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