Coffing Hoists EC Series User manual

P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
Before installing hoist, fill in the information below.
Model Number
Serial No.
Purchase Date
Please provide Serial Number when ordering parts.
CAPACITIES:
1/4 TON
1/2 TON
1 TON
2 TON
3 TON
Follow all instructions and warnings for inspecting,
maintaining and operating this hoist.
The use of any hoist presents some risk of personal injury
or property damage. That risk is greatly increased if proper
instructions and warnings are not followed. Before using
this hoist, each operator should become thoroughly familiar
with all warnings, instructions and recommendations in this
manual. Retain this manual for future reference and use.
Forward this manual to the hoist operator. Failure to operate
equipment as directed in manual may cause injury.
Columbus McKinnon Corporation
205 Crosspoint Parkway
Getzville, NY 14068
ELECTRIC CHAIN
EC SERIES
OPERATING, MAINTENANCE
& PARTS MANUAL

2P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
COFFING HOIST PARTS AND SERVICES ARE AVAILABLE IN THE UNITED STATES AND IN CANADA
As a COFFING Hoist and Trolley user you are assured of reliable repair and parts services through a network of Master Parts Depots and
Service Centers that are strategically located in the United States and Canada. These facilities have been selected on the basis of their
demonstrated ability to handle all parts and repair requirements promptly and efciently. To quickly obtain the name of the Master Parts
Depot or Service Center located nearest you, call [phone]. Fax: [phone].
LAS PIEZAS Y REPARACIONES DE LOS POLIPASTOS DE COFFING
ESTÁN ASEGURADAS EN ESTADOS UNIDOS Y CANADÁ
Como usuario de un polipasto y carro de COFFING le aseguramos cualquier reparación o la disponibilidad de cualquier pieza de repuesto a
través de una red de almacenes de piezas de repuesto y centros de servicio situados estratégicamente en Estados Unidos y Canadá. Estas
instalaciones se han seleccionado en base a su capacidad demostrada en la reparación de equipos y suminstro de piezas de repuesto de
forma rápida y ecaz. Para obtener la dirección del almacén de piezas de repuesto o del centro de servicio más cercano, llame al teléfono
[phone]. Fax: [phone] (sólo en Estados Unidos y Canadá).
LE SERVICE DE RÉPARATION ET DE PIÈCES POUR PALANS COFFING
EST DISPONIBLE AUX ÉTATS-UNIS ET AU CANADA
Soyez assurés qu'en temps d'utilisateur de palan et treuil COFFING, d'un service de réparation et de pièces able par l'entremise d'un
réseau de Centres de service et de Dépôts de pièces maîtresses qui sont stratégiquement situés aux États-Unis et au Canada. Ces
établissements ont été sélectionnés sur une base de leur habileté démontrée à s'occuper promptement et efcacement des besoins de
réparation de pièces. Appelez le [phone], Fax: [phone] pour obtenir rapidement le nom du dépôt de pièces maîtresses ou du
centre de service situé le plus près.

3P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
Improper operation of a hoist can create a potentially
hazardous situation which, if not avoided, could result in
death or serious injury. To avoid such a potentially hazardous
situation, THE OPERATOR SHALL:
a. NOT operate a damaged, malfunctioning or unusually
performing hoist.
b. NOT operate the hoist until you have thoroughly read and
understood this Operating, Maintenance and Parts Manual.
c. NOT operate a hoist which has been modied without the
manufacturer’s approval or without certication that it is in
conformity with ANSI/AMSE B30 volumes.
d. NOT lift more than rated load for the hoist.
e. NOT use hoist with twisted, kinked, damaged, or worn load
chain.
f. NOT use the hoist to lift, support, or transport people.
g. NOT lift loads over people.
h. NOT operate a hoist unless all persons are and remain clear
of the supported load.
i. NOT operate unless load is centered under hoist.
j. NOT attempt to lengthen the load chain or repair damaged
load chain.
k. Protect the hoist’s load chain from weld splatter or other
damaging contaminants.
l. NOT operate hoist when it is restricted from forming a
straight line from hook to hook in the direction of loading.
m. NOT use load chain as a sling, or wrap chain around load.
n. NOT apply the load to the tip of the hook or to the hook
latch.
o. NOT apply load unless load chain is properly seated in the
chain sprocket(s).
p. NOT apply load if bearing prevents equal loading on all load
supporting chains.
q. NOT operate beyond the limits of the load chain travel.
r. NOT leave load supported by the hoist unattended unless
specic precautions have been taken.
s. NOT allow the load chain or hook to be used as an electrical
or welding ground.
t. NOT allow the load chain or hook to be touched by a live
welding electrode.
u. NOT remove or obscure the warnings on the hoist.
v. NOT operate a hoist on which the safety placards or decals
are missing or illegible.
w. NOT operate a hoist unless it has been securely attached to
a suitable support.
x. NOT operate a hoist unless load slings or other approved
single attachments are properly sized and seated in the
hook saddle.
y. Take up slack carefully - make sure load is balanced and
load holding action is secure before continuing.
z. Shut down a hoist that malfunctions or performs unusually
and report such malfunction.
aa. Make sure hoist limit switches function properly.
ab. Warn personnel of an approaching load.
Improper operation of a hoist can create a potentially
hazardous situation which, if not avoided, could result
in minor or moderate injury. To avoid such a potentially
hazardous situation, THE OPERATOR SHALL:
a. Maintain rm footing or be otherwise secured
when operating the hoist.
b. Check brake function by tensioning the hoist prior
to each lift operation.
c. Use hook latches. Latches are to retain slings, chains, etc.
under slack conditions only.
d. Make sure the hook latches are closed and not supporting
any parts of the load.
e. Make sure the load is free to move and will clear
all obstructions.
f. Avoid swinging the load or hook.
g. Make sure hook travel is in the same direction as shown
on the controls.
h. Inspect the hoist regularly, replace damaged or worn parts,
and keep appropriate records of maintenance.
i. Use CM Hoists recommended parts when repairing
the unit.
j. Lubricate load chain per hoist manufacturer’s
recommendations.
k. NOT use the hoist’s overload limiting clutch to measure
load.
l. NOT use limit switches as routine operating stops.
They are emergency devices only.
m. NOT allow your attention to be diverted from operating
the hoist.
n. NOT allow the hoist to be subjected to sharp contact with
other hoists, structures, or objects through misuse.
o. NOT adjust or repair the hoist unless qualied to perform
such adjustments or repairs.
SAFETY PRECAUTIONS
Each Electric Chain Hoist is built in accordance with the specications
contained herein and at the time of manufacture complies with
our interpretation of applicable sections of *American Society of
Mechanical Engineers Code (ASME) B30.16 “Overhead Hoists,” the
National Electrical Code (ANSI/NFPA 70) and the Occupational Safety
and Health Act (OSHA). Since OSHA states the National Electrical Code
applies to all electric hoists, installers are required to provide current
overload protection and grounding on the branch circuit section in
keeping with the code. Check each installation for compliance with the
application, operation and maintenance sections of these articles.
The safety laws for elevators, lifting of people and for dumbwaiters
specify construction details that are not incorporated into
the hoists. For such applications, refer to the requirements of
applicable state and local codes, and the American National
Safety Code for elevators, dumbwaiters, escalators and moving
walks (ASME A17.1). Columbus McKinnon Corporation cannot be
responsible for applications other than those for which COFFING
equipment is intended. DO NOT use for guided loads.
*Copies of this standard can be obtained from ASME Order Department,
22 Law Drive, PO Box 2300, Faireld, NJ 07007- 2300, U.S.A.,
www.asme.org, 800-843-2763.
THIS SYMBOL POINTS OUT IMPORTANT SAFETY
INSTRUCTIONS WHICH IF NOT FOLLOWED COULD
ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY
OF YOURSELF AND OTHERS. READ AND FOLLOW ALL
INSTRUCTIONS IN THIS MANUAL AND ANY PROVIDED
WITH THE EQUIPMENT BEFORE ATTEMPTING TO
OPERATE YOUR HOIST.

4P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
DO NOT PULL AT AN ANGLE. BE SURE HOIST AND LOAD ARE
IN A STRAIGHT LINE.
DO NOT USE LOAD CHAIN AS A SLING.
USE HOIST PROPERLY
Be sure hoist is solidly held in the uppermost part of the support
hook arc.
Be sure hoist and load are in a straight line.
Do not pull at an angle.
Be sure load is hooked securely. Do not tip load the hook. Do not
load hook latch. Hook latch is to prevent detachment of load under
slack chain conditions only.
Do not use load chain as a sling. Such usage damages the chain
and lower hook.
Do not operate with hoist head resting against any object. Lift the
load gently. Do not jerk it.
DO NOT LIFT PEOPLE OR LOADS OVER PEOPLE
LIFT PROPERLY
Do not lift co-workers with a
hoist.
Make sure everyone is clear of
the load when you lift.
Do not remove or obscure
operational warning notices.
MAINTAIN PROPERLY
CLEANING
Hoists should be kept clean and free of dust, dirt, moisture, etc.,
which will in any way affect the operation or safety of the equipment.
LUBRICATION
Chain should be properly lubricated.
AFTER REPAIRS
Carefully operate the hoist
before returning it to full service.
HOIST SAFETY IS UP TO YOU...
DO NOT LIFT MORE THAN RATED LOAD.
CHOOSE THE RIGHT HOIST FOR THE JOB...
Choose a hoist with the capacity for
the job. Know the capacities of your
hoists and the weight of your loads.
Then match them.
The application, the size and type
of load, the attachments to be used
and the period of use must also be
taken into consideration in selecting
the right hoist for the job.
Remember, the hoist was
designed to ease our burden and
carelessness not only endangers the
operator, but in many cases, a valuable load.
DO NOT OPERATE DAMAGED OR MALFUNCTIONING HOIST.
DO NOT OPERATE WITH TWISTED, KINKED, OR DAMAGED CHAIN.
INSPECT
All hoists should be visually inspected before
use, in addition to regular, periodic maintenance
inspections.
Inspect hoists for operations warning notices and
legibility.
Deciencies should be noted and brought to the attention of
supervisors. Be sure defective hoists are tagged and taken out of
service until repairs are made.
Under no circumstances should you operate a malfunctioning hoist.
Check for gouged, twisted,
distorted links and foreign material.
Do not operate hoists with twisted,
kinked, or damaged chain links.
Load chain should be properly
lubricated.
Hooks that are bent, worn, or whose
openings are enlarged beyond
normal throat opening should not
be used. If latch does not engage
throat opening of hook, hoist should
be taken out of service.
Chains should be checked for
deposits of foreign material which
may be carried into the hoist
mechanism.
Check brake for evidence of slippage under load.
VIOLATIONS OF ANY OF THE WARNINGS LISTED MAY RESULT IN SERIOUS PERSONAL INJURY TO THE OPERATOR
OR NEARBY PERSONNEL BY NATURE OF RELEASED LOAD OR BROKEN HOIST COMPONENTS.

5P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
FOREWORD
This manual contains important information to help you properly install, operate and maintain your hoist for maximum performance, economy
and safety.
Please study its contents thoroughly before putting your hoist into operation. By practicing correct operating procedures and by carrying out
the recommended preventive maintenance suggestions, you will experience long, dependable and safe service. After you have completely
familiarized yourself with the contents of this manual, we recommend that you carefully le it for future reference.
The information herein is directed to the proper use, care and maintenance of the hoist and does not comprise a handbook on the broad
subject of rigging.
Rigging can be dened as the process of lifting and moving heavy loads using hoists and other mechanical equipment. Skill acquired through
specialized experience and study is essential to safe rigging operations. For rigging information, we recommend consulting a standard
textbook on the subject.
TABLE OF CONTENTS
Master Parts Depots And Service Centers ........................................ 2
Safety Precautions ............................................................................. 3
Foreword ........................................................................................... 5
INTRODUCTION
General Information............................................................................ 6
Safety Standards................................................................................ 6
Hoist Construction and Features ....................................................... 6
Basic Hoist Data................................................................................. 6
Application Information ...................................................................... 6
Warranty ............................................................................................. 6
INSTALLATION
Safety Notes....................................................................................... 6
Hanging the Hoist............................................................................... 6
Power Supply Connection.................................................................. 7
Vent Plug ............................................................................................ 7
Chain Lubrication ............................................................................... 7
Testing ................................................................................................ 7
Trolley Installation............................................................................... 7
Chain Container Installation ............................................................... 9
OPERATION
General............................................................................................. 10
Safety Notes..................................................................................... 10
Handling the Load............................................................................ 10
Overload Limiting Protection............................................................ 10
INSPECTION
General............................................................................................. 11
Frequent Inspection ......................................................................... 11
Periodic Inspection........................................................................... 11
Load Brake Function Check............................................................. 13
Chain Inspection .............................................................................. 13
Hook Throat Opening....................................................................... 14
MAINTENANCE AND REPEAT
General............................................................................................. 15
Limit Switch Adjustment .................................................................. 15
Motor Brake Adjustment .................................................................. 15
Top Suspension Removal and Replacement ................................... 15
Chain Replacement.......................................................................... 16
Lubrication........................................................................................ 16
TROUBLESHOOTING
General............................................................................................. 18
WIRING
Wiring Diagrams............................................................................... 19
Voltage Conversion .......................................................................... 19
REPAIR PARTS
General............................................................................................. 24
How to Use....................................................................................... 24
Hoist Model Number and Serial Number ........................................ 24
Recommended Spare Parts ............................................................ 45
LIST OF TABLES
TABLE DESCRIPTION PAGE
1-1 Basic Hoist Data ................................................................ 6
2-1 Washer Chart..................................................................... 8
4-1 Maximum Allowable Hook
Hook Throat Opening ..................................................... 14
5-1 Recommended Lubrication Schedule ............................. 17
6-1 Troubleshooting ............................................................... 18
LIST OF ILLUSTRATIONS
FIG. DESCRIPTION PAGE
2-1 CTA Trolley ........................................................................ 7
2-2 Lug Mounted Plain Trolley ................................................ 9
2-3 Chain Container ................................................................ 9
4-1 Recommended Inspection and
Maintenance Check List ................................................. 12
4-2 Recommended Inspector’s Report ................................. 13
4-3 Load Brake Function ...................................................... 13
4-4 Link Wear ........................................................................ 13
5-1 Limit Switch Adjustment ................................................. 15
5-2 Motor Brake Adjustment.................................................. 15
5-3 Chaining Hoist ................................................................ 16
5-4 Chaining and Suspension Diagrams .............................. 17
7-1 115V, 230V - 3 Phase, 1-Speed Hoist ............................ 20
7-2 230V, 460V - 3 Phase, 1-Speed Hoist ............................ 21
7-3 208V, 380V 575V - 3 Phase, 1-Speed Hoist ................... 22
7-4 208V, 230V, 460V, 575V - 3 Phase,
2-Speed Hoist ................................................................. 23
8-1 Suspension Assemblies................................................... 25
8-2 Basic Hoist....................................................................... 26
8-3A Motor Parts (One Speed) ................................................ 28
8-3B Motor Parts (Two Speed) ................................................ 29
8-4A Parts List for Electrical Parts for
115/230V - 1-Phase Models............................................ 30
8-4B Parts List for Electrical Parts
for 3-Phase Models ......................................................... 31
8-5 Transmission.................................................................... 32
8-6 Chaining Parts ................................................................. 34
8-7A Push Button (Single Speed Hoists).................................. 35
8-7B Push Button (Two Speed Hoists)..................................... 36
8-8A Parts List for Limit Switch Assembly ............................... 37
8-8B Parts List for Long Lift Limit Switch Assembly................ 38
8-9 Motor Brake Parts............................................................ 39
8-10A 1/4 Ton & 1/2 Ton Models................................................ 41
8-10B 1 Ton Models ................................................................... 41
8-10C Double Chain Models ...................................................... 41
8-10D Triple Chain Models ......................................................... 41
8-11 Chain Container Assemblies
(1/4 Ton & 1/2 Ton Models) .............................................. 42
8-12 CTA Plain Trolley Assembly ............................................. 43
8-13 CTA Geared Trolley Assembly.......................................... 44

6P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
SECTION I INTRODUCTION
1-1. GENERAL INFORMATION
This manual provides information for the safe operation and
maintenance of Cofng® EC-1 Series Hoists. All persons operating
or maintaining these hoists should be familiar with the information
contained herein. Adherence to the precautions, procedures, and
maintenance practices described should ensure long reliable
operation. Suggestions for improvements to this manual are
solicited.
To safeguard against the possibility of personal injury or property
damage, follow the recommendations and instructions of this
manual. This manual contains important information for the correct
installation, operation, and maintenance of this equipment. All
persons involved in the installation, operation, and maintenance of
this equipment should be thoroughly familiar with the contents of this
manual. Keep this manual for reference and further use.
To avoid personal injury:
Do not use the equipment shown in this manual to lift, support,
or otherwise transport people, or to suspend unattended loads
over people.
1-2. SAFETY STANDARDS
All persons concerned with the installation, operation, inspection
and maintenance of these hoists are urged to read ASME B30.16.
That Standard contains valuable guidelines concerning practices
designed to minimize hazards associated with the use of overhead
hoisting equipment. ASME B30.16 also contains detailed procedures
for establishing hoist inspection and maintenance programs and can
be of signicant assistance in maintaining compliance with OSHA
regulations.
1-3. HOIST CONSTRUCTION AND FEATURES
Strong, lightweight aluminum alloy die castings provide a compact,
protective enclosure for the mechanical and electrical components
of Cofng EC-1 Series Hoists. Heat treated alloy steel gearing
operates in an oil bath to provide the most reliable lubrication and
effective heat dissipation .
EC-1 Series Hoists incorporate the following features:
a. Overload limiting clutch.
b. Completely independent mechanical and electrical brakes.
c. Adjustable limit switches.
d. Tough, nylon weather resistant pushbutton stations.
e. Steel strain cable inside pushbutton cord.
f. Transformer isolated, low-voltage pushbutton controls.
g. Quick voltage conversion on dual-voltage units.
TABLE 1-1. BASIC HOIST DATA
Model No. Rated Load
(lb.)
Lift Speed at Rated
Load (ft. per min.) Motor HP
EC-0516 500 16 1/4
EC-0532 500 32 1/2
EC-0564 500 64 1
EC-1009 1000 9 1/4
EC-1016 1000 16 1/2
EC-1032 1000 32 1
EC-2004 2000 4 1/4
EC-2008 2000 8 1/2
EC-2012 2000 12 1
EC-2016 2000 16 1
EC-4006 4000 6 1
EC-4008 4000 8 1
EC-6005 6000 5 1
1-4. BASIC HOIST DATA
The basic hoist models covered by this manual are listed in Table 1-1.
1-5. APPLICATION INFORMATION
This hoist is intended for general industrial use in the lifting and
transporting of freely suspended material loads within its rated
load. Prior to installation and operation, the user should review his
application for abnormal environmental or handling conditions and
to observe the applicable recommendations as follows:
a. Adverse Environmental Conditions. Do not use the hoist in
areas containing ammable vapors, liquids, gases or any
combustible dusts or bers. Refer to Article 500 of The National
Electric Code. Do not use this hoist in highly corrosive, abrasive
or wet environments. Do not use this hoist in applications
involving extended exposure to ambient temperatures below
-10°F or above 130°F.
b. Lifting of Hazardous Loads. This hoist is not recommended
for use in lifting or transporting hazardous loads or materials
which could cause widespread damage if dropped. The lifting
of Ioads which could explode or create chemical or radioactive
contamination if dropped requires fail-safe redundant
supporting devices which are not incorporated into this hoist.
c. Lifting of Guided Loads. This hoist must not be used in the
lifting of guided loads, including dumbwaiters and non-riding
elevators. Such applications require additional protective
devices which are not incorporated into this hoist. Refer to
your state and local regulations governing the requirements for
elevator and dumbwaiter installations.
1-6. WARRANTY
Every hoist is thoroughly inspected and tested prior to shipment
from the factory. Should any problems develop, return the complete
hoist prepaid to your nearest Cofng Authorized Warranty Repair
Station. If inspection reveals that the problem is caused by defective
workmanship or material, repairs will be made without charge and
the hoist will be returned, transportation prepaid.
This warranty does not apply where: (1) deterioration is caused by
normal wear, abuse, improper or inadequate power supply, eccentric
or side loading, overloading, chemical or abrasive actions, improper
maintenance or excessive heat; (2) problems resulted from repairs,
modications or alterations made by persons other than factory
or Cofng Authorized Warranty Repair Station personnel; (3) the
hoist has been abused or damaged as a result of an accident; (4)
repair parts or accessories other than those supplied by Cofng are
used on the hoist. Equipment and accessories not of the seller's
manufacture are warranted only to the extent that they are warranted
by the manufacturer. EXCEPT AS STATED HEREIN, COFFING
MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE.
SECTION II INSTALLATION
2-1. SAFETY NOTES
a. Inspect the hoist for any evidence of shipping damage
or loose parts.
b. The supporting structure and load attaching devices should
have a load rating at least equal to that of the hoist.
c. This hoist is not suitable for use in uncovered outdoor locations
or areas containing explosive dust, vapors or gases.
d. The installation area must provide safe operating conditions
for the operator, including sufcient room for the operator and
other personnel to stand clear of the load at all times.
e. In areas where slack chain hanging from the hoist may create
a hazard, use a chain container (see Figure 2-2).
2-2. HANGING THE HOIST
Hook mounted hoists can be used with a variety of trolleys or
stationary hangers. It is recommended that a hand-geared or
motorized trolley be used when the pulling effort required to move
the hoist exceeds 100 pounds or when the application requires
frequent movement of the hoist.

7P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
a. Make sure that the hook latch closes after hanging the hoist.
b. The standard top hook is restrained from rotation by a plate and
two screws. The hook can be made to swivel freely by removing
the plate, or can be rotated 90° and xed in that position.
c. See Figure 2-1 for instructions on adjusting lug- mounted plain
trolleys.
d. Refer to Cofng Motorized Trolley Operating and Maintenance
Instructions manual for motorized trolley installation
instructions.
2-3. POWER SUPPLY CONNECTION
a. Disconnect power before making connections.
b. Voltage supplied to the hoist should be within plus or minus
10% of the voltage specied for the hoist. Hoists are tagged at
the factory with a tag indicating the voltage for which the hoist
is wired. Standard single phase hoists are convertible from 115
to 230 volts. Standard single speed, three phase hoists are
convertible from 460 volts to 230 volts. See the Wiring section
(paragraph 7-1) for voltage conversion instructions.
c. National Electrical Code (ANSI C2) and local electrical codes
should be consulted and proper disconnects, branch circuit
protectors, and wiring provided.
d. Power cables furnished with the hoist have a green colored
ground wire which must be securely connected to the electrical
system ground.
e. When installing a three-phase hoist, make only temporary
connections at the power line. Push the "UP" button and observe
the direction of the hook. If it raises, the phasing is correct and
permanent connections may be made at the power line. If the load
block lowers when the "UP" button is pushed, release the button
immediately since the limit switches will not operate to protect
the hoist from over-travel. Reverse the red and black wires at the
power line connection to correct the hook direction.
Do not change connections in the hoist or the pushbutton
assembly.
2-4. VENT PLUG
A pressure relief plug (Item 24, Figure 8-2) is provided which will vent
excess pressure from the transmission housing.
2-5. CHAIN LUBRICATION
The hoist chain should be liberally oiled before placing the hoist into
operation. For lubrication instructions, see paragraph 5-6a.
2-6. TESTING
a. Before placing the hoist into operation, check for proper limit
switch operation. Push the "UP" button and verify that the
hook block stops at least 2 inches from the bottom of the hoist.
Run the hoist down to its lower limit. At least 12 links of chain
should remain on the slack end. If either switch is not correct,
adjust according to the procedure outlined in paragraph 5-2.
NOTE
The upper and lower limit switches are factory set to provide the
maximum allowable hook travel. This travel adjustment should not be
increased. However, the switches may be adjusted to stop the hook
sooner at either end of its travel.
b. Attach a light load to the hook and check the hoist for proper
operation. The load should stop without noticeable drift when
the pushbutton is released. Increase the load to near rated
load. The hoist should still lift the load without hesitation and
stop with no more than one inch drift.
2-7. TROLLEY INSTALLATION
For Motorized, Lug Mounted and Plain Trolley congurations refer to
manual included with the Trolley.
• Motorized Trolley - manual p/n ECMT680-7
• Lug Mounted Trolley - manual p/n CTA698-1
• Plain Trolley - manual p/n CTA698-1
CT-Series Trolleys can be mounted on American Standard I-beams
From 6 to 18 inches high. Adjustment for different beam dimensions
is accomplished with proper placement of spacer washers as
described in below paragraph 2-7.
a. I-Beam Adjustment - Adjustment for I-Beam sizes and
tolerances is accomplished by locating the spacer washers as
shown in Figure 2-1. Normal placement of washers is given in
Table 2-2. Refer to Table 2-1 for identication of part names
and numbers.
BEAM MANUFACTURING TOLERANCES ALLOW WIDE
VARIATIONS FROM HANDBOOK FLANGE WIDTHS, AND
SLIGHT CHANGES TO THE RECOMMENDED WASHER
DISTRIBUTION MAY BE NECESSARY TO SUIT SPECIFIC
INSTALLATIONS.
The particular beam on which your hoist is to be installed
should be measured and trolley spacer washers adjusted to
achieve a clearance of 3/32” to 1/8”.
b. Periodic Inspection - The trolley should be inspected
periodically for evidence of excess wear or overload. Parts
should be replaced as required.
c. Lubrication - Trolley wheels are equipped with sealed, lifetime
lubricated, precision ball bearings which should not require
lubrication for the normal service of the trolley.
See Figure 8-12 and 8-13 for assembly details.
COLUMBUS McKINNON
C O R P O R A T I O N
A
1
2
6
6
4
3
7
5555
NOTE: 3.332" FLANGE WIDTH BEAM SHOWN.
3
13
12
11
109
2
WHEEL
BEAM
DETAIL
A
8
Columbus McKinnon Corporation
Amherst, NY USA
NOTICE TO PERSONS RECEIVING THIS DRAWING AND/OR TECHNICAL INFORMATION
A
8
7
6
8
7
6 5
4
3
2
1
B
C
D
B
C
D
CTA PLAIN TROLLEY
1:8
CT-A PLAIN TROLLEY
Modeled:
Drawn:
Approved:
Design Authority:
Original project:
Original scale:
Format
B
Number:
Dimensional Units
INCH
Sheet
Third Angle Projection
Description:
1
1
-
-
--
ECN
--
Rev.
-
Description of change Date
-
-
By
-
-
-
-
-
-
Material:
Columbus McKinnon Corporation
Hoist & Rigging - Americas
Amherst, NY USA
Material No:
Standard:
Standard Dimensional
Tolerances Unless
Otherwise Specified
0" to 60" Over 60"
.X .020 .025
.XX .010 .015
.XXX .005 .010
Ang 0 30' 0 30'
Columbus McKinnon Corporation (CMCO) claims proprietary rights in the material disclosed hereon. This drawing and/or technical information is issued in confidence for engineering information only and may not be reproduced or used to manufacture anything shown or referred to hereon without direct permission from CMCO to the user. This drawing and/or technical information is loaned for mutual assistance and is subject to recall by CMCO at any time. This drawing and/or technical information is the property of CMCO.
FIGURE 2-1. CTA TROLLEY

8P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
STANDARD
BEAM
Size & Weight
Flange Width
“Location A
H4210
(Thin)”
Location B
H4209
(Thick)
Location C
H4209
(Thick)
Location D
H4209
(Thick)
Location E
H4210
(Thin)
Location F
H4209
(Thick)
6" x 12.5# 3.332 1 13 10 9 1 14
6" x 17.3# 3.565 2 12 11 10 0 13
7" x 15.3# 3.662 0 12 11 10 2 13
7" x 20.0# 3.860 1 11 12 11 1 12
8" x 18.4# 4.001 1 11 12 12 1 11
8" x 23.0# 4.171 1 10 13 12 1 11
10" x 25.4# 4.661 1 8 15 14 1 9
10" x 35.0# 4.944 1 7 16 15 1 8
12" x 31.8# 5.000 0 7 16 15 2 8
12" x 35.0# 5.078 1 7 16 16 1 7
12" x 40.8# 5.252 1 6 17 16 1 7
12" x 50.0# 5.477 1 5 18 17 1 6
15" x 42.9# 5.501 1 5 18 17 1 6
15" x 50.0# 5.640 1 5 18 18 1 5
18" x 54.7# 6.001 1 3 20 19 1 4
18" x 70.0# 6.251 2 2 21 20 0 3
20" x 66.0# 6.255 2 2 21 20 0 3
24" x 80.0# 7.000 1 0 23 23 1 0
WIDE FLANGE
BEAM
Size & Weight
Flange Width
Location A
H4210
(Thin)
Location B
H4209
(Thick)
Location C
H4209
(Thick)
Location D
H4209
(Thick)
Location E
H4210
(Thin)
Location F
H4209
(Thick)
5" x 16.0# 5.000 0 7 16 15 2 8
5" x 19.0# 5.030 1 7 16 16 1 7
6" x 9.0# 3.940 1 11 12 12 1 11
6" x 12.0# 4.000 2 10 13 12 0 11
6" x 15.0# 5.990 1 3 20 19 1 4
6" x 16.0# 4.030 2 10 13 12 0 11
6" x 20.0# 6.020 2 3 20 20 0 3
6" x 25.0# 6.080 1 3 20 20 1 3
8" x 10.0# 3.940 1 11 12 12 1 11
8" x 13.0# 4.000 2 10 13 12 0 11
8" x 15.0# 4.015 2 10 13 12 0 11
8" x 18.0# 5.250 2 6 17 17 0 6
8" x 21.0# 5.270 1 6 17 17 1 6
8" x 24.0# 6.495 1 1 22 21 1 2
8" x 28.0# 6.535 1 1 22 21 1 2
10" x 12.0# 3.960 1 11 12 12 1 11
10" x 15.0# 4.000 2 10 13 12 0 11
10" x 17.0# 4.010 2 10 13 12 0 11
10" x 19.0# 4.020 2 10 13 12 0 11
10" x 22.0# 5.750 2 4 19 19 0 4
10" x 26.0# 5.770 2 4 19 19 0 4
10" x 30.0# 5.810 1 4 19 19 1 4
12" x 14.0# 3.970 1 11 12 12 1 11
12" x 16.0# 3.990 2 10 13 12 0 11
12" x 19.0# 4.005 2 10 13 12 0 11
12" x 22.0# 4.030 2 10 13 12 0 11
12" x 26.0# 6.490 1 1 22 21 1 2
12" x 30.0# 6.520 1 1 22 21 1 2
12" x 35.0# 6.560 2 1 22 22 0 1
14" x 22.0# 5.000 1 7 16 16 1 7
14" x 26.0# 5.025 1 7 16 16 1 7
14" x 30.0# 6.730 0 1 22 22 2 1
14" x 34.0# 6.745 0 1 22 22 2 1
14" x 38.0# 6.770 1 0 23 22 1 1
16" x 26.0# 5.500 2 5 18 18 0 5
16" x 31.0# 5.525 0 5 18 17 2 6
16" x 36.0# 6.985 0 0 22 23 2 0
16" x 40.0# 6.995 0 0 22 23 2 0
18" x 35.0# 6.000 1 3 20 19 1 4
18" x 40.0# 6.015 2 3 20 20 0 3
18" x 46.0# 6.060 0 3 20 19 2 4
21" x 44.0# 6.500 1 1 22 21 1 2
21" x 50.0# 6.530 1 1 22 21 1 2
21" x 57.0# 6.555 2 1 22 22 0 1
24" x 55.0# 7.005 0 0 23 23 2 0
TABLE 2-1. WASHER CHART

9P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
2-8. CHAIN CONTAINER INSTALLATION
a. Operate hoist in “down” direction until it is stopped by the limit
switch. Disconnect the slack end of the chain from the hoist
by using a small screwdriver to slide the spring-load pin to the
left. At least 8 inches of chain should hang from the hoist. If
less than 8 inches of slack chain is present, readjust lower limit
switch using the procedures detailed in paragraph 5-2.
b. Slide the spring-loaded pin aside and slip the mounting arm
into the slot until the pin ts through the hole in the plate (see
Figure 2-2). Be sure pin passes completely through plate and
into the opposite housing.
c. Use the two hex washer head screws provided to fasten the
two remaining hanger chains into the notches on the lower
edges of the hoist housing.
d. Be sure the end of the chain is started into the container. Run
hoist up until the hook block is even with the bottom of the
chain container.
e. Reset upper limit switch at this position (see procedure,
paragraph 5-2) to prevent the possibility of raising a load into
the chain container.
5
Country Club Road
P.O. Box 779
Wadesboro, NC 28170 USA
TEL: [phone]
FAX: [phone]
Hex Head
Washer Screw
Slot For
Small Screwdriver
Mounting Arm
Spring Loaded Pin
Chain Container
CAUTION
Short edge of chain container
body must be mounted toward
hoist (as shown).
FIGURE 2-2. LUG-MOUNTED PLAIN TROLLEYS
5
Country Club Road
P.O. Box 779
Wadesboro, NC 28170 USA
TEL: [phone]
FAX: [phone]
Hex Head
Washer Screw
Slot For
Small Screwdriver
Mounting Arm
Spring Loaded Pin
Chain Container
CAUTION
Short edge of chain container
body must be mounted toward
hoist (as shown).
FIGURE 2-3. CHAIN CONTAINER

10 P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
SECTION III OPERATION
3-1. GENERAL
This section presents information concerning the proper operation
of the Cofng Electric Chain Hoist. It is not intended to serve as
a handbook on rigging. Rigging, the process of moving heavy
loads using mechanical devises, requires special knowledge and
equipment. For information on the safe use of slings and similar
rigging gear, users are urged to consult a textbook on rigging.
3-1. SAFETY NOTES
a. Inspect the hoist for any sign of loose, broken, or
malfunctioning parts (see Section IV). Any malfunctioning hoist
should be tagged as “out of order: and removed from service
until the defect is corrected.
b. Before starting the hoist, the operator should be certain that all
personnel are clear.
c. Do not lift more than the rated load of the hoist.
d. Do not lift people or loads over people.
e. Avoid jogging controls or quick reversals of suspended loads.
f. Do not leave a suspended load unattended.
g. The operator should have a clear view of the load anytime it is
moving and should be sure that the load does not contact
any obstructions.
h. Read ASME B30.16 Safety Standard for Overhead Hoists.
3-3. HANDLING THE LOAD
a. Align hoist directly over load. Avoid side pull.
b. The hoist chain should not be wrapped around the load. Use
proper slings.
c. Be sure there are no twists in the load chain as it enters the hoist.
This condition should be constantly checked on double or triple
chain hoists because it is possible for the load block to be
“capsized” or ipped over one or more times, putting twist in
the chain. The presence of twist may not be obvious when the
hook block is in the lowered position but can cause serious chain
binding when the hook block is in its lly raised position.
d. Bring the hook into engagement with the load and make
sure it is well seated before proceeding to lift the load. On
multiple reeved hoists, be sure that the load is equalized on all
supporting chains.
e. Lift the load just clear of its supports and stop the hoist to
check for proper brake operation.
f. Avoid letting the hook or load swing excessively while moving a
trolley suspended hoist.
3-4. OVERLOAD LIMITING PROTECTION
This hoist is equipped with a factory-calibrated overload limiting
clutch. While the overload limiting clutch will protect the hoist from
damaging overloads, it will not ensure that a load is within the rated
capacity of the hoist. If the load exceeds the lifting capability of the
overload clutch, the hoist will not lift the load, but the motor will
continue to run as long as the “UP” button is pressed. Repeated
attempts to lift an excessive load will overheat the overload clutch
and cause permanent damage to the clutch.
The overload limiting clutch is an emergency protective device
and should not be used to measure the maximum load to be
lifted, or to sense the overload imposed by a constrained load.
While the overload limiting clutch will protect the hoist from
damaging overloads, it will not ensure that a load is within the
rated capacity of the hoist.

11 P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
SECTION IV INSPECTION
4-1. GENERAL
A scheduled inspection routine should be established for this hoist
based upon severity of use and environmental conditions. Some
inspections should be made frequently (daily to monthly) and others
periodically (monthly to yearly). It is suggested that an Inspection
and Maintenance Check List and an Inspector’s Report similar to
those shown in Figures 4-1 and 4-2 be used and led for reference.
All inspections should be made by a designated inspector. Special
inspections should be made after any signicant repairs or any
situation causing suspicion that the hoist may have been damaged.
Any hoist which has been removed from service for an extended
time should receive an inspection as described under Periodic
Inspections. ASME B30.16, Safety Standard for Overhead Hoists,
provides guidelines for hoist operation and inspection.
Any unsafe condition disclosed by any inspection must be
corrected before operation of the hoist is resumed.
4-2. FREQUENT INSPECTION
a. Check pushbutton station, brake and limit switches for proper
operation.
b. Check hooks for deformation, chemical damage or cracks.
Bent hooks or hooks damaged from chemicals, deformation,
cracks or having excessive throat opening (see paragraph 4-6)
should be replaced. Visible deformation of any hook may be
evidence of hoist abuse and overloading and indicates that a
thorough inspection of the complete hoist should be made.
c. Check that bottom hook swivels freely.
d. Check for missing, bent or otherwise damaged hook latches.
e. Check pushbutton and power cord for cuts or other damage.
f. Check load chain for adequate lubrication, as well as for signs
of excessive wear or stretch, cracked, damaged or twisted
links, corrosion or foreign substance.
4-3. PERIODIC INSPECTION
The exact period for the following inspections will depend on the
anticipated severity of hoist use. Determination of this period should
be based on the user’s experience. It is recommended that the user
begin with a monthly inspection and extend the periods to quarterly,
semiannually, or annually, based on his monthly inspection experience.
a. Clean hoist of any dirt or foreign material. Inspect bottom block
for accumulation of debris.
b. Perform all frequent inspections listed above.
c. Check for loose bolts, screws and nuts.
d. Check housings, load block, and other parts for wear,
corrosion, cracks or distortion. Check for abnormal openings
between housing sections.
e. Check motor brake for worn discs, oil contamination or
excessive clearance (see paragraph 5-3).
f. Check mechanical load brake function (see Figure 4-3).
g. Inspect the entire length of chain for gouges, nicks,
weld spatter, corrosion, distortion and wear. See CHAIN
INSPECTION, paragraph 4-5.
h. Inspect hooks and suspension parts for cracks, distortion or
extreme wear.
i. Inspect hooks for cracks using magnetic particle, dye penetrant
or other crack detecting methods.
j. Check limit switch set points and reset if necessary (see
paragraph 5-2).
k. Inspect all wiring for defective insulation, and check to be
sure all electrical connections are tight. Check motor reversing
contactor or relay for burned contacts.
l. Inspect for oil leaks. Check oil level.
m. Inspect for missing or illegible capacity or warning labels.
n. Inspect the supporting structure for continued ability to support
the hoist rated load.

12 P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
INSPECTION SCHEDULE AND MAINTENANCE REPORT
Type of Hoist Capacity (Tons)
Location Original Installation Date
Manufacturer Manufacturer’s Serial No.
Item
Frequency of Inspection
Possible Deficiencies OK Action RequiredFrequent Periodic
1-12 Months
Daily Monthly
Operating Controls • • • Any deficiency causing improper operation
Limit Switches • • •
•
Any deficiency causing improper operation
Pitting or deterioration
Disc (Motor) Brake • • •
•
Slippage or excessive wear
Glazing, contamination or excessive wear
Load Brake/ Mechanical • Failure to support load with disc brake open (see paragraph
4-3 f)
Hooks • •
•
•
Excessive throat opening, bent or twisted more than 10
degrees, damaged hook latch, wear, chemical damage, worn
hook bearing
Cracks (use dye penetrant, magnetic particle or other suitable
detection method)
Suspension Lug (if used)
•
•
Crack, excessive wear or other damage which may impair the
strength of the lug
Cracks (use dye penetrant, magnetic particle or other suitable
detection method)
Chain • • • Inadequate lubrication, excessive wear or stretch, cracked
damaged or twisted links, corrosion or foreign substance
Hook and Suspension
UigConnections •Cracks, bending, stripped threads, loose mounting screws
Pins, Bearings, Bushings, Shafts,
Couplings, Chain Guides •Excessive wear, corrosion, cracks, distortion
Nuts, Bolts, Rivets • Looseness, stripped and damaged threads, corrosion
Sheaves • Distortion, cracks and excessive wear. Buildup of foreign
substances
Housing, Load Block • Distortion, cracks and excessive wear, internal buildup of
foreign substances
Wiring and Terminals •Fraying, defective insulation
Contact Block, Magnetic Hoist
Control Switch, Other Electrical
Apparatus
•
Loose connections, burned or pitted contacts
Supporting Structure and Trolley
(if used) •Damage or wear which restricts ability to support imposed loads
Nameplates, Decals, Warning Labels •Missing, damaged or illegible
Transmission Lubricant • Low level, requires changing
Note: Refer to Maintenance and Inspection Sections of the Hoist Maintenance Manual for further details.
FREQUENCY OF INSPECTION:
Frequent - Indicates items requiring inspections daily to monthly Daily inspections may be performed by the operator if properly designated.
Periodic - Indicates items requiring inspection monthly to year y Inspections to be performed by or under the direction of a properly designated person. The exact period
of inspection will I depend on frequency and type of usage. Determination of this period will be based on the user’s experience. It is recommended that the user begin
with a monthly inspection and extend the periods to quarterly , semi-annually or annually based on his monthly experience
FIGURE 4-1. RECOMMENDED INSPECTION AND MAINTENANCE CHECK LIST

13 P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
INSPECTOR’S REPORT
Item Remarks (List Deficiencies and Recommended Action
Inspector’s Signature Date Inspected Approved By Date
FIGURE 4-2. RECOMMENDED INSPECTOR’S REPORT
4-4. LOAD BRAKE FUNCTION CHECK
To check the functioning of the mechanical load brake, proceed as
follows:
a. Attach a light load to the hoist and lift it several inches.
b. DISCONNECT HOIST FROM POWER SUPPLY and remove
short end brake cover (see Figure 8-2, Index No. 1)
c. Referring to Figure 4-3 and Figure 8-9, place screwdrivers No.1
and No.2 behind the plate and armature assembly and prepare
to pry against the transmission cover.
Note
Do not allow either screwdriver to contact brake disc
(see Figure 8-9, Index No. 7).
d. Carefully pry open motor brake (close solenoid gap) and observe
action of load. If the load accelerated, the mechanical load brake
is malfunctioning and must be repaired.
FIGURE 4-3. LOAD BRAKE FUNCTION
4-5 CHAIN INSPECTION
Chain inspection and lubrication are the more important aspects of
hoist maintenance. Removal of the chain from the hoist usually is not
necessary, but the chain should be run through the hoist enough that
every link is made visible for inspection.
a. Check each link for gouges, nicks, weld spatter, corrosion
and distortion.
b. Inspect each link for wear to the diameter of the link (see Figure
4-4). The nominal link diameter is 0.250 inch for chain on models
up to EC-2008 and 0.281 inch for models EC-2012 and above. If
the diameter of any link of 0.250 chain is worn to less than 0.200,
or the diameter of any link of 0.281 chain is less than 0.225, the
entire chain must be replaced.
FIGURE 4-4. LINK WEAR

14 P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
c. Chain Inspection
1. Check the chain for overall wear or stretch by selecting an
unworn, unstretched length of chain (at the slack end, for
example). Let the chain hang vertically with a light load (about
20 lbs.) on the chain to pull it taut. Use a large caliper to
measure the outside length of a convenient number of links
(about 12 inches). Measure the same number of links in a used
section of chain and calculate the percentage increase in length
of the worn chain.
2. If the length of the worn chain is more than 1.5% longer than
the unused chain (0.15” per inch of chain measured), then the
chain should be replaced. If the chain is worn less than 1.5%,
check it at several more places along its length. If any section
is worn more that 1.5%, the chain should be replaced.
d. The chain used in this hoist is accurately calibrated to operate
over the load sprocket and is very carefully heat treated for
maximum wear life and strength.
a. Do not weld or join hoist load chain.
b. Do not substitute another manufacturer’s chain in this hoist.
c. Damage or wear, beyond the stated limits, to any portion
of the chain requires that the entire length be replaced.
4-6. HOOK THROAT OPENING
Use Table 4-1 (below) to check hook throat opening.
TABLE 4-1. MAXIMUM ALLOWABLE HOOK THROAT OPENING
Hoist Load Rating (ton) Top Hook* (in.) Bottom Hook* (in.)
1 ton and under 1 1/4 1 1/8
2 ton 1 1/4 1 1/4
3 ton 1 9/16 1 9/16
*Figures given are for hook with latch. Add 1/16” if measured without hook latch

15 P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
SECTION V MAINTENANCE AND REPEAT
5-1. GENERAL
This section provides instruction for the most common routine
maintenance and adjustments. Major repairs are not within the
scope of this manual and should be referred to qualied service
facilities.
Safety Notice
Always remove load and disconnect hoist from power supply
before removing end covers or making repairs.
5-2. LIMIT SWITCH ADJUSMENT
Limit switches are provided to protect the hoist against damage
resulting from overtravel. For easy identication the upper (No. 2,
Figure 5-1) and lower (No. 3, Figure 5-1) limit switch adjusting nuts
are colored brass and zinc respectively. Each limit switch nut has ten
slots for adjustment, and the increment of adjustment is such that one
slot is equivalent to one link of chain travel. Care should be exercised
when adjusting either limit of travel. When a geared type limit switch is
furnished (long lift hoists) each adjustment is equal to 3 links of chain, or
30 links per revolution.
FIGURE 5-1. LIMIT SWITCH ADJUSTMENT
a. Adjusting Upper Limit (Brass Nut).
1. -Carefully raise the load block to a point where its top is 2”
or more from the hoist housing
2. Disconnect Power from the hoist and remove the short end
cover.
3. With a screwdriver, pry the spring guide plate (No. 1, Figure 5-1)
out of the slots in the colored limit switch nut (Nos. 2 and 3).
4. Turn the slotted brass nut (No. 2) toward its limit switch until
the switch clicks.
5. Release the spring guide plate and be sure it snaps back
into the slots in both nuts. Do not disturb the other slotted
nut if it has been previously set.
6. Replace the short end cover and reconnect power to the hoist.
7. Carefully raise the load block to its upper limit and observe
to see if it stops automatically at the desired point. Do
not allow the load block to run into the hoist housing. The
stopping point should be at least 2” below the hoist housing.
b. Adjusting Lower Limit (Zinc Nut)
1. Carefully lower the load block to a point where are least 12
links of slack chain hang down from the hoist housing.
2. Disconnect power from the hoist and remove the short end cover.
3. Adjust the zinc limit switch nut in the same manner
described above for the brass nut.
4. Replace the short end cover and reconnect power to the hoist.
5. Carefully lower the load block to its lower limit and observe
if it stops automatically at the desired level. Do not run chain
out of hoist or allow the slack end loop to become taut
against the hoist housing. At least 12 links of slack chain
should hang from the hoist.
Notice
If upper and lower limits are not operating satisfactorily,
repeat adjustment.
5-3. MOTOR BRAKE ADJUSTMENT
When properly adjusted, the multiple disc motor brake should
release promptly, operate without noticeable chatter, and stop the
load with no more than one inch of drift. If the hoist hesitates to lift
the load promptly when the pushbutton is depressed, the brake
should be adjusted per the following procedure.
a. Remove any load and disconnect power from hoist.
b. Remove the short end cover.
c. Referring to Figure 4-2, check the gap between armature (A)
and frame (B). the correct gap is .015”
d. Adjust the gap by turning the three lock nuts (F) and check with
a feeler gauge to be sure the gap is the same on both ends of
the solenoid.
FIGURE 5-2. MOTOR BRAKE ADJUSTMENT
Be sure the bottom of the armature does not touch the
splined adapter (H). As wear occurs, the original clearance
will be reduced. When this clearance is gone, THE BRAKE
DISCS MUST BE REPLACED.
e. Replace short end cover and reconnect power. If the brake
still chatters or is hesitant to release, refer to Section VI,
Troubleshooting.
5-4. TOP SUSPENSION REMOVAL
AND REPLACEMENT
A number of different top suspension assemblies are available to
accommodate different methods of hanging the hoist. If it should be
necessary to change top suspensions, proceed as follows:
a. Disconnect power from hoist and move the hoist to a safe working
area. If necessary, remove trolley and/or rotate suspension lug
to gain access to the socket head cap screws bolting the top
suspension yoke to the frame of the hoist.
b. Remove socket head screws (7/16” hex) and lift out the
suspension assembly.

16 P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
c. Install new suspension assembly and tighten socket head screws
to 75 ft-lbs torque.
Due to the off-center hood or lug hole, the suspension yoke
can be installed in the hoist in two different ways. With the hoist
level, the hook or lug must always be directly over the bottom
hook. Refer to Figure 5-4 for the proper yoke orientations for
single, double and triple chain hoists.
5-5. CHAIN REPLACEMENT
(OLD CHAIN STILL IN HOIST)
Refer to Figure 5-4, Chaining and Suspension Diagrams, and proceed
as follows:
a. Run the load block up to its top limit.
b. Disconnect power from the hoist and remove the short end cover.
c. With a screwdriver, push the spring guide plate (No. 1 Figure 5-1)
out of the slots in the limit switch nuts. Turn the brass slotted nut
(No. 2) back to about the center of the threaded screw. DO NOT
DISCONNECT THE WIRES FROM THE LIMIT SWITCHES.
FIGURE 5-3. CHAINING HOIST
d. Remove the load hook assembly from the old chain.
e. Make a “C” -shaped chain link by grinding through one side of
the end link of either the old or new chain. See Figure 5-3.
f. Hook the special “C” link to the end link of both chains to join
them. BE SURE the welds of the upstanding links of the new chain
are out away from the load sheave, and that proper orientation is
observed for attachment of the slack end in paragraph j. below.
Note
On triple chain hoists be sure all welds are aligned like the
welds on the old chain. It may be necessary to cut a link from
one or both ends of the chain to accomplish this.
g. With the end cover off, connect the hoist to power supply. Be sure
the green ground wire is properly grounded.
h. Carefully jog the “UP” button and run the joined pieces of chain
into the hoist until about 12 inches of the new chain comes out the
other side.
i. DISCONNECT POWER from the hoist.
j. Remove both the “C” link and the old chain from the slack end
pin (No. 28, Figure 8-6). This can be accomplished by depressing
the pin against the slack end spring (29) with a small screwdriver.
Remove the soft split link (23) from the old chain and attach the
link to the new chain. Depress the slack end pin and install the
split link observing proper orientation of the slack end of the chain
when secured. Avoid twists in the chain.
k. Adjust the lower limit switch per paragraph 5-2b.
l. Attach the bottom hook on single-chained hoists to the loose end
of the chain. On double-chained hoists, feed the loose end of the
chain through the load block (welds of the upstanding links will be
in towards the sheave) and fasten the end of the chain to the dead
end lug (No. 19 Figure 8-6).
Note
On triple chain hoists feed the loose ends of the chain
through the load block (welds away from sheave) around the
idler sheave in the hoist, and to the center of the load block.
m. Adjust the upper limit switch per paragraph 5-2.a.
n. Lubricate the new chain per paragraph 5-6.a and perform an
operation test of the hoist.
5-6 LUBRICATION
Proper lubrication is necessary for long, trouble-free hoist operation.
Refer to the following and to Table 5-1, Recommended Lubrication
Schedule, for lubrication points, type of lubricant, and frequency of
lubrication.
a. Load Chain – Clean the load chain with a non-acid and non-
caustic solvent and coat with SAE90 gear oil. Wipe excess
oil to prevent dripping. If the hoist is used in an atmosphere
containing abrasive dust, the chain should be cleaned and oiled
more frequently. Never apply grease to the chain.
b. Gearing – The gear case of the hoist is lled at assembly
with 46 oz. of a gear oil containing special friction reducing
additives.
The use of gear oils other than that recommended in Table
5-1 can cause brake chatter or can render the load brake
incapable of holding a load. A 48-oz. container of this oil is
available from COFFING. (Part No. 14J1).
1. To check the oil level, remove the 1/8” pipe plug from the
side of the hoist. With the hoist hanging level, transmission
oil should be even with the edge of the tapped plug hole.
2. The length of time between necessary oil changes will
depend on the severity of use the hoist receives. In general,
the oil should be changed every 12 months of normal
operation, or every 200 hours of actual hoist on-time.
Very heavy use or operation in high ambient temperatures
(over 105ºF) will require that oil be changed more often. An
indication of the need for oil replacement is load brake noise.
If an erratic tapping sound is made when lowering a load, the
oil should be changed.
c. Limit Switch Shaft – To prevent rust, the threaded limit switch
shaft should be given a light coat of grease or be sprayed with
a general purpose lubricant.
d. Idler Sheave Bearing (double and triple chain models only) –
Use a grease gun to put about a teaspoon of grease through
the grease tting in the bottom block shaft. Avoid pumping an
excessive amount of grease into the bottom block. On triple
chain hoists, use a grease gun to lubricate the idler sheave in
the hoist until fresh grease pumps from the end of the sheave
bearing.
e. Hook Bearing – Apply a few drops of SAE 30 oil around the
edge of the bearing.

17 P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
FIGURE 5-4. CHAINING AND SUSPENSION DIAGRAMS
TABLE 5-1. RECOMMENDED LUBRICATION SCHEDULE* MODEL EC ELECTRIC CHAIN HOIST
Figure and Index No. Component Type of Lubricant
Type of Service and Frequency of Lubrication
Heavy Normal Infrequent
Figure 8-6, No 7. Load Chain SAE 90 Gear Oil Daily Weekly Monthly
Figure 8-5 Gearing Coffing No. H-7813 transmission oil (Kit No. 14J1
contains quantity of oil sufficient for one oil change) At periodic inspection (See Figure 4-1, paragraph 5-6-2)
Figure 8-8A, No. 8;
Figure 8-8B, No. 7 Limit Switch Shaft “WD-40” or general purpose spray lubricant Monthly Yearly Yearly
Figure 8-10, No.
& No. Load Hook Bearing SAE 30 Gear or Motor Oil Weekly Monthly Yearly
Figure 8-1,
Nos. 1, 2, 3, 4, 5, 6 & 7
Top Hook or
Suspension Lug
Bearing Surfaces
SAE 30 Gear or Motor Oil Monthly Yearly Yearly
Figure 8-10C, No 11
Figure 8-10D, No.11
Idler Sheave Bearing
(Bushing)
NLGI #2 multi-purpose lithium base grease (Coffing
No. H-7610) At periodic inspection (See Figure 4-1)
Note: All bearings except hook and idler sheave bearings are pre-lubricated and sealed.
* This lubrication schedule is based on a hoist operating in normal environmental conditions. Hoists operating in adverse atmospheres containing excessive heat, corrosive fumes or vapors,
abrasive dust, etc. should be lubricated more frequently.
SINGLE CHAIN
POWER CORD
POWER CORD
POWER CORD
TRIPLE CHAIN
SIDE VIEW
END VIEW AS VIEWED
FROM END WITH
SHORT END COVER
END VIEW AS VIEWED
FROM END WITH
SHORT END COVER
END VIEW AS VIEWED
FROM END WITH
SHORT END COVER
NOTE POSITION
OF SUSPENSION
ASSEMBLY
DOUBLE CHAIN
TRIPLE CHAIN

18 P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
SECTION VI TROUBLESHOOTING
6-1. GENERAL
Use the following table as an aid to troubleshoot your hoist. If you do not have an experienced machinist-electrician
to do your repair work, we recommend that you send your hoist to an approved service center for repairs.
Problem Probable Cause Remedy
Hook Fails to
Stop at End of
Travel.
1. Limit switches not operating. 1. Check adjustment. See paragraph 5-2. Chock connections against wiring
diagram. Tighten loose connections or replace.
2. Limit switch nuts not moving on shaft. 2. Check for stripped threads or bent nut guide.
3. Magnetic reversing switch malfunction. 3. Remove electrical cover and check reversing switch.
Hoist Does Not
Respond to
Pushbutton.
1. Power failure in supply lines. 1. Check circuit breakers, switches and connections in power supply lines.
2. Wrong voltage or frequency. 2. Check voltage and frequency of power supply against the rating on the
nameplate of the hoist.
3. Improper connections in hoist or pushbutton station. 3. Check all connections at line connectors and on terminal block.
Check terminal block on dual voltage hoists [or proper voltage connections.
4. Motor brake does not release. 4. Check connections to the solenoid coil. Check for open or short circuit. Check
for proper adjustment. See paragraph 5-3.
5. Faulty magnetic hoist control switch. 5. Check coils for open or short circuit. Check all connections in control circuit.
Check for burned contacts. Replace as needed.
Hook Does Not
Stop Promptly.
1. Hoist overloaded. 1. Reduce load to within rated capacity of hoist.
2. Brake not holding. 2. Check motor brake adjustment (see paragraph 5-3) and load brake (Figure 4-3).
Hook Moves in
Wrong Direction.
1. Three-phase reversal. 1. Reverse any two wires (except the green ground wire) at the power source (see
paragraph 2-3).
2. Improper connections. 2. Check all connections against Wiring Diagram.
Hoist Hesitates
to lift When
Energized.
1. Hoist overloaded. 1. Reduce load to within rated capacity of hoist.
2. Motor brake requires adjustment. 2. Check motor brake adjustment (see paragraph 5-3)
3. Worn overload limiting clutch. 3. Replace clutch.
4. Low voltage. 4. Check voltage at hoist power cord with hoist starting. Voltage should be no less
than 90% of voltage specified on hoist.
5. Faulty SINPAC starting switch or start capacitor (single
phase hoists only).
5. Replace faulty component
Hook Raises But
Will Not Lower.
(Motor not
running)
1. “Down” circuit open. 1. Check circuit for loose connections. Check “Down” limit switch for malfunction.
2. Broken conductor in pushbutton cable. 2. Check each conductor in the cable. If one is broken, replace entire cable.
3. Faulty magnetic hoist control switch. 3. Check coils for open or short circuit. Check all connections in control circuit.
Check for burned contacts. Replace as needed.
Hook Raises But
Will Not Lower
When Motor Is
Operating.
Consult Factory or Authorized Duff-Norton Warranty Repair Station.
Hook Lowers But
Will Not Raise.
1. Hoist overloaded. 1. Reduce load to within rated capacity.
2. Low voltage. 2. Determine cause of low voltage and bring up to at least 10% of the voltage
specified on hoist. Line voltage should be measured while holding or lifting load.
3. “UP” circuit open. 3. Check circuit for loose connections. Check “UP” limit switch for malfunction.
4. Broken conductor in pushbutton cable. 4. Check each conductor in the cable. If one is broken, replace entire cable.
5. Faulty magnetic hoist control switch. 5. Check coils for open or short circuit. Check all connections in control circuit.
Check for burned Contacts. Replace as needed.
6. Faulty SINPAC Starting Switch or capacitor (single-phase
hoists only).
6. Replace faulty component.
7. Worn overload limiting clutch. 7. Replace clutch.

19 P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
SECTION VI TROUBLESHOOTING
Problem Probable Cause Remedy
Lack of Proper
Lifting Speed.
1. Hoist overloaded. 1. Reduce load to within rated capacity of hoist.
2. Motor brake is dragging. 2. Check for proper brake adjustment or other defects. Sec paragraph 5-3.
3. Low voltage. 3. Bring up voltage to plus or minus 10% of voltage specified on hoist. Line
voltage should be measured while hoist is lifting load.
4. Overload limiting clutch intermittently slipping. 4. Replace clutch,
Load Brake
“Noise.” (Erratic
tapping sounds
or squeals)
1 . Need transmission oil change, or improper lubricant has
been used.
1. Change transmission oil. Sec Table 5-1. Note: Hoist Warranty is void if
unapproved oil is used.
2. Load brake malfunctioning. 2. Check load brake operation. See Figure 4-3.
Motor Brake
Noise or Chatter.
(While starting
hoist)
1. Brake needs adjustment. 1. Adjust as per paragraph S-3.
2. Low voltage. 2. Check voltage at hoist power cord with hoist starting. Voltage should be no
less than 90% of the voltage specified. 115 volt hoists are particularly subject
to voltage drop problems due to their high current draw. Conversion to 230 volt
operation is suggested in extreme cases.
Motor Brake
“Buzz.” (Anytime
hoist is running)
1. Brake needs adjustment. 1. Adjust as per paragraph 5-3.
2. Broken shading coil on brake frame. 2. Replace shading coil or complete brake frame assembly.
* A more detailed explanation of electronics troubleshooting can be found with the CM interface cable kit. This procedure requires use of
extracted fault codes from the hoist memory, plus multimeter readings.
SECTION VII WIRING
SAFETY NOTES
Disconnect power from hoist before removing end covers.
7-1. WIRING DIAGRAMS
The wiring diagrams for standard hoist models are reproduced on
the following pages. In addition, every hoist should have a wiring
diagram located inside the long end cover.
7-2. VOLTAGE CONVERSION
Standard single phase units are convertible from 115 to 230 volts,
and standard single speed three phase units are convertible from
460 to 230 volts. Conversion to the alternate voltage can be
accomplished with the following procedure.
a. Be sure power is disconnected from hoist. Remove long end
cover.
b. SINGLE PHASE HOISTS (with SINPAC® switch): Transfer leads
per the appropriate terminal block schematic.
c. THREE PHASE HOISTS: Transfer leads per the appropriate
terminal block schematic.
Do not move any wires or make any changes to the wiring
except at the terminal block.
After converting voltage, check for proper phasing of three
phase units and check for proper limit switch operation.

20 P/N EC680-7 April 2017
Order # 5041558-0 & 5041679-0
FIGURE 7-1. 115V, 230V - 1 PHASE, 1-SPEED HOIST 981EE2100-000