Power Climber ASTRO E1500 User manual

WARNING:
Manufacturer: Power Climber 365 Upland Drive, Seattle, WA 98188 p/n 708052-1 Revision B
Phone [phone], Fax [phone] © 2014
• All persons operating this equipment must read and completely understand this manual
• All persons must be thoroughly trained in the use of the equipment, its operational and safety
features, and they must also be capable of carrying out the daily inspections.
• Only authorized persons shall operate the equipment.
• Any operation in violation of these instructions is at the operator’s own risk and may result in
serious injuries.
• Keep this manual with the hoist at all times.
• Use only spare parts and recommended steel wire rope from Power Climber®.
• It is the responsibility of the user of this hoist to determine that this hoist is suitable to be used in conjunction
with any other equipment. The user must also determine that this hoist and other components used will be in
strict conformity with the provisions of National, Provincial, and local ordinances and regulations.
OPERATING INSTRUCTIONS
ASTRO E1500 HOIST
PATENTS 419445, 4555091, 4611787
OTHER PATENTS PENDING
MEETS OR EXCEEDS
Canadian Standards Association
CAN/CSA -Z271
FOR USE IN CANADA ONLY

Page 2 of 35
Manufacturer
Power Climber
A Division of SafeWorks, LLC
365 Upland Drive
Seattle, WA 98188
Customer Support (North America)
Tel: [phone] (CLIMB)
or outside the U.S.: [phone]
Fax: [phone]
Email: [e-mail]
Web: www.PowerClimber.com
Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B

Page 3 of 35 Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
Table of Contents
1. SYMBOLS USED IN THIS MANUAL..................... 4
INTRODUCTION .......................................................... 5
2.4. Features................................................................ 5
3. INSTRUCTIONS........................................................ 7
3.1. General Specications ......................................... 7
3.2. Safety Summary .................................................. 8
3.3. Hazard Summary ............................................... 11
3.4. Wire Rope Specications................................... 12
3.5. Hoist Components ............................................. 15
3.6. Hoist Installation................................................ 16
4. SAFETY INSTRUCTIONS...................................... 18
4.1. Daily Tests ......................................................... 18
4.2. Daily Inspection................................................. 22
5. HOIST OPERATION................................................ 22
5.1. Cold Weather Operation .................................... 24
5.2. Dereeving........................................................... 24
5.3. Maintenance....................................................... 26
5.4. Troubleshooting................................................. 26
5.5. Labels................................................................. 30
6. CODE OF SAFE PRACTICES................................ 31

Page 4 of 35
1. SYMBOLS USED IN THIS MANUAL
Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
STOP
WARNING
CAUTION
ELECTRICAL
HAZARD
NOTE
INFORMATION
Stop action and follow the instructions before
continuing.
Warns against possible immediate serious
injury or death.
Warns against possible injury.
Warns against possible electrical shock hazard.
Must read this before performing any action
that follows.
Remember and take this into account.
SAFETY GEAR Safety gear that must be used while operating
this equipment.

INTRODUCTION
The ASTRO E1500 is used to raise, support and lower suspended scaffolds, work cages and
bosun chairs on, or in buildings and structures. If used for any other purpose, you must take all
necessary precautions to be sure that both design and operation are hazard free, and such use
conforms with manufacturer’s specications.
Before using the ASTRO E1500, learn the procedures described in this manual. Any operation
in violation of these instructions may result in bodily injury or death. The design and
manufacturing of the ASTRO E1500 must comply with CAN/CSA -Z271-98 standards.
It is the duty of the employer to provide this manual to each operator.
Power Climber reserves the right to make changes or modications to its hoist. Users of this
equipment must request current operating information prior to using this equipment. Call your
local Power Climber dealer.
This manual is included with each ASTRO E1500. Additional copies are available from your
Power Climber dealer. Keep a current copy of this manual with the hoist at all times.
Page 5 of 35 Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
Features of the ASTRO E1500 Hoist
Feature Function Benet
Operating Range:
220V, +/-10%
• Proven reliable performance
from 198 to 242 run volts
• Tested in 30 min. continuous
run tests
• Reduces service calls
• Extends electric component life
• Eliminates power-induced down
time
• Allows longer drops with yoked
hoists
• Saves time and money ($)
Load Sensitive
Traction
• Applies only the traction
needed to lift load, not full
1,500 lbs (6.67 kN) lifting
force on rope
• Greater tolerance of wire rope
condition
• Saves wear and tear on rope, extends
wire rope life
• Saves costly wire rope jam in eld

Page 6 of 35 Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
Features of the E1500 Hoist
Feature Function Benet
OPTIONAL Features of the E1500 Hoist
Features Function Benet
• Allows use of secondary
suspension wire rope for
required applications (double
deck, overhead protection,
some industrial applications)
or to eliminate independent
safety lines at very minor
additional cost
• Designed to mount into hoist
for maximum durability and
security
Built-in Secondary Wire
Rope
Voltage indicator
Built-in Overspeed Brake
Controlled Descent
Overload
(Optional) Top Limit
Switch
• Will trip at 1875 lbs (851 kg).
• Allows to be shop-set to
1,250 lbs (568 kg) on 1,500
lbs (681 kg) models
• Stops upward travel on
contact with an overhead
obstruction for special
applications
• More versatile hoist ready for
any application
• Eliminates possible loss /
damage because it is built-in,
rather than an added on
• Saves money because it is
less expensive than other
manufacturer’s.
• Reduces rigging material
and labor
• Easy installation
• Indicates voltage is owing to
unit
• Allows downward travel at a
controlled rate of speed in the
event of power loss
• Stops hoist in overspeed
condition
• Can’t be left behind in shop,
bypassed, or dismantled
• Easy visual inspection can
eliminate a service call
• Technician can diagnose
voltage problem by phone
• Ensures greater operator
safety
• Improved reliability
• Eliminates need for rescue
• Allows self-rescue of workers
and platforms
Remote Ready • Built-in pendant port accepts
plug-in remote control
• Compatible with 700786-xx
series remotes
• No need to drill and wire
remote into hoist
• Leaves hoist mounted
controls operable

Page 7 of 35 Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
GENERAL SPECIFICATIONS
Single Phase, 1.5 hp, 35 ft/min max.
Working Load Limit (WLL) 1,500 lbs. (681 kg)
Power Supply 220 VAC, 60 Hz, Single phase with automatic thermal
protection
Amperage at W.L.L. 10 Amps. 220V required at hoist.
Hoist Weight 136 lbs (62 kg)
Wire Rope Diameter 3/8” (9.53 mm)
Wire Rope Specication
6x19, IWRC (Independent Wire Rope Core), Right Regular
Lay, IPS (Improved Plow Steel) or EIPS (Extra Improved Plow
Steel), Preformed, Galvanized or Bright
User must verify that the wire rope meets or exceeds applicable
codes for breaking strength safety factor. Canadian standards
require 10:1, 3/8” (9.53 mm) wire rope with a min. breaking
strength of 15,000 lbs (66.7 kN) must be used when hoist is
used in Canada.
HAZARD SYMBOLS SUMMARY
Symbol Term Meaning
STOP Stop action and follow instructions before
continuing
WARNING Warns against possible immediate death or
serious injury
CAUTION Warns against possible injury
ELECTRICAL
HAZARD
Warns against possible electrical shock
hazard

Page 8 of 35 Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
HAZARD SYMBOLS SUMMARY (continued)
Symbol Term Meaning
READ Must read this before performing any action
that follows
NOTE / TIP Remember and take this into account
SAFETY GEAR Mandatory use of safety gear
SAFETY SUMMARY
Every year, workers on suspended scaffolds are injured, become disabled, or are killed
because of carelessness or because they did not understand how to correctly operate the
equipment. Do not become one of them. Know how to use this equipment and prevent
accidents.
NEVER operate equipment that you DO NOT understand. You may cause accidents,
resulting in injury or death to you or people around you.
This instruction manual is not all inclusive. It is impossible to anticipate every possible way
this equipment may be used, and all possible hazardous situations. It is very important that
you determine for yourself whether the equipment is safe. You must understand the operating
characteristics of this hoist. You must understand how the hoist will operate in your application.
You must be certain not to put yourself or others in danger, or cause damage to property or other
persons. Call your hoist supplier if you have any questions concerning this equipment.

Page 9 of 35 Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
SAFETY SUMMARY
(continued)
1. Read and understand this manual BEFORE using this equipment.
2. Use the Troubleshooting Guide in this manual to solve problems that may develop with the hoist.
Repairs must only be made by people trained and authorized to do so. NEVER maintain or repair the
equipment while the unit is suspended (above ground level).
3. Be careful when operating the hoist in freezing temperatures. Water or moisture may enter the hoist’s
overspeed brake or traction assembly. See Cold Weather Operating instructions in this manual.
4. Do not remove any parts from the hoist without replacing them. Do not change or substitute any
approved hoist parts for parts that do not meet manufacturer’s specications. Do not modify this
hoist without prior approval from Power Climber. Modications can put you in danger if not done
correctly. Making modications can also void any manufacturer’s warranty and make you liable for
any modications.
5. WARNING! Do not use suspended scaffolds unless:
a. You are wearing a personal fall arrest system that meets or exceeds your application
requirements.
b. You have personally made sure that
i. the roof support system is complete, properly assembled, counterweighted
(or otherwise anchored), tied off, and not overloaded; and
ii. hoists and platforms are not overloaded.
c. The wire rope is free of defects and is the size and type specied for the hoist.
d. Guardrails and toe boards are properly installed.
e. The main suspension wire rope is vertical.
Setup and use must comply with Power Climber instructions, and local codes.
6. Do not reset the overspeed brake until you have rst read and completely understood the
Troubleshooting Guidelines in this manual.
7. Do not use visibly worn, kinked, bird-caged, undersized, or damaged wire rope. Protect wire
rope from sharp or abrasive edges of building. Do not use wire rope that has been exposed to re,
excessive wear, corrosive atmosphere, chemicals, passage of electric current, or temperatures above
200 ° F.
8. Inspect the wire rope before rigging. Handle, inspect, and maintain wire rope carefully during and
after each job. Lubricate the wire rope according to the manufacturer’s recommendations.

Page 10 of 35 Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
SAFETY SUMMARY
(continued)
9. When welding from a suspended scaffold, provide proper electrical grounding for this hoist.
a. Assure platform is grounded to the structure.
b. Insulate wire rope 4 feet above and below the platform.
c. Insulate wire rope at suspension point and assure that the wire rope cannot contact the
structure along its entire length, including the tail line.
d. Cover the hoist with an insulating material.
11. Never operate an electric hoist in an explosive atmosphere such as a renery, chemical plant, grain
elevator, distilleries, ship or silo interiors, mines, around coal handling equipment, or around
explosive organic vapors or dust.
12. Never use hoists and aluminum platforms around caustic materials, acids, or acid fumes. Use hoist
covers when corrosive materials are present.
13. Maintain clearances and make sure no obstructions interfere with vertical travel.
14. Avoid power lines. Make sure the platform or hand tools cannot swing or be blown within a
minimum of 10 feet of a power line. Check your local codes for minimum distances. Never, under
any circumstances, rig a platform above electrical power lines.
15. Push the operating switch by hand only. Do not use foreign objects to operate the hoist.
16. When not in use, store hoist and stage to protect from unauthorized use. Cover the hoist if possible.
Always unplug power cord when not in use and equipment is not attended.
17. Do not allow anyone under suspended equipment. If necessary, provide protection below the
suspended equipment to prevent injury to people from falling objects. Use lanyards to secure
tools and materials from falling on personnel below.
18. Use approved personnel harnesses, lanyards, rope grabs, and independent lifelines at all times.
Attach the lifelines to a structural member of the building or structure, never to part of the rigging
unless specically designed for this purpose.
19. Comply with all local, provincial and federal safety codes and equipment instructions.
20. Only authorized and properly trained personnel shall operate this hoist. Each operator must
determine his own tness to operate this hoist. Consult your doctor if you are in doubt. Each
operator must not be under the inuence of alcohol or drugs.
21. If you hear any strange noises or if the hoist does not appear to work normally, stop using it
immediately. Do not continue to use the equipment until it is repaired.

Page 11 of 35 Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
HAZARD SUMMARY
WARNING
If the hoist is suspended in the air and the motor runs but the wire rope does not move
through the hoist, STOP the hoist immediately! Damaged wire rope may be jammed
inside the hoist. Any attempt to move the hoist up or down could damage the equipment
or cause injury or death.
There are many hazards when working on a suspended scaffold. The following are common
hazards. The list is not complete. It is provided to increase safety awareness on the job site.
MECHANICAL HAZARDS
• Crushing between the platform and the building or structure.
• Cutting or severing between moving machine parts.
• Loss of rigging stability because of one or more of the following:
• Insufcient counterweight or counterweights not properly xed
• Inadequate mechanical strength
• Increase in vertical load on suspension wire because the platform encounters an
obstacle, the platform overloads, or the suspension wire rope breaks
• Platform catches on overhang when going up
• Falling
• from the platform when working
• by using a wire rope that is too short
• if the platform is not strong enough for the weight and breaks
• if wire rope or platform interconnections fail
• rigging failure can cause falling
• Idling due to loss of traction
• Jamming due to damaged wire rope

Page 12 of 35 Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
ELECTRICAL HAZARDS
• Failure of the electrical supply may delay travel of the platform
• Control system failure can cause unwanted movement of the platform
• Improper power supply (voltage or frequency) may damage the hoist
ENVIRONMENTAL HAZARDS
• Consider and prepare for the effects of climate. (Heat/Cold/Ice/Wind)
• Sandblasting and acid wash procedures may introduce special concerns. They may
affect the immediate health of an operator and may pose serious risks to the hoist and
other equipment being used.
HAZARD PREVENTION
WIRE ROPE
• All electrical connections must be locked and supported by strain relief devices.
• Make sure the electrical cord and wire rope are long enough to allow full travel of the
suspended equipment.
GENERAL SPECIFICATIONS
Wire Rope Diameter 3/8” (9.5 mm)
Wire Rope Specication
6x19, IWRC (Independent Wire Rope Core), Right Regular Lay,
IPS (Improved Plow Steel) or EIPS (Extra Improved Plow Steel),
Preformed, Galvanized or Bright
User must verify that the wire rope meets or exceeds applicable
codes for breaking strength safety factor. Canadian standards
require 10:1, 3/8” (9.53 mm) wire rope with a min. breaking
strength of 15,000 lbs (66.7 kN).

Page 13 of 35 Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
1. Wire rope requires lubrication under normal conditions. Lightly lubricate it with a wire rope
lubricant specied by the wire rope manufacturer monthly or more often if necessary.
2. To prepare the end of IWRC wire rope for insertion, cut back the steel center at least 2”
(51mm) to allow for independent movement of the core. Braze and rough shape the end of
the wire rope to form a smooth, tapered, bullet shape no more than 1/4-in. (6.4 mm) long. DO
NOT cool the end of the hot wire rope in water or oil. This makes the end brittle and may
cause it to break off. Oil the bullet after it cools to prevent rusting.
3. Always uncoil and carefully examine the wire rope before use. Worn, kinked, bird-caged, or
damaged wire rope cannot be repaired. It must be replaced.
4. Use a heavy-duty thimble for the main suspension wire rope and follow the manufacturer’s
requirements for termination of the wire rope hardware that you are using.
5. Be sure there is enough wire rope to reach the lowest possible point of travel.
6. Wire rope begins to wear the moment it is used. It must be regularly inspected to be sure it
is in good condition. Wire rope must be removed from service when diameter loss or wire
breakage occurs as listed within CAN/CSA - Z271 (See following page)
WARNING
Wire rope stretches when loaded. The diameter is reduced. Always inspect the
wire rope termination and refer to the manufacturer’s inspection procedures.
ALL DIMENSIONS ARE INCHES.
( )
( )

Page 14 of 35 Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
WARNING:
Use protective gloves to handle the steel wire ropes
Use only Power Climber-approved steel wire rope. Steel wires
ropes must be replaced in any of the following conditions:
• More than 10 wires are broken on a length of 240mm
• Excessive corrosion
• Damage due to heat
• Reduction of the nominal diameter by more than 10%
• Kinking (1), crushing (2), bird caging (3) or any other
distortion of the wire rope structure.
Wire Rope Inspection Procedure
Wire Rope Inspection Procedure. The need for replacement of suspension wire ropes shall be determined by regular
inspection and shall be based on the condition of the wire rope inspected. Wire rope in active service should be
visually inspected once every working day. A thorough inspection shall be made once a month, or before each use
if the suspension wire ropes have been inactive for 30 days or longer and are placed into service. Dated and signed
monthly reports of that inspection must be kept, indicating the condition of the ropes.
Any of the following conditions, or combination of conditions, shall be considered as sufcient reason for the
removal of the wire rope from service:
CAN/CSA - Z271 7.7.4.1
Wire rope with one or more of the following defects shall be removed and replaced immediately.
1. Whenever there is severe corrosion. Any development of slight corrosion shall be noted and watched closely;
2. Whenever there are broken wires, as follows:
(a) When there is more than one valley break. A valley break is a wire break occurring in the valley
between two adjacent strands.
(b) Whenever there are six randomly distributed broken wires in one rope lay or three broken wires in one
strand in one rope lay. A rope lay is the length along the rope in which one strand makes a complete
revolution around the rope.
3. Whenever there are broken wires in the vicinity of attachments. If this condition is localized in an operating
rope, then the section in question may be eliminated by making a new attachment. This may be done rather
than replacing the entire rope.
4. Whenever there is abrasion, scrubbing, attening, or peening causing loss of more than one-third of the original
diameter of the outside wires.
5. When there are severe kinks, crushing, birdcaging, or other damage resulting in distortion of the rope structure.
6. Whenever there is evidence of any heat damage resulting from a torch or caused by contact with electrical
wires; and when the reduction from nominal diameter of the rope is:
(a) more than 1.2mm (0.047 in) for diameters up to and including 20mm (0.78 in)
(b) 1.5mm (0.059 in) for diameters 22 to 28 mm
(c) 2.5mm for diameters 32 to 40mm.

Page 15 of 35 Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
If it is not possible to lower the platform to the ground, secure the tail line* to prevent the platform from
running off the suspension ropes. Before rigging in such an area, consult a safety professional.
*Tail line
with loop
termination
NOTE: Do not expose the wire rope to re, temperatures above 200°F
(93.3°C), passage of electrical current, or corrosive atmospheres and
chemicals. This exposure will make the wire rope unsafe.
Acids will corrode and reduce the strength of both the inner and outer
strands. When using corrosive chemicals, discard the wire rope after
completing the project, or sooner of any damage is evident. Do not save
wire rope that has been in contact with corrosives. When in doubt, re-
place the wire rope.

Page 16 of 35 Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
FRONT AND BACK VIEWS OF HOIST
Wire rope insertion points
Overspeed brake test button
Overspeed brake reset knob
Up / Down operation switch
Emergency stop (power cut-off)
Indicator light
Pendant receptacle
(Pendant sold separately)
Controlled descent lever
Model designation
Serial number information
Exit spring
Manual
Crank Handle

Page 17 of 35 Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
INSTALLING HOIST TO PLATFORM
CAUTION
NOTE
• The voltage loss for 100ft (30.48m) of 10/3
electrical cable is 2 volts for each hoist used.
If startup is sluggish, determine the voltage at the
motors when running. UP is between 198- 242 VAC.
If the voltage is lower than 198 VAC when running:
• Increase voltage with a transformer at the power
source when voltage is low OR,
• Use larger gauge or separate electrical cables to
each hoist to improve voltage supply.
• Do not start both hoists at the same time to insure
better hoist performance. Always maintain a level
platform.
The electric supply must have sufcient
capacity, and the circuit breakers must be properly
rated.
= Inspect
= Verify
=Perform process
Optional
pendant
connection

Page 18 of 35 Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
REEEVING MAIN SUSPENSION WIRE ROPE
Check that the overspeed reset knob
is reset. While holding round eyelet guide
vertical, push the main suspension wire
rope bullet end into hoist.
Operate the hoist in the ↑ UP direction
while pushing the rope into the hoist.
Make sure the wire rope runs freely
through the “Wire Rope Exit Spring”
REEEVING SECONDARY WIRE ROPE (OPTIONAL)
Push secondary wire rope through
the “Wire Rope Insertion Point” for the
secondary rope until it exits the hoist.
Attach a 25lb (11.5 kg) weight to the
end of the secondary wire rope to assist
secondary rope travel.
= Inspect
= Verify
=Perform process

Page 19 of 35 Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
WARNING
Perform all daily tests to ensure correct operation! Do not use the hoist for lifting
until you have successfully completed the daily tests.
PRIOR USE REQUIREMENT
The following tests must be performed at the start of each work shift. If the hoist
fails any test, DO NOT use it until it is repaired. Refer to the pictures on page 16
to identify components. All tests are performed at or near ground level.
TESTING OVERSPEED BRAKE
While powering the hoist
↑ UP and ↓ DOWN
approximately 3 feet, look
through the window on the
Overspeed Compartment
to view that the ywheel is
turning.
Dereeve the wire rope.
1. Re-insert the rope about 12”
(30 cm) into the hoist.
2. Holding the wire rope rmly,
pull it out quickly. If the brake
is working correctly, it will grab
and hold the wire rope in less
than 4” (10 cm).
3. Repeat this test at least 3 times.
If the brake does not work cor-
rectly every time, return the hoist
to your hoist supplier. DO NOT
USE THIS HOIST.
= Inspect
= Verify
=Perform process

Page 20 of 35 Reference: 708052-1 Issue date: 23-Jul-2014 Revision: B
4. Reset the overspeed brake.
(Turn knob counter clockwise)
TESTING OVERSPEED BRAKE TEST BUTTON
Twist the
↑UP control switch
and raise the platform
approximately 3 ft (.9m)
While twisting the ↓ DOWN
control switch, push the Over-
speed Brake Test Button
The hoist should stop quickly.
= Inspect
= Verify
=Perform process
Overspeed Brake has tripped.