RGC Classic Power Drive 250HG User manual

CLASSIC POWER
DRIVE 250HG
INSTRUCTIONS
REIMANN & GEORGER CORPORATION
HOISTING PRODUCTS BUFFALO, NY
P/N 6102073 10/20/05

PRE-HOISTING CHECKLIST
This checklist must be checked prior to each use of the power drive. This checklist is to be used as a guideline in
conjunction with the maintenance and inspection procedures outlined in this manual. The power drive and related
equipment must be thoroughly inspected prior to each use by a trained person. A trained person is one who has read and
thoroughly understands this instruction manual and related equipment manuals and, through training and experience, has
shown knowledge regarding the safe operational procedures. If you do not have such a person in your organization,
please contact Reimann & Georger Corporation or its distributors and they will assist you in providing such a “trained
person.” Do not permit any person who is not fully trained to operate this power drive. It is recommended that this
checklist be maintained as a permanent record.
Discuss work plan, personal protective equipment, and each crew member’s responsibility before starting to set-up.
Insure OSHA compliant fall protection is in place.
Insure hoisting operation will clear all power lines and obstructions.
Insure hoisting area is secured from all unauthorized personnel.
Insure the track is securely tied to the roof to prevent track from slipping.
Insure that both track shoes are resting on a firm level surface to prevent track slippage or uneven loading.
Insure the load does not exceed the rated load capacity of the hoist model being used.
Insure all structural members of the power drive are free of defects and damage that may affect the integrity of the
power drive.
Insure brake rope is not wet.
Inspect wire rope for signs of wear and damage. Replace defective wire rope immediately.
Insure that at least three wraps of wire rope are on the power drive winch drum at maximum travel.
Insure that the screw securing wire rope end loop to the power drive brake sheave is tight and in good condition.
Insure wire rope is reeved properly for either one (1) part of line for the 200lb capacity hoist or two (2) parts of line
for the 400lb capacity hoist.
Insure that track support has been properly installed for track lengths over 28 feet.
Insure that the bottom of the track is away from the building 1/4 of the supported height plus the building overhang.
Insure that all bolts and nuts are tightened securely.
Insure all sheaves can rotate freely.
Insure safety latch on the hook does not support any load.
Insure power drive has been properly maintained.
Operate hoist with no load to test hoisting operation, controls, and power drive.
INSPECTOR: _____________________________________ DATE: ______________

RGC HOISTING PRODUCTS PHONE: [phone]
TABLE OF CONTENTS
CHAPTER TITLE PAGE
1 SAFETY........................................................................................................................................1
1.1 Introduction....................................................................................................................................1
1.2 Safety Definitions...........................................................................................................................1
1.3 Power Drive Safety Labels.............................................................................................................1
1.4 Power Drive Safety Rules ..............................................................................................................1
2 SPECIFICATIONS......................................................................................................................3
2.1 Power Drive Specifications...................................................................................................... .....3
2.2 Nameplate and Serial Number Tag........................................................................................... .....3
3 INSTALLATION AND SETUP..................................................................................................4
3.1 Prior to Setup..................................................................................................................................4
3.2 Mounting the Power Drive.............................................................................................................4
4 OPERATION................................................................................................................................6
4.1 Before Operating the Power Drive.................................................................................................6
4.2 Power Drive Startup.......................................................................................................................6
4.2.1 Gas Engine Startup.........................................................................................................................6
4.2.2 Raising and Lowering the Load .....................................................................................................7
4.3 Preparing Power Drive for Shutdown ............................................................................................8
5 DISASSEMBLY ...........................................................................................................................9
5.1 Prior to Disassembly.......................................................................................................................9
6 INSPECTION AND MAINTENANCE.....................................................................................10
6.1 General Maintenance Rules...........................................................................................................10
6.2 Initial Inspection............................................................................................................................10
6.3 Daily Inspection.............................................................................................................................10
6.4 Clutch-Brake Adjustment..............................................................................................................11
6.5 Oiling Mechanical Parts ................................................................................................................12
6.6 Engine Oil Requirements...............................................................................................................12
6.6.1 Honda Engines ..............................................................................................................................12
6.7 Engine Maintenance......................................................................................................................13
6.8 Wire Rope Inspection Procedure...................................................................................................14
6.9 Safety Hooks .................................................................................................................................15
6.10 Replacing Power Drive Wire Rope...............................................................................................15
7 TROUBLESHOOTING..............................................................................................................16
8 PARTS LISTS..............................................................................................................................17
8.1 Classic 250HG Power Drive .........................................................................................................17
LIST OF FIGURES
FIGURE DESCRIPTION PAGE
2-1 Typical Hoist Product Nameplate...................................................................................................3
3-1 Power Drive Installation on Pro Track...........................................................................................5
6-1 Clutch-Brake Adjustment Detail ...................................................................................................11
6-2 Wire Rope Components ................................................................................................................14
6-3 Power Drive Wire Rope Installation on Brake Sheave .................................................................15
8-1 Classic 250HG Power Drive Assembly Drawing..........................................................................18

1
1SAFETY
1.1 INTRODUCTION
Your Reimann & Georger Corporation Classic 250HG Power Drive is engineered to provide lifting performance, long
term economics and safety advantages that no other type can match. However, even well designed and well built
equipment can malfunction or become hazardous in the hands of an inexperienced and/or untrained user. Therefore, read
this manual and related equipment manuals thoroughly before operating your power drive to provide maximum safety for
all operating personnel, and to get the maximum benefit from your equipment.
1.2 SAFETY DEFINITIONS
A safety message alerts you to potential hazards that could injure you or others or cause property damage. The safety
messages or signal words for product safety signs are DANGER, WARNING, and CAUTION. Each safety message is
preceded by a safety alert symbol and is defined as follows:
DANGER: Indicates an imminently hazardous situation which, if not avoided, will cause death or serious injury. This
safety message is limited to the most extreme situations.
WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It
may also be used to alert against unsafe practices and property-damage-only accidents.
1.3 POWER DRIVE SAFETY LABELS
These labels warn you of potential hazards that could cause injury. Read them carefully. If a label comes off or becomes
illegible, contact Reimann & Georger Corporation for a free replacement.
1.4 POWER DRIVE SAFETY RULES
1. Operators must be trained before operating this power drive. A trained person is one who has read and thoroughly
understands this instruction manual and related equipment manuals and, through training and experience, has shown
knowledge regarding the safe operational procedures.
2. Prior to setting up the power drive there must be a plan of action outlining the work to be accomplished, individual
responsibilities, personal protective equipment, and method of communication.
3. All personnel shall be protected by OSHA compliant fall protection where applicable.
4. Never use the power drive or hoist structure to anchor life lines, worker’s harnesses or other attachments.
5. Always use safety footwear, safety glasses, and head protection devices.
6. A good line of communication must be maintained between the power drive operator and the roof crew.
7. Hoisting area is to be kept clear of unauthorized personnel at all times. Place barricades or secure the area in such a
manner that if there were an equipment failure, no personnel would be injured.
8. Hoisting area is to be clear of power lines. Consult power company before you work near power lines.
9. Follow the Pre-Hoisting Checklist before operating.
10. Wear heavy leather gloves when handling wire rope.
11. Secure load before lifting.

2
12. Do not remove material from the platform until it has stopped completely.
13. Keep out from under a raised load.
14. Never stand in-line with the raising or lowering of the platform at either the top or bottom of the hoist track.
15. Never hoist over an open doorway.
16. Never exceed the Rated Load Capacity of 200 pounds for the PL250 hoist, or PRO200 hoist, or 400 pounds for the
PL400 hoist, or PRO400 hoist. The Rated Load Capacity is the maximum load that should ever be applied to the
hoist.
17. Avoid sudden stops and shock loads.
18. No person shall be allowed to ride on the hoist.
19. NEVER climb the track; use a ladder.
20. Check the hoist periodically during operation. Know how to stop the power drive quickly in case of emergency.
21. Do not attempt to make adjustments while the hoist is being operated.
22. If the engine fails during operation, release control levers to prevent load from falling.
23. Keep all body parts clear of moving parts.
24. Do not operate power drive when brake rope is wet.
25. Do not operate power drive when under the influence of drugs, alcohol, or medication.
26. At end of operation, the power drive and hoist should be secured to prevent unauthorized use. Never assume you
will find the hoist in the same condition in which you left it.
27. Do not weld or otherwise modify the power drive. Such alterations may weaken the structural integrity of the power
drive and invalidate your warranty.
28. Only trained personnel are authorized to do repairs.

2SPECIFICATIONS
2.1 POWER DRIVE SPECIFICATIONS
250HG (Gas engine): 4 cycle, 4 HP Honda
Wire rope 5/32-in. diameter, 7 x 19 galvanized aircraft wire rope
Note that platform speed and capacity is based on 5/32 inch wire rope diameter. As wire rope builds up on drum, lifting
speed increases and lifting capacity decreases in direct proportion to drum diameter.
2.2 NAMEPLATE AND SERIAL NUMBER TAG
It is important to identify your power drive completely and accurately whenever ordering spare parts or requesting
assistance in service. The power drive has a product nameplate located on the power drive frame. The label shows the
model number, serial number and the capacity rating. The power drive label should appear as the sample nameplate
shown in Figure 2-1. Record the model and serial numbers, and capacity rating for future reference.
HOIST
CAP. lbs.
MODEL
SERIAL NO.
Figure 2-1.
Typical Hoist Product Nameplate
MODEL__________________________________
SERIAL NUMBER_________________________
CAPACITY RATING_______________________
3

3INSTALLATION AND SETUP
3.1 PRIOR TO SETUP
1. Insure all structural members of the power drive are free of defects and damage that may affect the integrity of the
unit.
2. Insure the hoisting area is secured from all unauthorized personnel.
3. Referring to Figure 3-1. and the instructions included with the additional cross tie stiffener install a cross tie stiffener
in the 5th cross tie from the swivel shoe end of the base track section.
WARNING:
INSURE THAT OSHA COMPLIANT FALL PROTECTION IS IN PLACE.
WARNING:
PRIOR TO SETTING UP THE HOIST THERE MUST BE A PLAN OF ACTION OUTLINING
THE WORK TO BE ACCOMPLISHED, INDIVIDUAL RESPONSIBILITIES, PERSONAL
PROTECTIVE EQUIPMENT, AND THE METHOD OF COMMUNICATION. FAILURE TO DO
THIS CAN RESULT IN DEATH, SERIOUS PERSONAL INJURY OR EQUIPMENT FAILURE.
WARNING:
INSURE THAT ALL BOLTS AND NUTS ARE TIGHTENED SECURELY TO PREVENT
EQUIPMENT DAMAGE AND/OR SERIOUS INJURY.
3.2 MOUNTING THE POWER DRIVE
WARNING:
THE HOISTING OPERATION MUST BE CLEAR OF ALL ELECTRICAL LINES AND
OBSTRUCTIONS TO PREVENT EQUIPMENT DAMAGE AND/OR SERIOUS PERSONAL
INJURY. CONSULT POWER COMPANY BEFORE WORKING NEAR POWER LINES.
WARNING:
NEVER CLIMB ON THE TRACK. THIS CAN CAUSE SERIOUS PERSONAL INJURY OR
DEATH. USE A LADDER.
4. Mount the power drive in an essentially vertical position. If the power drive is not vertical, the brake and clutch
levers will not work and the engine may not operate. Referring to Figure 3-1, position the power drive on the 3rd
and 5th reinforced track cross ties from the bottom with the clamp on the 5th cross tie. Power drive should be on the
underside of the track. Center the drive between the track rails and lock in place by rotating the lock to the left.
Insert a #38 lock pin in the hole provided to prevent lock from loosening. Fasten the operating handles on the power
drive. When facing the power drive from the rear or building side of the track, the power drive operator handles will
be on your right. Details on power drive startup are given in Chapter 4.
5. Before reeving the hoist, inspect the wire rope for wear and damage. Detailed inspection procedures are in Chapter 6.
WARNING:
WEAR HEAVY LEATHER GLOVES WHEN HANDLING WIRE ROPE. INSUFFICIENT HAND
PROTECTION WHEN HANDLING WIRE ROPE CAN CAUSE SERIOUS PERSONAL INJURY.
4

WARNING:
USING DEFECTIVE WIRE ROPE CAN CAUSE EQUIPMENT DAMAGE, SERIOUS
PERSONAL INJURY, OR DEATH.
5.)Alwaysusesafetyfootwear,safetyglasses,and
6.)Wearheavyleathergloveswhenhandlingwire
4.)AllpersonnelshallbeprotectedbyOSHA
compliantfallprotectionwhereapplicable.
headprotectiondevices.
ofmovingparts.
hoistisbeingoperated.Keepallbodypartsclear
preventunathorizeduse.Neverassumeyouwill
findthehoistinthesameconditioninwhichyou
20.)Donotattempttomakeadjustmentswhilethe
21.)Atendofoperation,thehoistshouldbesecuredto
leftit.
22.)Donotweldorotherwisemodifythehoist.Such
23.)Onlytrainedpersonnelareauthorizedtomake
alterationsmayweakenthestructuralintegrityof
repairs.
thehoist.
62156789901
Donotclimbthetrack;usealadder.
hasstoppedcompletely.
16.)Keepoutfromunderaraisedload.Neverhoist
19.)Nopersonshallbeallowedtorideonthehoist.
17.)Neverstandin-linewiththeraisingorloweringof
theplatformateitherthetoporthebottomofthe
18.)Donotremovematerialfromtheplatformuntilit
10.)Donotoperatehoistwhenundertheinfluenceof
11.)Donotoperatehoistifbrakeropeiswet.
13.)NeverexceedtheRatedLoadCapacityof200lbs.
forPL-250hoist,or400poundsforthePL-400
14.)Iftheengineormotorfailsduringoperation,
releasecontrolleverstopreventloadfromfalling.
15.)Controlloadatalltimes.Avoidsuddenstops
hoist.TheRatedLoadCapacityisthemaximum
loadthatmusteverbeappliedtothehoist.
7.)Hoistingareaistobekeptclearofunathorized
personnelatalltimes.Placebarricadesorsecure
theareainsuchmannerthatiftherewerean
8.)Hoistingareaistobeclearofpowerlines.Consult
PowerCompanybeforeyouworknearpower
equipmentfailure,nopersonnelwouldbeinjured.
9.)FollowthePre-HoistingChecklistbeforeoperating.
overanopendoorway.
hoisttrack.
drugs,alcohol,ormedication.
12.)Secureloadbeforelifting.
andshockloads.
lines.
rope.
individualresponsibilities,personalprotective
PL-250/400HOISTSAFETYRULES:
operatingthishoist.Atrainedpersonisonewho
1.)Operatorsmustbethoroughlytrainedbefore
hasreadandthoroughlyunderstandsthe
instructionmanualandrelatedequipment
manualsand,throughtrainingandexperience,
hasshownknowledgeregardingsafeoperating
2.)Priortosettingupthehoisttheremustbeaplanof
actionoutliningtheworktobeaccomplished,
3.)Agoodlineofcommunicationmustbemaintained
betweenthehoistoperatorandroofcrew.
equipment,andmethodofcommunication.
procedures.
3RD CROSSTIE
CROSS TIE CLAMP
5TH CROSSTIE
Figure 3-1.
Classic Power Drive 250HG Installation on Pro track
5

4OPERATION
4.1 BEFORE OPERATING THE POWER DRIVE
WARNING:
A GOOD LINE OF COMMUNICATION MUST BE MAINTAINED BETWEEN THE HOIST
OPERATOR AND THE ROOF CREW.
1. Only trained personnel shall operate this equipment. A trained person is one who has read and thoroughly
understands this instruction manual and related equipment manuals and, through training and experience, has shown
knowledge regarding the safe operational procedures.
2. Obey all safety labels provided on your power drive. These labels warn you of potential hazards that can cause
serious injury. If a label comes off or becomes hard to read, contact Reimann & Georger Corporation for a
replacement.
3. Follow the Pre-hoisting Checklist in the front of this manual before operating.
4. Never use the power drive or hoist structure to anchor lifelines, worker harnesses, or other attachments.
5. Always use safety footwear, safety glasses, and head protection devices.
6. Before lifting, insure the safety latch on the hook is not supporting any load. Never hoist over an open doorway.
WARNING:
THE HOISTING OPERATION MUST BE CLEAR OF ALL ELECTRICAL LINES AND
OBSTRUCTIONS TO PREVENT EQUIPMENT DAMAGE AND/OR SERIOUS PERSONAL
INJURY. CONSULT POWER COMPANY BEFORE WORKING NEAR POWER LINES.
7. Hoisting area is to be kept clear of unauthorized personnel. Place barricades or secure the area in such a manner that
if there were an equipment failure, no personnel would be injured.
8. Inspect wire rope for damage, wear, or unraveling. Replace as necessary.
9. Check all hooks and sheaves. Replace as necessary.
4.2 POWER DRIVE STARTUP
4.2.1 Gas Engine Startup
1. Handle fuel with care. It is highly flammable. Use approved fuel container. Fill tank outdoors in a well ventilated
area on a bare surface. Make sure the gas caps on the engine and fuel can are properly tightened. Insure the fuel
storage area is at least 10 feet from the power drive before starting the engine. Never remove the fuel cap or add fuel
to a running or hot engine. Let the engine cool 2 minutes before fueling.
2. Check oil level in both the crankcase and reducer. Always add oil with the power drive on the level. Follow
manufacturer specifications on type and amount of oil to add. Refer to the manufacturer’s instructions and to Chapter
6 of this manual.
6

CAUTION:
GASOLINE ENGINES ARE SHIPPED WITHOUT OIL IN THE CRANKCASE. ATTEMPTING
TO RUN THE ENGINE WITHOUT FILLING THE CRANKCASE AND TOPPING OFF THE
REDUCER WITH OIL WILL CAUSE SERIOUS ENGINE DAMAGE AND MAY VOID THE
WARRANTY.
3. Check the engine air cleaner and air intake screen for dirt or obstruction. Clean as required.
4. Move choke control to choke or start position and move throttle to half throttle position to start a cold engine. Move
choke control to run position slowly after engine starts and allow a warm up. The choke must be in the run position
during normal operation or when starting a warm engine. Placing the throttle in the slow position before stopping the
engine permits a cooling period.
WARNING:
DO NOT USE IN WET CONDITIONS.
4.2.2 RAISING AND LOWERING THE LOAD
WARNING:
SECURE THE LOAD BEFORE LIFTING.
WARNING:
DO NOT OPERATE HOIST WHEN BRAKE ROPE IS WET
1. Before operating the clutch and brake levers, install the provided lever handles using the provided spring locks.
Install the #25 handle extension shown in Figure 8-1 on the clutch lever handle using the nut and bolt provided.
2. Make a few “dry runs” (no load), to test power drive, hoisting operation, and controls.
WARNING:
NEVER STAND IN-LINE WITH THE RAISING OR LOWERING OF THE PLATFORM AT
EITHER THE TOP OR BOTTOM OF THE HOIST TRACK.
3. To raise the load, first advance the throttle to increase the engine speed. Then lift the left clutch handle slowly with a
smooth upward motion. This automatically tightens the drive belt and releases the brake, permitting the platform to
roll up the track.
4. When the platform reaches the top of the track, release the clutch lever. This action stops the platform and
automatically applies the brake, which holds the load and platform. The load will now roll automatically off the
platform onto the roller angle guide if you are using one.
WARNING:
KEEP OUT FROM UNDER A RAISED LOAD.
7

WARNING:
IF THE ENGINE FAILS DURING OPERATION, RELEASE CONTROL LEVERS TO PREVENT
LOAD FROM FALLING.
5. Do not allow the platform to jam against the spring stops on the top bracket. The drive belt may jam in the drum
sheave, preventing the lowering of the platform.
WARNING:
DO NOT REMOVE MATERIAL FROM THE HOIST UNTIL IT HAS STOPPED
COMPLETELY.
6. Lift the brake lever slowly to lower platform to the ground. Lowering speed for SAFE operation should not
exceed 50 feet/minute. Continue to decelerate the platform as it nears the ground to prevent damage to platform or
track. Do not allow the platform to strike the track shoes on reaching the bottom of the track. If necessary,
extra downward pressure on the brake lever can be applied to stop the load.
WARNING:
AVOID SUDDEN BRAKING WHEN HANDLING A LOAD.
7. Check the hoist periodically during operation. Do not attempt to make adjustments during operation.
WARNING:
KEEP ALL BODY PARTS CLEAR OF MOVING PARTS.
4.3 PREPARING POWER DRIVE FOR SHUTDOWN
At the end of operation, secure the equipment to prevent unauthorized use. Never assume you will find the equipment in
the same condition that you left it. Proceed as follows:
1. Insure that all lifting tension has been removed from the wire rope.
2. Shut off power drive and take necessary action to prevent its unauthorized use.
3. If the power drive is being permanently disassembled, at the end of a project for example, follow the detailed
disassembly procedures in Chapter 5.
8

5 DISASSEMBLY
5.1 PRIOR TO DISASSEMBLY
1. Before disassembling the power drive, read and follow all the safety rules of this manual. Failure to do this can lead
to equipment damage and/or serious personal injury.
2. Insure that the platform is not supporting any load before proceeding.
3. Before dismantling, attach a tie rope to hold the platform in position at the base of the track.
4. Insure the track is securely tied to the roof with a rope fastened to a cross tie or top bracket to prevent track from
slipping.
5. Check carefully for proximity of power lines or other overhead obstructions.
WARNING:
NEVER CLIMB ON THE TRACK FOR ANY REASON. THIS CAN CAUSE SERIOUS
PERSONAL INJURY OR DEATH.
WARNING:
WEAR HEAVY LEATHER GLOVES WHEN HANDLING WIRE ROPE. INSUFFICIENT HAND
PROTECTION WHEN HANDLING WIRE ROPE CAN CAUSE SERIOUS PERSONAL INJURY.
1. Tie a safety line at least 5 feet long to the wire rope end to prevent any accidental drawing of the operator’s hand into
the power drive winch during rewinding.
2. Start the power drive and lift the clutch handle to rewind wire rope. Insure that the wire rope is rewinding evenly on
the drum. As the wire rope end approaches the drum, handle the wire rope only by the safety line.
4. When the wire rope end reaches the drum, release the clutch handle, shut off the power drive and remove the safety
line. Anchor the wire rope end on the drum with a light rope or tape.
5. Remove the operating handles from the power drive. Remove the lock pin from the hole provided and loosen the
lock by rotating it to the right. Then remove the power drive from the cross ties.
9

6 INSPECTION AND MAINTENANCE
6.1 GENERAL MAINTENANCE RULES
1. Proper maintenance of the power drive and related equipment consists of adhering to all the guidelines given in this
chapter and in the Pre-Hoisting Checklist in the front of this manual. Proper maintenance is required to maintain the
system in good condition, which is defined as each part being free of rust or other corrosion, bends, breaks, or other
defects.
2. Review and follow all the safety rules given in Chapter 1 before attempting any maintenance.
3. Only authorized personnel should be allowed in the maintenance area. Authorized personnel are the trained people
as defined below and their supervision.
4. Repairs must be made only by trained personnel. A trained person is one who has read and thoroughly understands
this instruction manual and related equipment manuals and, through training and experience, has shown knowledge
regarding the safe operational procedures.
WARNING:
WEAR HEAVY LEATHER GLOVES WHEN HANDLING WIRE ROPE. INSUFFICIENT HAND
PROTECTION WHEN HANDLING WIRE ROPE CAN CAUSE SERIOUS PERSONAL INJURY.
5. Do not weld or otherwise modify the power drive. Such alterations may weaken the structural integrity of the power
drive and invalidate your warranty.
WARNING:
DURING ANY ERECTION, MAINTENANCE, OR REPAIR PROCEDURES, DO NOT ATTEMPT
ANY HOISTING. THIS CAN CAUSE EQUIPMENT DAMAGE AND/OR SERIOUS PERSONAL
INJURY.
WARNING:
EXCEPT FOR MAINTENANCE AND REPAIRS THAT CANNOT BE DONE OTHERWISE,
SHUT DOWN AND LOCK OUT THE POWER DRIVE TO PREVENT ACCIDENTAL
STARTUP.
WARNING:
NEVER CLIMB THE TRACK TO DO MAINTENANCE. THIS CAN LEAD TO SERIOUS
PERSONAL INJURY.
6.2 INITIAL INSPECTION
Power drive assembly and disassembly, must be done by trained personnel only as defined in Section 6.1. Each time after
setting up the hoist and before placing it in service, all parts of the hoist structure, power drive, and other equipment must
be thoroughly inspected by trained personnel as described in the remainder of this chapter and related equipment
manuals.
6.3 DAILY INSPECTION
It is important that all the maintenance procedures outlined in the Pre-Hoisting Checklist in the front of this manual be
done daily. Details on inspecting the wire rope are given in Section 6.9. All broken, worn or defective parts must be
repaired or replaced before startup.
10

6.4 CLUTCH-BRAKE ADJUSTMENT
The combination clutch and brake actions to raise rated loads with the clutch handle are adjusted at the factory. If field
adjustments are needed, proceed as follows. Refer to Figure 6-1 for adjustment details.
1. The Dacron brake holds the load when the clutch lever is released. If the load drifts down, tighten the nut at the base
of the #24 spring to compress this spring. This increases the initial load on the brake lever. Note that the #24 spring
should be compressed to about 3 1/8 ±1/16 inches with about 3/8 inches movement on the bottom edge of the #8
brake differential.
2. Excessive tightening fully compresses the spring and the brake will not release. There should always be a 1/32 inch
gap between brake lever #3 and nuts “B” and “C”. If this “play” in brake lever #3 is absent, you can flex the rod and
break it.
3. If the load still drifts down move the brake rope end “D” from the outer hole to the inner hole on the #8 brake
differential. As the Dacron brake wears, the brake lever may need adjusting to bring the lever up to its proper
operating position. Alternate holes are provided in the brake rope ends for this purpose.
4. When properly adjusted, the brake will release before the #10 clutch spring is entirely compressed. Gap “A” is
widened or narrowed by screwing or unscrewing, respectively, nuts “B” and “C”. Make this adjustment carefully. If
there is no gap “A”, the brake will release before the clutch belt is tightened. This will cause a sudden jerking before
the clutch belt is tightened, resulting in an overload on the hoist, wire rope, and track. The clutch can be engaged
sooner to help avoid this overloading by tightening the top nut on the #10 clutch spring shown in Figure 8-1. The
clutch spring is preset at the factory to a compressed height of 1 11/16 inches.
11
Figure 6-1.
Clutch-Brake Adjustment Detail

6.5 OILING MECHANICAL PARTS
The main bearings (shown as #18 in Figure 8-1) are lubricated for life and need no attention. Oil all pivots and linkage
joints occasionally.
6.6 ENGINE OIL REQUIREMENTS
CAUTION:
GASOLINE ENGINES ARE SHIPPED WITHOUT OIL IN THE CRANKCASE.
ATTEMPTING TO RUN THE ENGINE WITHOUT FILLING THE CRANKCASE AND
REDUCER WITH OIL WILL CAUSE SERIOUS ENGINE DAMAGE AND MAY VOID THE
WARRANTY.
6.6.1 Honda Engines
For both the engine and gear reducer, use Honda 4-stroke oil or an equivalent high detergent, premium quality motor oil
certified to meet or exceed U.S. automobile manufacturer’s requirements for Service Classification SG,SF/CC, CD. SAE
10W-30 is recommended for general, all temperature use. Other viscosity’s shown on the chart in your engine manual
may be used when the average temperature in your area is within the indicated range. The oil capacity is 0.6 liters (20
oz.). The gear reducer oil capacity is 0.15 liters (5 oz.). The engine itself (not the power drive) must be in the upright
(level) position when filling and checking the oil. Oil filling instructions are included in the Honda engine manual.
After filling with, or changing oil, start and run the engine at idle for 30 seconds. Shut engine off. Wait 30 seconds and
check oil level.
The engine itself (not the power drive) must be in the upright (level) position when filling and checking oil.
CAUTION:
HONDA ENGINES ARE EQUIPPED WITH AN OIL ALERT UNIT. FAILURE TO ADD THE
PROPER AMOUNT OF OIL MAY RESULT IN THE ENGINE FAILING TO START. THE
ENGINE MAY ALSO SHUT DOWN IF INCLINED DURING OPERATION.
12

13
6.7 ENGINE MAINTENANCE
The engine is guaranteed against defects by its manufacturer. Follow the manufacturer’s instructions for proper
lubrication and maintenance. The following table summarizes the type and frequency of maintenance required.
Follow the hourly or calendar intervals, whichever occurs first. For repairs, contact the nearest authorized service
center.
TYPE OF MAINTENANCE FREQUENCY OF SERVICE
Check oil level Every 5 hours or daily
Change oil After first 5 hours, then after every 50
hours or every season. Change oil every
25 hours when operating under heavy
load or in high temperatures.
Change oil in gear reduction 100 hours or every season
Service air cleaner pre-cleaner if equipped, or air cleaner cartridge if not
equipped with pre-cleaner. 25 hours or every season. Clean more often under dusty conditions or when
airborne debris is present. Replace air
cleaner parts if very dirty.
Service air cleaner cartridge if equipped with pre-cleaner. 100 hours or every season. Clean more
often under dusty conditions or when
airborne debris is present. Replace air
cleaner parts if very dirty.
Clean cooling system. 100 hours or every season. Clean more
often under dusty conditions or when
airborne debris is present. Replace air
cleaner parts if very dirty.
Inspect spark arrester, if equipped. 50 hours or every season.
Replace or clean spark plug. 100 hours or every season.
Clean combustion chamber deposits. 100-300 hours.

6.8 WIRE ROPE INSPECTION PROCEDURE
Inspect the wire rope prior to each use and at least daily for signs of wear, damage, or pinching. Inspect the entire wire
rope working length. Thoroughly inspect the rope sections that pass over sheaves or drums, or that make opposing turns.
Inspect wire rope and end attachments carefully. While inspecting, examine sheaves, guards, guides, drums, flanges, and
other surfaces contacting wire rope during operation. Correct any condition harming the rope in use or other damage or
worn surfaces at this time.
Remove or replace immediately wire rope with one or more of the following defects:
1. Corrosion
2. Broken wires:
(a) One or more valley breaks. A valley break is a wire break occurring in the valley between two adjacent strands.
(b) Six randomly distributed broken wires in one rope lay. A rope lay is the length of rope along which one strand
makes a complete revolution around the rope. See Figure 6-2. Keeping the rope clean and wound evenly on the
drum will increase its life and efficiency.
3. Abrasion: Scrubbing, flattening or peening causing loss of more than one-third of the original diameter of the outside
wires.
4. Kinking: Severe kinking, crushing, bird caging or other damage causing distortion of the rope structure. Bird caging
is a bulging in the wire rope caused by the individual wires becoming untwisted. This untwisting of individual wires
is usually caused by impact loading on the wire rope (such as a sudden stop).
5. Heat damage: Evidence of any heat damage caused by a torch or by contact with electrical wires.
6. Reduction of more than 1/64 inch from a nominal 5/16-inch or less diameter wire rope.
Figure 6-2.
Wire Rope Components
6.9 SAFETY HOOKS
The hook to which the power drive wire rope is attached will be either the platform safety hook on the PL250 & PRO200
models or the top bracket hook on the PL400 & PRO400 models. If these hooks should become broken, bent, or
disassembled, they should be replaced immediately.
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6.10 REPLACING POWER DRIVE WIRE ROPE
Each end of the hoist wire rope is equipped with loops. The small loop is attached to the #17 brake sheave (see Figure 6-
3) by passing it through the hole and bending it back against the pull or load. It is snubbed over the web of the sheave
and fastened to the sheave with the screw provided. The large loop is used for attaching loads with a shackle and hook.
On platform units, the hook is mounted on the platform or top bracket, and the loop is slipped over the hook.
Figure 6-3.
Power Drive Wire Rope Installation on Brake Sheave
15

16
7TROUBLESHOOTING
The following chart is intended to assist with troubleshooting the power drive. While not all inclusive, the chart outlines
the most common causes of a problem and the recommended course of action.
The troubleshooting guide for the associated platform hoist is in the instruction manual specifically for that unit.
SYMPTOM CAUSE AND CORRECTIVE ACTION
Gas engine will not start Air filter clogged—replace filter
1. Too much oil in crankcase—pistons can’t come back
down which can saturate air filter with oil.
2. Tipping the engine, allowing oil to run up the relief tube.
3. Air filter dirty after normal use.
Clogged fuel line—replace fuel filter.
Fuel shut off in OFF position—turn ON
Engine switch in OFF position—turn ON
Engine low oil trip—engine is positioned at an angle.
Engine must be level to start. Check oil level.
Power Drive won’t lift load or is lifting it very
slowly. No oil in engine to build compression—must add oil. Check piston rings for compression.
Hoist attempting to lift more than stated capacity of unit—check
capacity rating and reduce load weight as needed
Brake is dragging which may cause a “squealing” noise—adjust
as described in Chapter 6.
Clutch not properly adjusted—adjust as described in Chapter 6.
Platform not moving freely—check for track obstructions or
block and wire rope malfunctions
Engine related problems—refer to beginning of this table.
Reference to manufacturer’s instruction manual may be
necessary.
Engine speed too slow—increase throttling.
Too much wire rope on drum—hoisting capacity decreases as
wire rope diameter increases.
Engine stalls when clutch handle is lifted. Brake is releasing before clutch belt is tightened—close the gap
by unscrewing nuts “B” and “C” to lower brake lever as
described in Chapter 6.
Power Drive will not lower platform. Platform has been allowed to jam against the spring stops on the
top bracket causing the drive belt to jam in the drum sheave—
shut off the gas engine. Then release the jammed belt by
inserting a screw driver between the belt and the sheave groove.
Load drifts down. Spring #24 as shown in Figure 6-1 needs compressing—tighten
the nut as described in Chapter 6.
Brake rope end “D” needs adjusting—move from the outer hole
to the inner hole on the brake differential.

17
8PARTS LISTS
Each item number on the following parts lists can be matched with the item number shown on the corresponding
assembly drawing as indicated below.
8.1 CLASSIC 250HG POWER DRIVE
Refer to Figure 8-1.
Item Number Part Number Quantity Description
1 0400708 1 FRAME
2 0404402 1 CLUTCH LEVER
2A 0404403 1 CLUTCH HANDLE
3 0404404 1 BRAKE LEVER
3A 0404405 1 BRAKE HANDLE W/ GRIP & DECAL
4 0404406 1 ENGINE PLATE
5 0404407 1 PIVOT SHAFT
6 0404525 1 CROSS TIE CLAMP
7 0402225 1 CROSS TIE LOCK
8 0404410 1 BRAKE DIFFERENTIAL
9 0404411 1 SHAFT
10 5800149 1 SPRING
11 0404423 1 BELT GUIDE
12 0404413 1 PIN
13 0462801 1 BRAKE ROPE
16 6400654 1 HANDLE GRIP 7/8”
17 7300611 1 BRAKE SHEAVE 10”
18 5100718 2 BEARING PB100 X 1
19 6700719 1 V BELT B56
20 0400720 1 SHEAVE & DRUM (LESS BRAKE SHEAVE)
21 5800131 1 SPRING
22 5800136 1 SPRING
23 0400739 1 BOLT EYE 14 3/4”
24 5800661 1 SPRING
25 0404414 1 HANDLE EXTENSION W/ GRIP & DECAL
26 5500630 1 ENGINE GAS 4 HP
32 7300732 1 SHEAVE BK52 X ¾
37 0405407 1 GUARD
38 5800138 3 SPRING & LOCK PIN
44 6400143 1 HANDLE GRIP 1”
51 7304300 1 WIRE ROPE 5/32”