ted coil winding: op,en wiring ha rness
circuit. Check continuity and repair or replace
de fecth'e part. A rmature binding: brnke not Prol).
erly adjusted. See Page 12.
Reduce loading to t he ca]lRcit y limit of hoi!!t as
indicated on t he identificntion plate.
See Page 3 .
b) Rever se wind ing of
Rope has been wound on wrong !!ide of dr um.
Rewind and check rope for damage.
. ) Excessi ve load
b ) Open hoisti ng circuit
16
Main line or branch circuit switch open: branch
line fuse blown or circuit breaker tripped. Close.
replace or re-set.
Grounded or faulty connection in supply lines or
curren t collectors.
Open ci rcuit, grounded or faully connection in one
line of supply system. collector!!. hoist wi r ing.
reve rsing co ntactor. moto r leads or windings.
Check for electric;11 co ntinui t y.
Open or sho rted wi nd ing in t rnnsfor mer 01· reve rsing contactor coil: loose connection or broken wire
in circuit: mechanica l binding in contactor : cont rol station contacts not mak ing. Check continuity
and repair or replace def<!Ctive pa rts.
The voltage an d frequency must be t he Mme as
shown on hoist identification plate.
Read \'oltage at the plug end of hoist powe r cable
whi le operating hoist in ... UP di rection with full
load. Reading should be all follows:
.) P hase reversal
ro , ~
3) Hook lowe rs but
will not raise
REM EDY
CAU SE MAY BE
Reduce 10Hding to the cHJ).'l.city limit of t he
as indicated on t he ide nt ificntion plnt e.
h oi~ t
Open or de fective moto r the rmal switch . Switch
automatically resets wh en motor has cooled sufficiently to resume operation. in approximately one
hou r . Check conti nuity in the switch after mot ol·
has cooled and replace if it shows an open ci r cuit .
Open or shorted winding in reversing contactor
coil: loose connection or broken wire in hoisting
circuit: control station contncts not making.
Adjustments (Cont'd)
rope nnchor through s witch assembly, insert anchor bushing in Monitor assembly,
seat rope anchor into bushing recesa. allow
assembly to seat against anchor plate by releasi ng grasp on rope anchor.
Pull rope until end anchor seals properly on
the underside of Monitor assembly,
Cheek to be sure everything is properly
seated a nd that Monitor is properly nested
in its protected posi t ion between the z-bars
of the hoist frame.
Tighten up dead end spool screw. Be sure
that screw is not binding on rope.
sheaves. assembled on hook block
shnft, on the lower loops of rope.
hook block side plates over sheave
and hook block trunnion.
hook block spacers in position, slide
hook block bolts through capncity plates,
side plates and spacers.
Lock in position with nuts.
8. Place the two halves of limit switch weight
around rope j ust below dead end spool. Lock
in position with screws. Limit switch weight
must be free to slide on rope.
9. Check rope to make su re there a re no tw ists.
Twists can be remo\'ed as follows:
a ) Operate the lowering control until hook has
reached its lowe r limit of travel. There
s hould be at leas t 2 wraps of rope remaining on drum.
b ) Disconnect hoist from power su pply.
c) Now pull the dead end of hoisting rope
downward until the hook is within several
feet of bottom of hoist.
eI) Then retu r n hoisting rope to its operating
position making sure the rope anchor is
seated properly on the underside of anchor
bushing. and Monitor assembly.
e) Repeat above pulling on t he dead end if
twis t remains. While pulling, a twisting
motion imparted to the dead end fitting by
hand will ex pedite removal of hoisting rope
t wists.
Instructions For Installing Meteor Monitor
1. Disconnect lower hook from any loads. discon-
6. Mount the relay using the screw and sealing
nect power supply. remove moto r cover.
Remove dead end spool screw and lockwRSher.
Slide molded slipper between wi re rope and
dead end spool until slot in slipper is centered
Ol'er screw hole, slot should be open toward
moto r. Slide slipper spring over dead end spool
screw and lockwasher. Re-install screw lJO that
the tangs of the spring fit into the groo\'es in
the slipper and tighten screw secu rely. Refer
to F ig. 4.
Do Not Ta ke Switch Assembly Apa rt . Grasp
the dead end rope a nchor and pull down several
inches of wire rope. Thread rope ancho r
through switch assembly, insert anchor bushing in Monitor assembly. seat rope anchor into
bushing recess, allow Msembly to seat against
ancho r plate by releasing grasp on rope anchor.
Check to be sure everything is properl y seated
and that Monito r is properl y nested in its protected position between the z-bars of the hoist
frame. Refer to Fig. 4.
Run Monitor leads along inboard side of moto r
power conduit and secu re leads wit h two cable
ties. (This ste p should be omitted on 5-ton
model hoists) .
Remove control housing covers. remove rubber
brake lead grommet. Pass Monitor leads
through grommet hole. slip grommet over the
fou r brake and Monitor leads and install grommet in control housing. Seal wi res passing
t h rough g rommet by forcing Silastic, RTV.
Permntex, glazing compound or other nonhardening sealant bet ween wi res a nd into
grommet.
washe r. Be sure locating bo8s on relay rests in
drilled hole. Connect relay per wi ring diagram.
(60 FPM units only).
7. Re41ssemble control housing cover a nd gasket.
re-asse mble motor cover.
8. Operate hoist in "down" direction (to energize
relay on 60 FPl\l unit) and then check for
proper hoist operation under no load condition.
NOTE :
I. Although the Monitor is weathe r resistant. it is not recommended fo r use in
severe acid environments.
2. Do not disassemble or re-calibrate the
Monitor Assembl y.
3. Check color code on chart Page 16 to
make sure Monitor is for proper hoist
model.
2.
3.
4.
5.
. . ..
~.
---
,
FIGURE 4
15
Adju stments (ConI' d)
3. Remove dead end spool serew, iockwasher, and
slipper spring. Grasp t he dead end rope anchor
and pull down several inches of wire rope. Remove anchor bushing and puJl anchor through
Monitor assembly. Slide molded slipper a nd
wire rope ou t of slot and off of dead end spool.
4. UllinII' heavy can\'as or leather gloves, operate
hoist in the lowering direction keeping t he rope
under tension until it i8 completely unwound
from d rum.
5. Unscrew drum ancho r insert screw a nd rethread it into the tapped hole in dru m anchor
insert to provide a grip for removing the insert.
6. Pry out imsert and withdraw the rope end.
INSTALLING ROPE
I. Uncoil the rope and stra ighten it out along the
!loor to remove all twists. Keep rope clean.
2. Insert rope end anchor into hote in dru m.
3. Move rope sideways into slot. A straight pull
on ro pe should not release it.
4. Secure rope in this position with dl'um anchor
insert.
5. Lock insert in place with screw.
6. Wind the rope on drum under tension, by
opera ting ' " UP Control. leaving about 10 feet
hanging for two-part rope. about 15 feet for
four-part rope and about 20 feet for six-par t
...
7. Two-part rope unit
",.
Loop the end of rope over dead end spool
while sliding molded slipper between wire
rope and dead end spool until slot in slipper
is centered over screw hole. slot should be
open toward motor. Slide slipper spring over
dead end spool screw and lockwasher. Reinstall screw so that the tangs of the spring
lit into the grooves in the slipper.
Grasp the dead end rope ancho r and pull
down Se\'eral inches of wire rope. Thread
rope anchor through switch assembly, insert anchor bushing in Monitor assembly.
seat rope ancho r into bushing recess. allow
assembly to seat against a nchor plate by
releasing grasp on rope anchor .
p un rope until end anchor seats properly
on the unde rside of Monitor assembly.
Check to be sure everything is properly
seated and that Mon itor is properly nested
in its protected position between the 2:-bars
of the hoist frame .
Tighten up dead end spool screw. Be .'lure
that sCl'ew is not binding on rope.
Place hook block sheave on the rope.
Place sheave with two spacers in position
into hook block yoke.
Insert sheave shaft.
Re-assemble covers.
Four·part ro pe unit
Make a three-foot loop in the rope in the
counter-clockwise direction looking from
motor side.
14
Place idler sheave in top of loop.
Insert shea\'e between the two plates hanging from 2:-hars. The f ree end of rope
should be next to the side of sheave f urther_
est from dead end spool.
Insert idler sheave shaft.
Lock in pla ce with keeper plate.
Loop the end of rope over dead end s pool
while slidi ng molded slipper between wire
rope and dead end spool until slot in slipper
is centered over screw hole. slot should be
open toward motor. Slide slil)per spri ng over
dead end spool screw and lockwasher. Reinstall screw so that the tangs of the spring
lit into the gTOO \'e9 in the slipper.
Grasp the dead end rope anchor and pull
dow n se\'eral inches of wil'e rope. Thread
rope anchor th ro ugh s witch ASse mbl y. insert
anchor bushing in Monitor Mscmbly. scat
rope a nchor into bushi ng recess. allow 88sem bly to sellt against anchor plate by releasing gras p on rope Ancho r.
Pull !'Ol>e until end anchor seats properly on
t he underside of Monitor assembly.
Check to be sure evcrything is properly
seated and that Monitor is properly nested
in its protected position between t he 2:-bars
of the hoist frame .
Tighten up dead end spool screw. Be sure
that scre w is not binding on rope.
Place sheaves. assembled on hook block
yoke and s ha ft. on t he lower loops of rope.
When re-aSl!embling cO\·ers. tighten each
cover screw an equal amount to align the
sheaves below the cover openings.
Six- part rope unit
Make two t hree· foot loops in the rope in the
clockwise direction looki ng from motor side.
Place two idle r sheaves in t he top of loops.
Insert sheaves between sides of idler sheave
housing in the same order the loops were
made.
Insert idler shea ve shaft through hOUSing
and shea ves.
Lock in place with keeper plate.
With idler sheave housing held under the
hois t in approximate position. check the
reeving of unit as shown in dillg ram on
Page 13.
If correct. secure in position with idler
sheave housi ng su pport pin.
Loop the end of rope over dcad end spool
while sliding molded slipper between wi re
rope a nd dead e nd spool until slot in slipper
is centered over screw hole. slot should be
open toward motor. Slide sliPl>er spring over
dead end s pool screw and lockwasher. Reinstall screw so that the tllngs of the s pring
fit into the g rooves in the slipper.
Gras p the dead end rope anchor and pull
down se\'eral inches of wire rope. Thread
DEAD END
SPOOL SCR EW
DEAD END
SPOOL
IDLER SHEAVE
SHAfT MONITOR
IDLER SHEAVE SHAfT
KEEPER PLATE - IDLER SHEAVE HOUSING
SUPPORT
IDLER SHEAVE r---,,SHAfT KEEPER
IDLER
PLATE_
Y
LIMIT / /
LIMIT
SWITCH
WEIGHT
"L~IMIT SWITCH
TWO PART REEVING
,p, BLOCK
FOUR PART REEVING
WEIGHT
HOOK BLOCK
SIDE
PLATE
TAPPED
HOLE IN
INSERT
HOOK BLOCK
TRUNNION
(BEHIND COVER)
SIX PART REEVING
SCREW
Adjustments (Cont'd)
HOISTING ROPE
Rope is furnished complete with assembled end
fittings. The ends are interchangeable and the
rope can be reversed to distribute wear and obtain
longer life.
Refer to the following illustrations for assistance in remo\'i ng and installing rope.
CAUTION: If replace ment wi re rope Is not pur·
chased from Columhus McKinnon
Corporation. extreme care must be
used in attachi ng t he end fittings.
Ap ply for furthe r Information. When
remo\'ing or installi ng rope on hoists
eq uipped with screw limit switch.
fi rst remO\'e limit switch g uide screw.
Arter installation. then re-set limits.
REMOVING ROPE
L Remove limit switch weight from rope.
2. Two-part rope hoist
Remove hook block covers.
P ull out sheave shaft.
Remove rope from sheave.
Four· pa rt rope hoist
Remove hook block covers.
Remove rope from sheaves.
Remove idler sheave shaft keeper plate.
P ush out idler s heave shaft.
Remove rope from sheave.
Six-pa rt rope hoist
Remove hook block plates.
Remove rope from s heaves.
Remove idler shellve housing support pin
a llowing idler sheave housing to be removed
from the hoist.
Remove idler sheave shaft keeper plate.
Push ou t idler sheave 8haft.
Remove rope from sheaves.
18
Trolley Lubrication
GEARED TROLLEY
MOTOR DRIVEN TROLLEY
•
•
•
Once a month lubricate trackwheel gears with
Texaco Novatex No.2 or an equivalent heavy
cup grease or graph ite gr ease.
Every six month s lubricate handwheel shaft
bearings with 3-in-1 or light machine oil.
Once a mont h lubricate trackwheel gea rs with
Texaco Novat ex No. 2 or an equivalent heavy
cu p grease or graphite grease.
• The motor benr ings an d reduction gears r e·
qui re no addit ional lubrication. However. if
gears are disassembled upon reassembly use
Texaco Novatex No.1 or an equivalent medium
cup g rea8e.
Adjustments
ElECTRIC BRAKE ASSEMBLY
The correct air gap between
aod
fie ld, when brake is not energized, i
inch
and need not be adjusted until the gap reaches
0.045 inch.
To adjust the brake, proceed as follows:
1. Disconnect hoist from power su pply.
2. Remove motor cover.
3. Befor e adjusting the gap, back off t he stud
nuts nnd examine f riction lini ngs and Criction
surface8 for wear, scoring or warpage. Also
check shading coils to be su re they are in place
and not broken. A miSlling or broken shading
coil will cause the brake to be noisy when hoist
is operated.
On units h aving a weatherprooC brake housing.
remove the two rectangular covers on s ide of
housing to check parts and measure air gap,
a nd remove the t hree plugs in end of housi ng
to reach adjusting nuts.
4. T ur n adjusting nuts clockwi8e gaging the air
gap at both ends.
5. Heplace cover (s), reconnect t he power and
check oper at ion.
UPPER LIMIT SWITCH
If 8witch operation has been checked as descr ibed on Page 3 and is not operating correctl y,
proceed as follows:
I. Disconnect hoist Crom power supply.
2. Remove control housing cover.
3. Lift limit switch weight slowly - a sharp click
when cam lifts the rolle r of right ha nd s ~'itch
indicates that the hoisting cont rol circuit is
interru pted. Continue to lift the weight and
the left hand switch should click when its roller
drops into the cam dep ression _ indicating
thnt the lowering circuit is ene rgized to reverse
motor.
4. If either or both 8witches fail t o operate. loosen
the two screws thnt hold the limit swit ches t o
bracket. Move right hand switch until the
clearance between the cam and switch roller is
1/32 inch. Make 8ure left hand switch roller is
in contact with its eam. Tighten serew8. replace
cover, reconnect the power nnd ch eck operat ion.
LOWER HOOK
When replacing a hook. allow
12
~
inch clearance
between hook shoulder and bottom of h ook yoke
sub-allllembly or hook trunnion.
ADJUSTABLE SCREW LIMIT SWITCH
1.
2.
3.
4.
5.
To ndjust hook travel, proceed as follow8:
Disconnect hoist from power supply.
Remove control housing cover.
Wi thd raw guide screw from between limit
switch nuts.
Turning t he limit switch nut one notch changes
hook position ap proximately 21f:! inches on twopart rope. I If,,- inches on fou r_par t r ope or 13/ 16
inch on six-purt rope hoists.
Moving one nut toward the other increases
hook t ravel and nway from the other decreases
t he travel.
The nut nearest cover operates at upper hook
position and the nut nearest hoist operates at
lower limit of hook tra \'el.
The screw limit switch should be adj usted 80
that at le1\8t 2 wraps of rope remain on the
drum nt the lower limit of t ravel.
Replace guide screw and cover. Reconnect the
power a nd check operation.
MONITOR CALIBRATION
When Re-Calibration becomes necessary due to
repair of the Monitor switch asse mbly proceed as
follows:
1. After repairs are completed and hoist is reassembled. place a load of 140% hoist capacity
on unit.
2. Raise load ap proximately I" off floor and adjust
i\lonitor switch adjusting screw unti l switch
ol>cra tes nnd load cannot be raised.
3. Lower load. disconnect lower hook from load,
and disconnect power su pply.
4. Grasp the dead end rope anchor and pull down
until Monitor adju8ting screw is accessi ble.
Appl y Loctite 242 to adjusting IICrew at trip
plate and let dry.
NOTE: The Meteor Monito r is intended to a llow handling of rated loads. If. in the case o f
some high speed hoists. th e above procedu re
prevents lifting a r ated capacity load. the
Monitor should be readjusted to perm it han.
dling th e rated load.
•
at a n angle. These edges should be smoothed
and rounded.
h) Inspect trolley trackwheels for external wear
on the tread and nange, and fo r wear on
internal bearing surraces as evidenced by a
looseness on the stud.
i) Inspect the complete unit for wear or damage
to adjacent pa rts, corrosion. loose fastenings,
bent or cracked covers or housings. damaged
wires or insulation, loose or dirty connections.
j) Inspect collector shoes for wear. Badly worn
parts should be replaced.
TESTI NG:
Prior to initial usc, all altered or repaired
hoists or used hoists that have lIot been operated
for the previous 12 mo nths shall be tested by the
user for proper operation. Test the unit tirst in
the unloaded state and then with a light load of
50 pounds times the number of load lIupporting
parts of wire r ope to be su re it operates properly
and the brake holds the load when the control is
released; then test with a load of· 125 70 of rated
capacity.
In addition, hoists in which load sustaining
parts have been replaced shall be tested with ·
1 25 ~f
of rated capacity by or under the direction
of an appointed person and a written report prepared for record purposes.
After this test, the fun ction of the Monitor is
to be tested. If the Monitor permits lifting a load
in excclIS of 140 % of rated load it should be adjusted as described on page 12.
NOTE: For additional information on inspection
and testi ng, refer to Code 830.16 "Overhead
Hoists," obtainable from American National
Standards Institute, 1430 Broadway, New York,
N. Y. 10018 U.S.A.
· 1/ the Monitor prcvimts Ii/ ting 0/ (I. lo«d 0/
1257<> 0/ !"ateli caP(l.city, "educe load to rated
cfI/Xlcity.
HOOKS:
Hooks damaged from chemicals, defonnations
or cracks, or that have more than a 10 degiee
twist from the plane of the unbent hook or excessive opening or seat wea r must be replaced.
Any hook that is twisted or has excessive
throat opening indicates abuse or overloading of
the unit. Other load sustaining components of the
hoist should be inspected for damage.
Unit
Clpacity
HO'"
us<
"A"
Replace Hook When
,~.
LOWER
"h
,
"8" MIN .
t
Hoist Lubrication
GEARS
•
•
Check oil level in gear housing at leas t once a
month, maintaining it at the bottom of oil level
hole in gear housing cover.
Drain housing every 2-3 years and refill with
II good grade of SAE 80 or 90 gear lubricating
oil- 2 quarts are required.
•
BEARINGS
•
All bearings except the lower hook thrust bearings are pre-lubricated or are in nn oil bath
and need no lubrication. The lower hook thrust
bearing should be lubricated at least once a
month.
LIMIT SWITCH ASSEMB LY
•
WIRE ROPE
•
•
A small amount of lub ricant will greatly increase the life of hoisting rope, therefo re. the
rope should not be allowed to run dry.
Keep it clean and lubricate at regular intervals
with a commercial wi re rope lubricant or
SOOW oil. Under ordinary conditions. monthly
lubrication is satisfactory but under hot and
dirty conditions. it may be necessa ry to clean
the hoisting rope at least once a day and lubri_
cate it several times between cleanings.
Particular attention should be directed to lubrication of the rope where it passes around the
dead end spool as well liS that section which
passes over the sheaves.
•
Every six months remove the control housing
cover and oil the limit switch cam shaft, camll
and switch rollers using 3-in-l or light machine
oil.
If hoist is equipped with an adjustable screw
limit switch, oil the screw. bushings at each
end. gellr teeth and switch rollers.
11
SECTION C - MAINTENANCE
Inspection
To maintain cont inuOU8 Rnd satisfactory operation. a regular inspection procedure must be initi-
ated so that worn or damaged parts ean be replaced before they become unsafe. The intervals
of inspection must be determined by t he individ ual
application and a re based upon the type of service
to which the hoist will be sUbjected and the nature
of the cr iti cal componen ttl and the degree of their
exposure tc wear. deterioration or malfunction.
The inspection of hois ts is divided into two general
classificat ions designa ted 8S " frequent" and "periodic."
The type of 8erviee to wh ich the hoist is subjected can be classified as "Norm al." " Heavy," and
"Se"ere...
Normal service involves ope rating the hoist at
less than 85 7< of its rated capacity and nol more
than 10 lift cycles pe r hou r, except for isolated
instances.
Heav)' service involves ope rating the hoist a t
85 7< to 100 r: of r a ted capacity or in excess of 10
lift cycles per hou r as a regula r 8pedfied procedu re.
Severe sen'ice is normal or he avy ser vice cou·
pled with the possibility of abnorma l. unfor!ICCn
conditions.
Below is the recommended. minimum intervals
of insl)CCtion. When the unit is subjected t o ex tra
hea vy usage or dus ty, gri tty. moist . or other ad·
ver se atmosph eric cond itio ns. lIhorter time inter .
vals must be usigned. Duri ng the Periodi c Tfillpect ion. inspection must be made of a ll parts for unusual wear. corrosion effect. or damage. in addition
to those specifically mentioned.
Any defi ciencies noted ure to be corrected before th e hoist is put into service.
Periodic Inspection & Maintenance Procedure
CAUTION: The out board bearings s upporting th e
intermedi a te gea rs nr c located in gea r
hous ing co\'er . th erefore, it s hould be
care full y rem on~d .
It is s uggested. in ord er t o retai n t he
gears in gear hous ing, t ha t th e hois t
be ti pped sligh tly upwa rd or positi oned on end. th en ca refull y lift co\'er .
A s ma ll wedge should be i n~r1 ed
between hois t dru m a nd fra me to pre·
,'ent th e hoistin g rope f rom unreeling.
in case any of t he gears a r e remo,'ed
during or afte r co\'er r .-mol·a !.
Minimum Inspection Schedule
FREQUENT INSPECTION S:
These inspections nre usuall y visual examinations by t he operator or other desi gnated personnel and reco rds of such inspecti ons are not required. F or No r mal. Heavy a nd Severe Service.
the frequent inspections are to be performed dail y
or monthly and shall include the following items :
a) Brake for evidence of slippage - dail)'.
b) Limit s witchell for proper operation - daily
(refer to page 3) .
c) Inspect hoisti ng r ope for kinks. cru shed
strands. fra yed or broken wires and corrosion
- da ily (refe r to page 11 ).
d) Hooks for dam age. cra cks. twists. ell"cessive
ope nin g. 1:ltch engagement :md la tch operation
-dail y (refer to cha rt on page 11).
PERIODIC INSPECTIONS:
These inspections ar e visua l inspections of external condi t ions by a n a ppointed perso n and ree-
10
ord s of periodic inspections nre to be kept to
provide the basis for continuing evaluatio n of the
condition of the hoist. For Normal and HeaVY
Service, t he periodic inspections are to be performed yearly wit h the hoist in 1)lace. For Severe
Service. the periodic inspections nre to be performed quarterly.
Periodic Inspections a re to include those items
list ed un der frequent inspections as well as t he
following :
a) Ch eck upper limit switch (or operation as de·
lICribed on Page 3,
b) Ins pect cont acto r (s) and control station for
burnt or )litted contacts and loose or corroded
t erminals.
c) Inspect control station cord and power cables
for damaged wires or insulation .
d) Check oil level in gea r houlling as desc ribed on
Page 3.
e) Inspect electric brake friction linings and frietion lIu rfacell for wear. !!Coring or warpage.
Ch eck ai r ga p between armature an d field an d
if the gap exceed !! 0.045 inch adj u!!t a s de!!Cribed on Page 12.
n Inspect sheaves for wear _ a deepen ing and
narrowing of t he g roove. which causes pinching a nd severe abrasion of hoisting rope: spiral
ridges or flutes in bottom of groove wh ich
cause chating of the rope, T hill can be corrected
by machining th e s hea ve groove until the
rid ges a re removed using a 3/ 16 inch radi us
cutter. Replace sheave when groove diameter
h as been reduced to 51,:! inches.
g) Inspect hoisti ng rope drum for burrs or sbarp
edges between g rooves. caused by pulling loads
,
4. The control station used on two speed hoist is
similar to the single speed unit. except that
either of two delinite speeds may be selected
by the operator in both hoisting and lowering,
Each control when partially depressed provide~
stow speed and when fully depressed gives fast
speed. Partial release of control returns hoist
to slow speed. while full release allows hoist to
stop. Rated lifting speeds are shown on hoist
identification plate.
Slow speed is intended 8S a means of carefully
controlling or "spotting" the load. although the
hoist ma y be operated !\Olely at this speed if
de.~ired. It is not necessary to operate in the
slow SI>eed position as the hoist wi!! pick up a
CRlmeity load at fas t speed from a s tanding
start. In ot he r wo rds, i t is not necessary to
hesitate at the slow position when moving control from Stop to }o'ast position or vice versu.
5. If mate ria l being handled must be immersed
in water. pickling baths. any liquid. dusty or
loose solids. use a sling chain of ample length
so that the hook is always abo\'e the surface.
Bearings in the hook block are shielded only
ilgainst ordina ry atmospheric conditions.
Operating Instructions
HorST
I. Before picking up a load, check to see that the
hoist is directly overhead and that the hoisting
rope is property arranged in drum grooves. If
rope has !>een displaced. unwind it as far as
necessary and rewind cor rectly.
2. The hoist is designed to raise a load vertically
and should not be used for pulling at an angle.
When a pplyi ng a lond it s hould be directly
under hoist or t rolley. Avoid off cente r load ing
of a ny kind. P ulling to the s ide causes tipping
of hoist, allows hoilJting rope to foul upper limit
switch and to chafe against hoist {rame. Pulling toward the end permits rope to climb out
of drum grooves and overwind at one end,
causing severe chafing and wear to the rope.
Trolley mounted hoists may jump suddenly
along runway beam if the load is not directly
beneath hoist when slac k is taken up.
3. Take up a slack rope carefully and start load
easily to a\'oid .!hock and jerking of hoist ropes.
If there is any evidence of o\'erloading, immediately lower the load and l"1!move the e)[ceu load.
4. Do not allow the load to swing while hoisting
as rope will not wind properly on d r um.
5. When hook is lowered the fu!! length of its
rated lift, there are at least 2 wraps of rope
remaining on drum. The hook must not be
lowered beyond this point unless load is re-
moved. Continued operation with lowering control depressed after hook reaches the lowest
position causes hook to raise by winding the
rope onto re\'erse side of dru m. Se\'ere damage
to r011e occurs by chafing again!!t hoist frame;
UP IIeI' limit switch will be inoperative and will
cause breaking of hoisting rope or burning out
of motor when the hook block reache!! it. The
rope must a lways wind on a nd ofT dr um on the
side nearest hoist motor_ ne"e r on t he outs ide.
HOIST WITH PLAtN TROLLEY
This unit should be mO\'ed by pushing on the
.!uspended load or by pulling the empty hook.
The pendant chain support ing control station
!lhould not be used for this purpose.
HOIST WtTH GEARED TROLLEY
This unit should be moved by means of the
llendant hand chain. Pull on the chain filrthest
from end toward which the unit is to t ravel.
HOtST WITH MOTOR DRtVEN TROLLEY
!h',"lld be moved by operating
marked . FORWARD and
control station. Unless altered
by the erector. depre ssi ng . FO R WA R D
control wi!! move hoist toward gear housing
end. Anticipate the stopping point and allow
trolley to coast to a smooth s top. Reversing or
"plugging" to stop trolley cau!!es overheatinlt
of motor and swaying of load.
Safety Procedures
1. When preparing to lift a load. be su re that the
attachments to the hook are firmly seated in
hook saddle. Avoid off center 10Hding of any
kind, especially loading on the point of hook.
2. When lifting. raise the load only enough to
clear the floor or support and check to be sure
brake will hold the load and that the attachmen t.! to hook and load are firmly seated.
Continue lift only after you are a8.!u red the
1000d is free of all obstru ctions.
3. Do not load hoist beyond the rated capacity
shown on hoist identification plate and on lower
hook block. Overload can cause immediate
4.
5.
6.
7.
failure of some load carrying part or create a
defect causing future failure at less than rated
capacity. When in doubt, use the next large r
capacity of eM Meteor Hoist.
1)0 not use this or any other overhead materials
handling equipment for lifting persons.
Stand clear of all loads and avoid moving a
load over the head.! of other personne\. Warn
personnel of you r intention to move a load in
their a rea.
Do not leave the load .!uspended in the air
unattended.
Permit only qualified per!lOnnel to operate unit.
9
" .,...., ..,... . , -+-- .
CAUTION : Trolley beam should a lways be electrically grounded. Be SUfe that there is good eleet r iea! contact between trolley beRm li nd t rackwheels. Avoid the ll!le of paint or other coati ngs on
the beam Hange which might (orm an insulation.
~
......•• . •••
- ,.,
•• •
"
•
••
.
.... " ~'O
~,
,•
.
•
,) ."0..,
tOl.ue 1011 LOCAT ION
·If conductor system includes transfer guides,
conductors are spaced a t 3" apart.
no" .. CA'
Y,·2 T• JI Sf
•
•
•
,•
,
•
,•
,
fiGURE 3
ALTE RN ATE METHODS OF WI RING
A flex ible conductor cable can be used to supply power to a t rolley mounted hoist. The length
of conductor should be a dequate (or the fuJI lra \'el
of t rolley. A tong conductor wi11 usuall y requi re a
clam p or strain relief (available from factory)
fitting at the hoist to pre\'ent k inking where the
condu ctor enters hoist. To keep the I lack conductor a way from the hoi~t and load, a messenger
wi re sy~tem , a coun te r weighted pulley or a spring
loaded cord reel (available from manufacturer )
can be used.
Adjustable Screw limit Switch
Th is optional equipment device. if factory
installed, ill lIet for nearly full hook travel. If it is
ne<:es~ary to change t he setti ng, in~tru ctions a re
given in Section C,
Where t h i~ de vice has been purchased separately, refe r to the instructions packed with device.
SECTION B - OPERATION
General
I. The e M Me teor Monito r is designed to protect
the Meteor Hoist from excessive, infrequent
overloads, T he device provides safety and protects against motor burnout.
CAUTiON: The Monitor is not intended to be
used as a scaling device for purposes of de termining what is an appropriate or safe load to
be lifted on a regular bl\sis.
A make-before-break relay is requi red in t he
high speed (60 FPM) Meteors.
The hoist will not operate in the hoist ing direction unlellS t he relay is energized. The relay,
however, does not affect lowering, and the hoist
will always lower. Pushing the "DOWN" control
energizell the relay and closes the relay-mai n_
tain circuit which kee ps the relay energized
afte r the "DOWN" control is released. Wh en a
hoist ove rload trips the Monitor switch, this
opens the relay-maintain circuit . making t he
hoist inopemble in the up direction. To restore
the circuit. the overload must be lowered to the
floor to reset the Monitor switch. P ushing t he
"DOWN" control to lower the load al80 resets
the relay, once t he Monitor switch reseh.
NOTE: it is only necessary to energize the
hoist in the down direction at initial "start-up"
8
or in t he event of nn overload. It is not necessary to depres~ the DOWN control each time
the hoist is opera ted.
2. The hoist is equipped with an upper limit switch
which opens the hoisting circuit. If hoist does
not halt promptly, a second limit switch momentarily reverses the motor to stop the hook
positively. This protection exists only when the
power supply to the motor is correctly phased.
On hoish eq ui pped with t he adjusta ble screw
limit s wi tch. this device au tomatically stops
hook at any predetermined point in either
hoisting or lowering and does not. in any way.
affect the opera tion of upper limit switch. As
above, t his protection exists only when the
powe r supply to motor is correctly phased.
3. The hoist motor normal1y is equi pllCd with a
thermal protec tion switch. which interrupts
the hoisting operation when motor reaches i19
maximum safe temperature. If this switch
opens while a load is suspended from hoist,
the hook may be lowered to remove t he load
while moto r is cooling off. The the rmal switch
ll.u tomatical1y rese ts when motor has cooled
suffi ciently to resume operation. in ap proximately one hour under normal conditions.
~
Motor Driven Trolleys
The moto r dri\'en trolley i~ shipped Ilssembled
Ilnd wired to the hoist. howe\·er. IIlmcing of trackwheels fo r the actual beam the unit is to be installed on must be checked.
Before operating trolley. lubricate trackwheel
gears wit h Texaco Nova tex No.2 or an equivalent
heavy cup g.rease or graphite grease.
T he motor d riven t rolley is wired in such a
way that when the hoist motor is operati ng
cor rectly, as described on Page 3, the trolley
will move toward the gear housing end when
t FORWARD cont rol is depressed.
With a capacity l()!\d on hoist. operate trolley
over the enti re length of runway or monorail
system to be sure that the adjustment a nd operation is satisfactory.
For Separllte Motor Driven Trolley ( tro lley
shi]l]X!d seplu'ately from hoist ). refer to the instructions ])acked with unit and the in formation
given abo\'e.
!MPORTANT ADJUSTMENT !NSTRUC TI ONS
METEOR
_ _
_
TROll£TS
.. .......... . _.
..., ,- "'.... "....""'. .""
...-,-, ... ,"'..,... "--,,
"
._.
..
_It,
.....
,..
....
.
..
.
.....
_
...
_
....
.
. " " -......... ',,.. .-",
,_
...
....
.
..
_
...
... -_.....
"...............
..
- "'...
.
..
_
.......
-"
'
__ ... toM,,, ..... to _ "_
,,
.. , - . •• t .... . . . ., , , . - .. . .. ,
..... to .... ' .. . . - . . "". ' ..
~
- Dimension applies to minimum ' ·beam and will
\'a ry with larger I-beams.
Enclosed Collectors and Wiring
Collectors can be installed on either side of a
plain trolley and on plain side of a geared or
motor driven t rolley.
Installation Procedu re 1. Make sure that power supply to condu ctor
system is shut off.
2. Refer to Figure 3 to dete r mine the proper
mounting position for the collector bar and
bracket.
3. Attach the brackets by inserlinr the screws
into tapped holes in the side frames. Tighten
screws securely.
4. Place an insulator on collector bar .
5. Position the bar in the bracket and lock with
sct screws. Mount collectors on bar to match
conductor system.
G. Aga in refe r to Figu re 3: position the coHectors on the bar as shown.
7. Measure the length of power cable needed to
reac h the far thest collector. Allow for connecting the wire to the collector shunt screw
and cut off the cable.
S. Strip back the insulation as required and cut
off Green wire if no ground conductor is in.
stalled.
9. Attach wire~ to collector's shu nt termina1.
shun t te r minul screw is inter nal (refer to Fig.
2 Hnd Page ,10).
10. Check instnllatiOll to make su re that the collectors make proper contact t hroughout the
entire length of t rolley travel.
11. Energize conducto r system. Check for proper
direction of hook travel by following instr uc_
tions on page 3.
EncloHd Collector
SHUHT '[IIM'HA1. SCIIEW
FIGURE 2
7
Hook Suspension
For hook suspension hoists, the support!! for
wch hook must be capable of sustaining the hoist
plus II capadt)' load, due to the fad that the load
mo\'es horizontally 3.'1 it ill raised and lowered.
PARTS
0'
HORIZONTAL TRAVel Of LOWER
HOOK BLOCK
COFT
ROPE
2
•6
'"
""
'"
DI MENSION "A" IN INCHES
HIGH HOOK
LOW HOOK
4\oS
0,IV.
."
."
'"
•
""
- Mi nimum dimension for "A" is 3" when hook is
10 ft. from hoist.
Dimension "A" is measured from the center of
suspension bolt at control end, Hook is on center
when hoist is viewed from end.
All Trolleys
F or nil trolley sUPl>orted hoists, rail stops mu!'!1
be installed. T hese stops must not be l>OlIitio ned to
cxert. impact force on the hoillt hut should contact
the trolley side frames.
A cha rt on page 7 s hows the number of spacer
washe rs to be installed between trolley side
frames and hoist suspension lugs for the nominal
beam sizes indicated. It is suggested that t he beam
flange wid th be measu red and trollcy side frames
be tem l>o rar ily installed on hoist before installation to de termine the exact distribution of wash_
ers. T he distance between trackw heel flanges
should be 1/8 to 3/16 inch greater than the beam
flange width fo r str aight runway beams, an d 3/16
to 1/ 4 inch if runway system includes sharp
cu r ves, T he number of washers between side
frames and hoist lUg!! should be the same or differ
only by one washer, in order to keep the ho ist hook
cente red un de r runway beam. T he distribu t ion of
washers outside the trolley frames is unimportant
except that the total numbe r used must be suflicient to keep the slotted nuts and cotter pins in
engagement.
When installing hoist and trolley on beam,
tighten slotted nutll sn ugly so that the trolley
frames a re parallel and vertical. Do not o\'crtighte n.
The suspension bolts are made of heat treated
s teel fin d should not be replaced with ordinary
medium ca r bon steel bolts.
WAR NING: Deviation from CM washcr adjustment recomm cndations co uld cause the trolley to
fall from the beam, The trolley should be inspec ted
periodicall y to assure its continued safe Ollerntion.
Plain and Geared Trolleys
These trolleys ar e shipped sepa rately and
must be IlrOlle rly adjusted by the customer to fit
ru nway beam,
On a geared trolley. the hand chain wheel
should be installed on d r um side of hoiJlt. The
we ight of hoist motor will the n counterbalance
hand chain pull when the hoist is moved without
a load. Before operati ng troitey, lubricate t r ack_
wheel gea rs with T exaco No va tex No. 2 or an
equivalent heavy cup grease or graphite g rease.
If it is necessa ry to change the length of the hand
chain, lind the un welded link and Ollen it by
spread ing with a chisel or twist one end with a
wrench while holding the other end in a vise or
anothe r wrenc h. Remo\'e an eveN Number of links
(2.4. 6, etc,) 8l! necessar y to shorten the chain or
add an even number to lengthen it (in this latter
calle. another open link will be requ ired, which can
6
be made from a welded link by cutting through the
weld with a hacksaw ) . Make ce rta in that the
chain is not twisted - the n re-install and do.'IC
the open link.
With a capacity load on hoist. ope ra te trolley
o\'er the enti re length of runway or mono rail ~ys­
tem to be su re that the adjustme nt and oper ati on
is sat isfactory.
On the 5-ton unit. the t wo sus pension bolt.,
supplied with trolley fit the end holes of side
frames . Cente r hole is for shea\'e housing sUllport
pin, wh ich is sup plied with ho ist. Slide the pin
until slot at the one end ill just outside side frame .
Lock pin in position by placing the keeller pla te in
slot and secu r ing it in posit ion with screw.
The JluslloCnsion bolts are made of heat treated
steel and should not be replaced with ordin ar y
med ium ca rbon steel bolts.
....--...
Lug Suspension
For lug suspension hoists. it is suggested that the unit be installed on suppor ts of the following design
and spacing.
'- .,
'
----------
•
,
£:. lOll2t TO
.t. ON !5 TON UNITS A SHEAVE MOUSING PIN IS
LOCATED HALF WAY BETWEEN THESE: 8OLTS •
., ON !5 TON UNITS 1liE SUPPORTS
MUST BE' OC,ATE D ON OUTSIDE
OF WGS.
If supports are to be located at A. remove a
group of washers equal to thickness T .
If supports are to be located at B. keep all
washe rs on the outside of hoist lugs and put
spacers inside to keep hoist frOm shifti ng sideways. Spacers may be made from standard one
inch pipe.
Both suspension members must be on the in_
side of hoist lugs. as at B. or both on the outside
as at A. FOr proper balance and stress d istr ibution. keep both A dimensions equ al for outside
suspension lUld both d imensions B e(lual for inside
suspension.
T he sus]lension bolts furnished with hoist are
heat treated alloy steel and dimensions gi\'en in
the above diagram are ba.o.ed on the use of the~e
bolts. If other suspension bolt~ are UMld. the.'\('
dimensions will no longer apply and the su pport!'
must be designed to avoid excessi\'e bending
stresses.
Dimenlliolls Wand T gi\'en for the SUI)llOrt.;;
are calculated for ordinary medium carbon steet
with a snfety factor of five. E ach s uppor t is designed for the hoist plu~ a callacit.\' load.
T he one_half inch dimension fo r suspenlliOll
member.~ on the outside of hoist m\l~t )1<' held in
order to permit remo\'nl of th e cO\,l!r on moto r
side of hoist.
5
All Hoists (Cont'd)
SHORTENING THE CONTROL COR D
If it iii necessa ry to shorten the cord, it is reethat a "Cont rol Cord Alteration K it"
be obtained f rom the manufactu rer.
kit
all of the necessary solde r less
terminals. insulators, clam p. a nd instructi
shortening the cord.
Uowever. if the proper terminals, etc. a r c
available the cor d can be shor tened by using the
prellared end of the cord as a guide. After the
ho ist operates proper ly, disconnect the power supply. open control station. di5Conned all wi r es Il:nd
ground cable. Remo\'c cord from control station
and slide the grommet and retaine r up on the cord.
';':';r:"
Cut off the cord fo r a length equal to the distance the station is to be raised, measu r ing f rom
the end of the longest wire. Using the cut off piece
of cord as a guide, strip outer insulation jacket
and shorten individual wires (except g reen wi re)
to the lengths previously used. Strip insulation
f rom each wire for the distance required for the
allpr opr illte terminal,
On the green wi r e, cut and str ip insulation for
2-5/16" from the end of the insulation jacket.
Slide clamp slee\'e onto ground cable and form a
tight loop liS shown in figure 1. Crimp sleeve to
secure loop. Insert contr ol cord into control station and attach ground cable and reconnect wires
per wiring diagram. Reposition grommet and secure slime with retainer ring.
Reassemble cover and gasket a nd operate hoist ~
and / or trolley in both directions to check cor rectness of eledr ical connections.
...",~~~ t- I V ~2 M _,"
GR OUNO CAB LE
DI AM ETE R OF LOOP APPROX . 1/4 "
:=
F========O
CL AM P SLEEVE
2 5/16"
_____.+_
FIGURE 1
SHORTENING CONTROL CORD
•
LENGTH BE FORE
MAKING LOO P
I
FOREWORD (Cont'd)
study i~ essential to sa fe riggi ng operations. For
rigging information. we re<:ommend consulting a
standard te;(tbook on the subject.
The postage paid guarantee card included in
the elwelope with this manual should be filled in
and mailed to the Cactory at once for recording
and valida ting.
We assume no responsibility for unauthorized
repaiu.
Use of mate ria ls or replacement par b othe r
than eM manufacture may lead to dangeroull operation. Accordingly, C;\I cannot be responsible in
lIuch cases and the guarantee would be \·oid.
e M GUARANTEE
The Monitor is designed to protect t he Meteor
Hoist from excesai\'e. infrequent overloads. The
Monitor is not intended to be used as a scaling
device for purposes of determining what is an
appropriate or S<\fe load to be lifted on a regular
basis.
If any part pro\'es defective within one year
of shipment. we will replace the part at no charge,
F.O.B. our facto r y. prodded the part claimed defective is returned to our factory transportation
prepaid.
eM METEOR MONITOR
SECTION A - INSTALLATION
All Hoists
r
r
Before installing hoist. sec that current to be
used is same as that shown on hoist na me plate.
Inspect external wiring for broken leads or
damaged insulation which may have been caused
during shi pment or handling.
T he hoist should be connected to a branch ci r.
cui t which complies with the requirements of the
National Electrical Code.
The I·beam or other suspension system should
be permanently grOunded.
Four bosses or feet are provided to support the
hoist on the floor. These Ilroted the hoisti ng rope
and control station cord from chating or cuttinga l!!O can be used to hold a rope or chain sling in
place for liftillg the hoist.
After hoist is mounted on illS 8uspension sys·
tem. remo\'e Inrge plug in top of gear housing
and pour in the two l .quart cans of SAE 80 oil
furni shed with hoist. Check oille\'el by remo\'ing
small plug in gear housing co\·er. Oil level should
be in line with bottom of hole. Sec that the oil tiller
plug in top. the drain plug in bottom of housing
and the lel'el plug in cover lire tight.
Before OllE!rating hoist. remove shipping wedge
located between hoist drum and frame.
Since II three.phase electric hoist motor can
rot.ate in either direction, depending on the man·
ner in which it is connected to the power supply,
the direction of hook movement must be checked
during originnl installation and each time hois t is
mo\'ed to a new 100ltion. Serious damage can
result if hook is run to the uppe r or lower li mit of
travel with hook operating in a direction oppoaite
to that indicated by the control station. Therefore.
proceed as follows:
Make temporary connections to power supply.
Operate " UP control in control station mo.-
mentarily. If hook raises. con nections are cor·
recl and can be made per manent. If hook
l owe r.~, it is neces~ary to change d irection by
interchanging lhe RED lead-marked L2 and
the BLACK lead-mnrked 1.3 of hoist power
cable at power supply. Under no circumstance
should internal wi ring of control station be
changed to re\'erse hook direction. Wiring ill
inSllCCted nnd tested before lea\'ing the factory.
CAUTION; (GO FPM Units Only)
The hoillt will not operate in the hoisting
direction unlesa the relay i~ energi7.ed. The relay,
hOI\·e\·er. does not nffect lowering. a nd the hoist
will always lower. Push ing the "DOWN" control
energi7.es the relay and closes the relay-maintain
circuit which keeps the relay energized a fter the
"DOWN" button is released. Afte r relay is ener·
gi7.ed check power connection~ us.ing same pro.cedure all pre\'iously outlined.
NOTE: It ill only necessa ry to energi7.e the hois t
in the down direction at initial "lIta rt·up" or in the
e\'ent of an o\·erload. It is not necessary to de tlress
the DOW N control each time the hoist i.~ operated.
If hoisting rope hus. been displaced from drum
g rooves during shipment or handling. operate
lowering control until the rO\>C is unwound as far
as nece~5ary. Rewind cnreful y. allowing it to seat
properly in drum grooves.
Operate hoist over the full length of its rated
lift. fir st checking the upper limit switch for correcl operation. The hOisting ollE!ration should
automatically stol) when hook block contacts and
slightly raises the limit switch weight. If adjustment is nece!Ulary see Page 12. At low hook
position there should be at least 2 wraps of rope
remaining on d r um.
,
SAFETY CODES
" Each Meleor hoist is built In accordance with the specifica tion s contained
herein and at the time of manufact ure complies with our interpretation of
applicable sections 01 the Amer ican National Standard Institute Code 630. 16·
1973 " Overhead Hoists" , the National Electrical Code (AN SI C·I ) and the
Occupational Safety and Health Act- I970. Since OSHA states that the Na·
t ional Electrical Code applies to all electric hoists. installers are required
to provide cu rrent overload protection and ground ing in keeping wit h the
code. Users should check installation lor compliance with the application,
operat ion and maintenance requ irements of this law.
" The safety laws for elevators where the lilting of people are involved and for
dumbwaiters may speci fy cons truct ion details that are not necessarily in·
corporated in CM industrial hoists. We recommend the use of equipment that
meets state and national safety codes. Columbus McKi nnon Corporation can·
not be re sponsible for applica ti ons other than those for wh ich CM equipment
is recommended."
FOREWORD
Th is manual contains important information
to help ~'o u properly install, operate and maintain
you r Mctcor Hoist for maximum performance.
economy and safety,
Please s tudy its contents thoroughly before
putting your hoist into operation. By practicing
correct operating procedures a nd by carrying out
the recommended pre\'entati \'e maintenance suggestions, you will be assu red of long, dependable
and safe ser vice,
After you ha\'e completely familiar ized your2
self with the con tents of this manual, we recom·
me nd that you carefully file it for future reference,
The informntion herein is directed to the
proper use, care and maintenance of the Meteor
Hoist and does not comprise a handbook on the
broad subject of riggi ng.
A word about r igging, Rigging can be defined
as the process of lifting and moving hea \'y loads
us ing hoist., and other mechanical equipment.
Skill acquired th rough specia lized experience and
Current Collector Mounting for Meteor Trolleys
Bar. Copp. r Wire Condudor SYlt. m
Shoe Con. dor
Wh.1'I Con.dor
AnACH HOI $T !'OW!! COft! TO COuteIO. SHUNT KlEW
SURFACE
or
CONDUCTOR
,
,, s
,-+-. -
--I
,,
T
1
,
COLLECTOR SYSTEM
I-e ..
DIMENSION
SHOE
WHEEL
,
•3 10
•3 10
u
1'10
3
S
1
1
GROUND CONDUCTOR
(I F INS TALLE D)
COL LECTOR lOCU IOH
CAUTI ON,
Trolley bltOm Ihoul d olworl be .I.dricoll, grounded. a. lur. that Ih... is g ood
. Ie drical conlo" betw •• n Iroll., b. am and trackwh.. ',. Avo id the ule of point
or olh. r coolingl on th. bltOm flang. which might form an inwlolion.
Brack.t & lor Anong.."enl
nc o A
!lC. •
COWCTOR SYSTEM
I· IMS
L,i
151
SHOf
AMElI . STD.
!lC. C
•
•
7
I
WHEEl
YI . 2T
3.'
YI.2 T
A
-
A
•c
-
A
-
A
A
•
10
C
C
12
C
C
IS&Over
C
C
•
•
C
3. '
I
I
•
c
I
I
C
41