Yale Lodeking LT Series Installation and operation manual

OPERATING &
MAINTENANCE MANUAL
MANUAL #: 11854801 REV AC
Capacities from 10 to 25 Tons
HIGH CAPACITY ELECTRIC WIRE ROPE HOISTS
P/N: 11854801 REV. AC September 2017

2P/N: 11854801 REV. AC September 2017
TABLE OF CONTENTS
ORDERING/MODEL NUMBER SYSTEM
General Information........................................................... 3
HOIST OPERATION & MAINTENANCE
Safe Hoisting Practices .................................................... 4
Before Operating Hoist
Applying the Load
Moving the Load
Parking
Safety Laws for Passenger Elevators
Inspection, Preventive Maintenance and Testing
Yale Hoist Duty Service Classifications ............................ 5
Repair Parts Ordering & Return Information
Hoist Serial Numbers
Installation Instructions
Geared Limit Switch Use And Maintenance Instructions . 6
Basic Suspensions ........................................................... 7
Hoist Maintenance and Inspection ............................... 7-9
Daily Inspection
Monthly Inspection
Quarterly Inspection
Annual Inspection
Function Testing After Repair
WIre Rope Mainenance and Inspection
Reeving ....................................................................... 9-10
Lubricant Specifications ................................................. 11
Inspection Schedule and Maintenance Report .............. 12
Disassembly & Reassembly ..................................... 13-14
Troubleshooting .............................................................. 15
Hoist Gear Drive Information .................................... 16-17
Helical & Bevel Reducer Lubrication ........................ 18-20
TROLLEY OPERATION & MAINTENANCE
General Information ........................................................ 21
Installation ...................................................................... 21
Start-up and Pre-Operational Inspection ....................... 22
Operation .................................................................. 22-26
Inspection ................................................................. 26-27
Maintenance ............................................................. 27-49
Replacement Parts ......................................................... 36
RECOMMENDED SPARE PARTS
General Information ........................................................ 52
WARRANTY
General Information ........................................................ 52

3P/N: 11854801 REV. AC September 2017
LODEKING LT MODEL
NUMBER SYSTEM
Example: Model # T025T02511072
Model
Capacity (Tons)
Suspension Or Mounting
Lift (Feet)
Lifting Speed (FPM)
Gage (In.)
"T" for "Top Runner"
or "D" for "Deck Mount"
"T" for "LODEKING LT"
25-ton LODEKING LT
Top running suspension
23 ft. of lift (11 st./min. hoist speed)
11 ft./min. hoist speed
Gage is 72 in.
(1) (3) (1) (3) (3)(2)
11 072T T 023020

HOIST OPERATION & MAINTENANCE
4P/N: 11854801 REV. AC September 2017
SAFE HOISTING PRACTICES
For your own safety and that of your fellow workers, Material
Handling Equipment must be used as recommended by the
Manufacturer. Failure to heed the following recommendations could
endanger your life. Use good common sense and judgement at all
times. Safety is the responsibility of the operator of the equipment.
You must be competent and attempt to foresee and avoid all
hazardous conditions. To be safe as possible, the hoist must be
given proper preventive maintenance and testing as described
in the ANSI B30.2 Overhead and Gantry Cranes.
BEFORE OPERATING HOIST
1. Do not operate hoist unless you are properly trained, physically t,
and authorized to do so. You must be familiar with all operating
controls of the hoist, warnings and instructions on the hoist, the
safe hoisting practices listed in this manual, ANSI B30.16 Safety
Code For Overhead Hoists, and all pertinent Federal, State, and
local regulations before beginning operation.
2. Do not allow unqualied personnel to operate the hoist.
3. Test all controls and limit switches and make sure hoist is well
lubricated at beginning of each shift. Make sure needed lubrication,
adjustments, or repairs are made by appointed personnel before
operations are begun.
4. Be familiar with the equipment and its proper care. Do not operate
hoist if adjustments or repairs are necessary, if any damage or
undue wear is known or suspected, or if any warning, operating,
or capacity instructions normally attached to hoist are damaged,
obscured or missing. Report these items promptly to the proper
person and also notify next operator when changing shifts.
5. Do not operate hoist if it is functioning improperly.
6. Do not operate hoist with an out-of-order sign attached until sign
has been removed by a properly authorized person.
7. Do not adjust or repair hoist unless qualied for maintenance of
hoist.
8. Be sure the power supply is disconnected before maintenance and
repair procedure is performed.
9. Do not use the wire rope as a ground for welding.
10. Do not touch a welding electrode to the wire rope.
APPLYING THE LOAD
11. Never wrap the wire rope around the load, or allow it to drag under
load.
12. Always use slings or other approved devices to attach load.
13. Be sure the sling is properly seated in the saddle of the hook.
Do not allow hook latch to support any part of load.
14. Do not apply a load to tip of hook, or in such a way as to cause
bending, or prying forces on the hook or hook support block.
15. Be sure wire ropes are not kinked or twisted or that multiple part
ropes are not twisted about each other.
16. Do not operate hoist if wire rope is not seated properly in the
grooves of the drum or sheaves.
17. Do not load hoist with less than two wraps of rope on the drum.
18. Center hoist unit over the load before lifting. Avoid side pull.
19. Never pick up a load beyond the rated capacity appearing on the
hoist, except for properly authorized tests.
20. Do not use a load limiting device to measure the maximum load to
be lifted. It is a safety device only.
MOVING THE LOAD
21. Do not engage in any activity which will divert your attention while
operating hoist.
22. Respond to signals from designated personnel only,
except for stop signals.
23. Never lift a load with the hoist until you and all other personnel are
clear of load.
24. Make sure load has proper clearance before moving.
25. Inch the hoist slowly into engagement with a load, but avoid
excessive plugging, inching, and quick reversals of load.
26. Do not lift load more than a few inches until it is well
balanced in the sling or lifting device.
27. Each time a load approaching rated capacity is handled, check load
brake action by raising load just clear of supports and
continuing only after you are sure brake is operating properly.
28. Do not transport load over personnel.
29. Never carry personnel on the hook or the load.
30. Avoid swinging of load or load hook when traveling the hoist.
31. On trolley mounted hoists, avoid sharp contact between
trolleys, or between trolleys and rail stops.
32. Do not use limit devices as a normal means of stopping
the hoist. These are emergency devices only.
33. Do not exceed the maximum duty cycle specied by
the manufacturer.
PARKING
34. Do not leave load suspended in the air for extended or unattended
periods.
35. Keep load block above head level when not in use.
SAFETY LAWS FOR PASSENGER ELEVATORS
The safety laws for passenger elevators specify construction details
that are not incorporated In Yale Hoists. We recommend that
passenger elevator operation equipment be used that meets all state
and national safety codes. Yale Hoists will not accept responsibility
for applications of Yale Hoists on passenger elevators.
DO NOT USE YALE HOISTS OR TROLLEYS FOR PASSENGER
ELEVATOR APPLICATIONS.
INSPECTION, PREVENTIVE MAINTENANCE
AND TESTING
A preventive maintenance program should be initiated for this
hoist immediately after it is entered into service. The preventive
maintenance program should comply with recommendations in
the applicable Yale Parts and Instruction Manual, and all pertinent
Federal, State and Local regulations. Regular inspections,
maintenance and testing required should be followed for the life of
the hoist and written inspection records kept as specied. Sample
inspection checklists are included in back of this manual. Extra
inspection checklists can be obtained from your nearest authorized
Yale Distributor.
REPAIR PARTS ORDERING INFORMATION
This parts and instruction manual contains information required to
install and maintain your Yale LodeKing Series Electric Hoist. To
insure prompt service, each repair parts order should be placed with
your local distributor, and must contain the following information:
Please give all information listed below in items 1 through 4.
This will enable your distributor to fill your order promptly.
1. Give complete data from hoist nameplate, including hoist
serial number, model number, voltage, frequency, and hertz.
2. Give part numbers, description and quantity of parts required.
3. Give correct shipping destination.
4. For ordering motor repair parts, give all data on the hoist,
gearcase and motor nameplates.
HOIST SERIAL NUMBERS
The hoist serial number is stamped on the nameplate. The
nameplates also designate the model number, capacity, speed,
current characteristics, and service rating of the hoist or trolley.
RETURN OF PARTS
If it becomes necessary to return the complete hoist or certain parts
to the factory, a letter requesting such a return is necessary. This
letter should contain an explanation for requesting the return. A
return authorization will be issued giving you clearance for returning
the hoist or parts to the factory.

HOIST OPERATION & MAINTENANCE
5P/N: 11854801 REV. AC September 2017
Yale
Hoist
Duty
Class
Typical Areas
of Application
Operational Time Ratings
Uniformly Distributed
Work Periods
Infrequent Work Period
Hoist Running 50% Time
(3)
Max. on Time
Min./Hr.
(4)
Max. No. of
Starts/Hr.
(5)
Max. Time From
Cold Start Min.
(6)
Max. No. of
Starts
H3
General Machine Shop, fabricating, assembly, storage and
warehousing. Where loads and utilization are randomly
distributed, with total running time of equipment not
exceeding 15-25% of the work period.
15 150 30 200
H4
High volume handling in steel warehousing, general
machine shops, fabricating, assembly, mills and foundries.
Total running time does not exceed 35% of work period.
Loads at or near rated capacity frequently handled.
30 300 30 300
YALE HOIST DUTY SERVICE CLASSIFICATIONS
DECK MOUNT INSTALLATION INSTRUCTIONS
1. It is the responsibility of the Crane Builder to ensure that the trolley
system meets all applicable standards and guidelines available from
but not limited to ANSI, HMI and CMAA in terms of load ratings,
duty cycles and factors of safety.
2. CMCO does not participate in or condone eld modication or
product usage in a manner inconsistent with the design function. It
is the responsibility of the crane builder to ensure compliance with
CMCO specications and guidelines for mounting and operation of
this equipment
3. Refer to drawing C45570401 LodeKing Deck Mount Clearance
Diagram and the specic order clearance diagram for details such
as frame loading, mounting pad dimensional specications and
overall unit envelope dimensions
4. Weld on shear blocks shall be attached by a qualied welder using
a weld that has been sized properly for the application, and welded
per AWS D14 Specications.
5. The weld on shear blocks and the angle iron feet shall not be
subject to loading in the vertical direction. The shear block systems
is designed to resist hoist motion in the horizontal direction only.
Hoist frame loading in areas not approved by CMCO is prohibited.
6. Welding the shear blocks while still attached to the hoist frame is
not recommended due to the possibility of stray voltage from the
welding operation damaging the electrical components present on
the hoist
7. The trolley mounting surfaces shall be at and in the same plane
within 0.015”
8. Hoist frame loading in areas not approved by CMCO is prohibited
9. Deck mount angles to shear block mounting bolts shall be installed
with Loctite, and torqued to 300-325 ft-lbs. Bolts shall be checked
at least yearly for signs of loosening.
INSTALLATION INSTRUCTIONS
Before the unit is shipped from the factory it is rigidly tested and
carefully adjusted for proper operation. However, the following points
must be checked to insure correct installation and avoid damage to
the hoist.
1. ROPE AND DRUM: Check the hoist rope for any signs of
damage and make sure it lies properly in the grooves of
the drum and sheaves. Make sure the rope is well lubricated.
2. LUBRICATION: Every attempt has been made to ship the
hoist with the proper amount of lubricating oil in the gearcase.
Before placing the unit-in operation, check the level on the sight
gauge. The oil should be level with the level hole. If more oil is
needed, consult the Lubrication Chart. Also make sure breather
plug hole is cleared.
3. CURRENT SUPPLY: make sure the electric current supply
corresponds with the rating listed on the hoist nameplate.
Make sure duty cycle capabilities of hoist are fully understood
by all operators.
4. ELECTRICAL CONNECTIONS: Open the control box and
check all the electrical connections ~ to be sure they are tight
and that none of the hardware vibrated loose during shipment.
5. PUSH BUTTON CONTROL:
THE HOIST MUST BE GROUNDED. TO DO THIS CONNECT
A SUITABLE GROUND WIRE IN THE SUPPLY WIRING TO A
SOLID GROUND AND TO THE SUPPLY GROUNDING LUG
SUPPLIED IN THE HOIST CONTROL PANEL.
TO INSURE CORRECT OPERATION OF THE SAFETY LIMIT
STOPS, IT IS VERY IMPORTANT THAT THE HOOK TRAVEL
IS IN THE HOISTING DIRECTION WHEN THE ‘UP’ BUTTON
IS PRESSED. IF IT IS NOT, INTERCHANGE ANY TWO OF THE
MOTOR LEADS IN THE MOTOR CONDUIT BOX. DO NOT
CHANGE PUSHBUTTON WIRING. INTERCHANGING WIRES
ON THE LINE SIDE OF THE INVERTER WILL NOT AFFECT
SHAFT ROTATION DIRECTION. IF THE HOIST IS OPERATED
WITH INCORRECT POWER CONNECTIONS, THE SAFETY
LIMIT STOPS WILL BE INEFFECTIVE AND SERIOUS DAMAGE
AND DANGEROUS ACCIDENTS MAY RESULT.

HOIST OPERATION & MAINTENANCE
6P/N: 11854801 REV. AC September 2017
Italiano Base
TER Tecno Elettrica Ravasi s.r.l.
Via Garibaldi 29/31 - 23885 Calco (LC) - Italy
Tel. [phone] - Fax [phone]
E-mail: [email protected] - www.terworld.com
Sede Legale - Registered Office
Via San Vigilio 2 - 23887 Olgiate Molgora (LC) - Italy
Immagine a scopo illustrativo
Numero e tipo delle camme varia
a seconda del modello
Image for illustrative purpose
the Number and type of cams is different
according to the model
07
08
IP 66 / IP 67 / IP 69K
IP 66 / IP 67 / IP 69K
Istruzioni d’uso e manutenzione
Il necorsa a giri Base è un dispositivo elettromeccanico per circuiti di comando/controllo e
manovra a bassa tensione (EN 60947-1, EN 60947-5-1) da utilizzarsi come equipaggiamento
elettrico di macchine (EN 60204-1) in conformità a quanto previsto dai requisiti essenziali
della Direttiva Bassa tensione 2006/95/CE e della Direttiva Macchine 2006/42/CE.
Il necorsa è previsto per impiego in ambiente industriale con condizioni climatiche anche
particolarmente gravose (temperature di impiego da –40°C a +80°C ed idoneità per utilizzo
in ambienti tropicali). L’apparecchio non è idoneo per impiego in ambienti con atmosfere
potenzialmente esplosive, in presenza di agenti corrosivi od elevata percentuale di cloruro
di sodio (nebbia salina). Il contatto con oli, acidi e solventi può danneggiare l’apparecchio;
evitare di usarli per operazioni di pulizia.
Non è consentito collegare più di una fase per ogni interruttore. Non oliare od ingrassare
gli elementi di comando o gli interruttori.
L’installazione del necorsa deve essere effettuata da personale competente ed addestrato.
I cablaggi elettrici devono essere effettuati a regola d’arte secondo le disposizioni vigenti.
Prima di eseguire l’installazione e la manutenzione del necorsa è necessario spegnere
l’alimentazione principale della macchina.
Operazioni per una corretta installazione del necorsa
1- togliere il coperchio (03) svitando le viti di ssaggio (04)
2- unire l’albero del necorsa (02) con l’albero del riduttore; evitare disassamenti tra i
due alberi;
3- ssare il necorsa in modo stabile al ne di evitare vibrazioni anomale dell’apparecchio
durante il funzionamento; per il ssaggio utilizzare esclusivamente i fori sulla cassetta
(01)
4- avvitare il pressacavo (05) nell’apposita sede.
5- introdurre il cavo multipolare nel necorsa attraverso l’apposito pressacavo (05)
6- spelare il cavo multipolare per una lunghezza adeguata alle operazione di connessione
elettrica con gli interruttori
7- nastrare la parte iniziale spelata del cavo multipolare
8- serrare il cavo nel pressacavo (05)
9- effettuare le connessioni elettriche con gli interruttori rispettando lo schema dei contatti
riportato sugli interruttori medesimi o lo schema di collegamento presente sul retro
delle istruzioni (utilizzare prese Faston da 6.3 mm).
10- effettuare la regolazione del punto di intervento delle camme; per una corretta
regolazione allentare la vite centrale (07) del gruppo camme, impostare il punto di
intervento di ogni singola camma agendo sulla relativa vite di regolazione (08) (viti
numerate ad indicare le camme in ordine crescente dal basso verso l’alto del gruppo),
quindi serrare la vite centrale (07)
11- richiudere il necorsa utilizzando le viti (04) inlando in una di esse l’estremita del
cavetto antiperdita (09), se presente. Porre attenzione al corretto posizionamento
della gomma (06) assemblata sul coperchio (03) e stringere le viti (04) con una forza
di 80/100cNm
Operazioni di manutenzione periodica
- vericare il corretto serraggio delle viti (04) del coperchio (03)
- vericare il corretto serraggio della vite centrale (07) di ssaggio delle camme
- verificare le condizioni dei cablaggi (in particolare nella zona di fissaggio
sull’interruttore)
- vericare le condizioni della gomma (06) assemblata tra il coperchio (03) e la cassetta
(01) ed il serraggio del pressacavo (05) sul cavo multipolare
- vericare l’integrità dell’involucro del necorsa (01, 03)
- vericare l’assialità tra l’albero del necorsa (02) e l’albero del riduttore
- vericare il ssaggio del necorsa
- vericare le condizioni del tappo anticondensa, se presente
Qualsiasi modica ai componenti del necorsa annulla la validità dei dati di targa ed
identicazione dell’apparecchio e fa decadere i termini di garanzia. In caso di sostituzione
di un qualsiasi componente utilizzare esclusivamente ricambi originali.
TER declina ogni responsabilità da danni derivanti dall’uso improprio dell’apparecchio o da
una sua installazione non corretta.
Caratteristiche Tecniche
Conformità alle Direttive Comunitarie 2006/95/CE 2006/42/CE
Conformità alle Norme EN 60204-1 EN 60947-1 EN60947-5-1
EN 60529
Temperatura ambiente Immagazzinaggio -40°C/+80°C
Funzionamento -40°C/+80°C
Grado di protezione IP 42
IP 65
IP 66 / IP 67 / IP 69K
Categoria di isolamento Classe II
Ingresso cavi Pressacavo M16
Velocità massima 800 giri/min
Marcature C
Caratteristiche Tecniche degli Interruttori
Categoria di impiego AC 15
Corrente nominale di impiego 3 A
Tensione nominale di impiego 250 V
Corrente nominale termica 10 A
Tensione nominale di isolamento 300 V~
Durata meccanica 1x106 manovre
Identicazione dei morsetti Secondo EN 50013
Connessioni Faston 6.3 mm
Marcature CX
Caratteristiche Tecniche UL dei Finecorsa
Finecorsa certicati PFA9042AXXXXXXX
PFA9067AXXXXXXX
Caratteristiche elettriche Interruttori B300, R300
Enclosure Finecorsa Tipo 1 PFA9042AXXXXXXX
Tipo 3 PFA9067AXXXXXXX
Conduttori Rame (CU) 60/75°C
Marcatura
PRIS090700 rev. 06
IP 42
IP 42
14
12
11
Schema di collegamento interruttori
Wiring Layout Switches
Schéma des contacts
CONDITION OF ACCEPTABILITY Underwriters Laboratories:
Use - For use only in (or with) complete equipment, when the acceptability of the combination is determined by Underwriters Laboratories Inc.
1. Cable Gland - Suitable Listed outlet bushing and ttings (QCRV/7) for models PF A90 42 xxxx xxx and suitable Listed outlet bushing and ttings (QCRV/7), “liquid Tight” for
models PF A90 67 xxxx xxx has to be installed in eld in order to maintain the enclosure respectively type1 and type 3 ratings.
2. The quick connect terminal and the wiring in general are suitable for factory wiring only.
3.Cord - Suitable Listed (ZJCZ/7) exible cord type minimum S or SJ shall be installed in eld in conjunction with the cable gland for models PF A90 42 xxxx xxx. Suitable Listed
(ZJCZ/7) exible cord type minimum SW or SJW shall be installed in eld in conjunction with the cable gland for models PF A90 67 xxxx xxx.
CONDITION D’ACCEPTANCE DE Underwriters Laboratories:
Utilisation - Utilisation uniquement dans (ou avec) un équipement complet, lorsque l’acceptabilité de l’association est déterminée par Underwriters Laboratories Inc.
1. Presse-étoupe - Convient douille de sortie de Listed et accessoires (QCRV / 7) pour les modèles PF A90 42 xxxx xxx et la douille de sortie Listed approprié et raccords (QCRV / 7),
« étanche aux liquides » pour les modèles PF A90 67 xxxx xxx doit être installé dans domaine an de maintenir l’enceinte respectivement type1 et 3 votes Type.
2. Le terminal de connexion rapide et le câblage en général sont appropriés pour le câblage en usine seulement.
3.Cord - Listed approprié (ZJCZ / 7) minimum type de cordon souple S ou SJ doit être installé dans un champ en conjonction avec le presse-étoupe pour les modèles PF A90 42
xxxx xxx. Cord - Listed approprié (ZJCZ / 7 minimum type de cordon souple SW ou SJW doit être installé dans un champ en conjonction avec le presse-étoupe pour les modèles PF
A90 67 xxxx xxx.
IP 65
1
5
2
4
4
3
1
5
3
9
2
4
4
6
1
5
4
4
3
2
6
IP 65
Rating codes for d-c control-circuit contacts
Valeurs pour les interrupteurs circuit de commande d-c
Contact rating code
designation
Caractéristique électriques
des interrupteurs
Thermal continuous
test current, amperes
Courant nominal
thermique, amperes
Maximum make or break current, amperes
Courant maximum disjonction ou interruption, amperes
125 Volt 250 Volt 301 ÷ 600 Volt
R300 1.0 0.22 0.11 -
R150 1.0 0.22 - -
Rating codes for a-c control-circuit contacts at 50 and 60 hertz
Valeurs pour les interrupteurs circuit de commande a-c à 50 et 60 hertz
Contact rating
code designation
Caractéristique
électriques des
interrupteurs
Thermal
continuous test
current amperes
Courant nominal
thermique,
amperes
Maximum current, amperes / Courant maximum, amperes
120 Volt 240 Volt 480 Volt 600 Volt
Make
Disjonction
Break
Interruption
Make
Disjonction
Break
Interruption
Make
Disjonction
Break
Interruption
Make
Disjonction
Break
Interruption
B300 5 30 3.00 15 1.50 - - - -
B150 5 30 3.00 - - - - - -
RATING ELETTRICI UL DEGLI INTERRUTTORI / UL ELECTRICAL RATING OF THE SWITCHES
GEARED LIMIT SWITCH USE AND
MAINTENANCE INSTRUCTIONS
Base rotary limit switch is an electromechanical device for low voltage control
circuits (EN 60947-1, EN 60947-5-1) to be used as electrical equipment on
machines (EN 60204-1) in compliance with the fundamental requirements of the
Low Voltage Directive 2006/95/CE and of the Machine Directive 2006/42/CE.
The limit switch is designed for use in industrialal environments under even severe
climatic conditions (operational temperature from –40°C to +80°C, suitable for use
in tropical environment). The equipment is not suitable for use in environments
with potentially explosive atmosphere, corrosive agents or a high percentage of
sodium chloride (saline fog). Oils, acids or solvents may damage the equipment;
avoid using them for cleaning. Do not connect more than one phase to each
switch. Do not oil or grease the control elements or the switches.
The installation of the limit switch shall be carried out by expert and trained
personnel. Wiring shall be properly done according to the current instructions.
Prior to the installation and the maintenance of the limit switch, the main
power of the machinery shall be turned off.
Steps for the proper installation of the limit switch
1. loosen the xing screw (04) and remove the cover (03)
2. connect the limit switch shaft (02) to the reduction gear shaft avoiding
any misalignment between the two shafts
3. x the limit switch rmly in place to prevent abnormal vibrations of the
equipment during operation; use only the xing holes on the base (01) to
x the equipment
4. tighten the cable clamp (05) into appropriate place.
5. insert the cable into the limit switch through the cable clamp (05)
6. strip the cable to a length suitable for wiring the switches
7. tape the stripped part of the cable
8. clamp the wire into the cable clamp (05)
9. connect the switches according to the contact scheme printed on the
switches or to the wiring scheme on the back of the instructions (use 6.3
mm Faston taps)
10. adjust the operating point of the cams; for proper adjustment, loosen the
central screw (07) of the cam set, adjust the operating point of each single
cam by turning its screw (08) (the numbers on the screws refer to the cams
counting from bottom to top), then tighten the central screw (07)
11. insert the free end of the no-drop wire (09) into one of the screws (04),
then close the limit switch using the screws (04); check the proper
positioning of the rubber (06) in the cover (03) and tighten the screws
(04) with a torque of 80/100 cNm
Periodic maintenance steps
- check the proper tightening of the screws (04) and cover (03)
- check the proper tightening of the central screw (07) holding the cams
- check the wiring conditions (in particular where wires clamp into the switch)
- check the conditions of the rubber (06) t between the cover (03) and the
base (01) and check the tightening of the cable clamp (05) around the cable
- check that the limit switch enclosure (01, 03) is not broken
- check the alignment between the limit switch shaft (02) and the reduction
gear shaft
- check that the limit switch is properly xed
- if there is an anti-moisture plug, check its conditions
In case any component of the limit switch is modied, the validity of the
markings and the guarantee on the equipment are annulled. Should any
component need replacement, use original spare parts only.
TER declines all responsibility for damages caused by the improper use or
installation of the equipment.
TECHNICAL SPECIFICATIONS
Conformity to
Community Directives 2006/95/CE 2006/42/CE
Conformity to Standards EN 60204-1 EN 60947-1 EN60947-5-1
EN 60529
Ambient temperature Storage -40°C/+80°C
Operational -40°C/+80°C
Protection degree IP 42
IP 65
IP 66 / IP 67 / IP 69K
Insulation category Class II
Cable entry Cable clamp M16
Maximum speed 800 rev/min
Markings C
TECHNICAL SPECIFICATIONS OF THE
SWITCHES
Utilisation category AC 15
Rated operational current 3 A
Rated operational voltage 250 V
Rated thermal current 10 A
Rated insulation voltage 300 V~
Mechanical life 1x106operations
Terminal referencing According to EN 50013
Connections 6.3 mm Faston taps
Markings C X
TECHNICAL SPECIFICATIONS UL
OF THE ROTARY LIMIT SWITCHES
Certied rotary limit switches PFA9042AXXXXXXX
PFA9067AXXXXXXX
Switches Electrical Ratings B300, R300
Rotary limit switch Enclosure Type 1 PFA9042AXXXXXXX
Type 3 PFA9067AXXXXXXX
Conductors Copper (CU) 60/75°C
Be certain that electrical power supply is OFF and locked in
the open position before removing limit switch cover
Check limit switch operation carefully, without load, before
placing hoist in service. If misadjusted, SEVERE DAMAGE AND/
OR A DROPPED LOAD COULD RESULT. Allow 3" for hook drift
in both directions. Never allow less than three (3) complete
wraps of rope on drum with hook in lowest position.
WHEN ADJUSTING LIMIT SWITCHES
HAZARDOUS VOLTAGE. CAN CAUSE DEATH, SERIOUS
PERSONAL INJURY, OR PROPERTY DAMAGE.
DISCONNECT POWER BEFORE WORKING ON THIS EQUIPMENT.
EACH STEP OUTLINED BELOW MUST BE FOLLOWED FOR
PROTECTION AGAINST ELECTRICAL SHOCK AND INJURY
FROM MOVING COMPONENTS.
AT LEAST THREE WRAPS OF ROPE MUST REMAIN ON THE
DRUM IN THE LOWEST POSITION.
MAKE SURE GEARED LIMIT SWITCH TRIPS FIRST,
ALLOWING THE ROD OR WEIGHT TYPE SWITCH TO
ACT AS THE BACKUP LIMIT.

HOIST OPERATION & MAINTENANCE
7P/N: 11854801 REV. AC September 2017
BASIC SUSPENSIONS
The basic hoist suspension type is a top running motorized trolley
for double rails. Before mounting on beam or rail, make sure
supporting structure has adequate strength to safely support the
loading which will be imposed.
On top running motorized trolleys, make sure rail size is correct
for wheels and that distance between rails is correct for trolley
throughout entire rail lengths.
PREVENTATIVE
MAINTENANCE SCHEDULE
The required periods between inspections will vary due to the wide
range of duty cycles and operating conditions encountered with
equipment. The following recommended inspection periods are
based on duty of specied service rating with single shift operation
(40 hours per week) under normal environmental conditions. If the
hoist is used under adverse environmental conditions it should be
inspected more frequently.
DAILY INSPECTION
Inspect the following items before operating hoist:
1. ELECTRICAL CONNECTIONS: Check for worn or frayed
wires, for loose connections and for damage to, or improper
operation of, push button assembly.
2. LIMIT SWITCH: Check the upper and lower limit switch by
running the hook without load, and at the slowest speed
obtainable, to the maximum up and maximum down positions.
Then test with increasing speeds up to maximum. The switch
should shut the hoist off before the bottom block contacts the
rod or weight type limit switch at the upper extreme. Three
wraps of rope should remain on the drum at the shut-off point
at the lowest extreme. If adjustment is necessary, refer to
geared limit switch section.
3. HOOK: Check for cracks or deformation. Check for damaged
or missing latch. A bent or twisted hook indicates overloading
or abuse of unit. Other load bearing components of the hoist
or trolley should be inspected if overloading is apparent or
suspected. The bottom hook must swivel freely.
4. WIRE ROPE: Check for proper seating in drum grooves. Check
for wear, unstranding, fraying, kinks, or broken wires in the wire
rope, and condition of end connections. (If damage is noted,
see wire rope instructions under monthly inspection.)
5. HOOK DRIFT: With a load, the hook should stop promptly
when the push button is released. Hook drift of more than
2 inches indicates the motor brake is malfunctioning. (See
quarterly and annual inspection instructions for more details.)
6. UNUSUAL CONDITIONS: Excessive noise, oil leaks, etc.
should be investigated.
DO NOT OPERATE THE HOIST IF ABOVE
INSPECTION INDICATES THAT MAINTENANCE
IS NEEDED.
MONTHLY INSPECTION
1. ALL ITEMS UNDER DAILY INSPECTION.
2. LUBRICATION: Check the level and condition of the gearcase
lubricant. The level must be maintained at the gearcase sight
gauge. If the level is low, check for leaks. Replace gaskets and
shaft seals if necessary. An excessively black color lubricant
indicates a chemical change in the lubricant caused by
excessive heat, which in turn is caused by heavy duty cycles.
Lubricant that is very black in color must be replaced to prevent
shortened life of drive components. Lubricate wire rope and
other points as required. Refer to lubrication chart.
FOR OPTIMUM LUBRICATION AND COOLING,
OIL LEVEL MUST BE MAINTAINED AT THE
SIGHT GAUGE LEVEL.
3. HOOK: Check hook retaining nuts and collars, and means used
to secure them. Replace hook if throat opening allows safety
latch to disengage from throat opening, or if there is 10 degrees
or more twist from normal plane of hook.
4. PUSH BUTTON: Check the ground connections to be sure
that the wire cores from the push button cable and the power
cord are secured. Tighten the grounding screw and replace the
lockwasher if it is missing.
5. BEARINGS: Check all bearings for noisy operation, which is an
indication of wear.
6. HARDWARE: Check for loose bolts, nuts and rivets.
7. WIRE ROPE: Check conditions of wire rope using inspection
checklist. Refer to wire rope inspection.
8. WARNING LABELS: Check for absence or illegibility of warning
decals and tags and replace if necessary.
NEVER ALLOW WIRE ROPE TO OPERATE DRY.
9. SUPPORTING STRUCTURE OR TROLLEY: Should be
checked for continued ability to support the imposed loads.
Check for loose suspension or support bolts, axle nuts, etc.
10. INSPECTION CHECKLIST: Fill out inspection checklist at the
back of this manual, sign, date and le for future reference.
PRE-OPERATION INSPECTION CHECKLIST
Item Inspection Instruction
 Tagged Crane or Hoist Check that crane or hoist is not tagged with
an out-of-order sign.
 Control Devices Test run that all motions agree with control device
markings.
 Brakes Check that all motions do not excessive drift and
that stopping distance is normal.
 Hook
Check for damage, cracks, nicks, gouges, deforma-
tions of the throat opening, wear on saddle or
load bearing point, and twist. Refer to the manual
furnished by the original crane manufacturer.
 Hook Latch If a hook latch is required, check for
proper operation.
 Wire Rope Check for broken wires, broken strands, kinks, and
any deformation or damage to the rope structure.
 Reeving Check that the wire rope is properly reeved and that
rope parts are not twisted about each other.
 Limit Switches Check that the upper limit device stops the lifting
motion of the hoist load block before striking any
part of the hoist or crane.
 Oil Leakage Check for any sign of oil leakage on the crane
and on the floor beneath the crane.
 Unusual Sounds Check for any unusual sounds from the crane or
hoist mechanism while operating the crane or hoist.
 Warning and Safety
Labels
Check that warning and other safety labels
are not missing and are legible.
 Housekeeping and
Lighting
Check area for accumulation of material to prevent
tripping or slipping. Also check area for poor lighting.
QUARTERLY INSPECTION
1. ALL ITEMS UNDER DAILY AND MONTHLY INSPECTION.
2. MOTOR BRAKE: Check for excessive or uneven disc wear.
Check for excessive magnet gap. Lubricate linkage as
required.

HOIST OPERATION & MAINTENANCE
8P/N: 11854801 REV. AC September 2017
ANNUAL INSPECTION
1. ALL ITEMS UNDER DAILY, MONTHLY AND QUARTERLY
INSPECTION.
2. EQUALIZE SHEAVE, IDLER SHEAVE, AND PINS.
Check for cracked or worn sheaves, pins and bearings.
3. HOOKS: Magnetic particle or other suitable crack detecting
inspection should be performed if need is indicated by external
appearance. Check for loose retaining nuts and collars.
4. LOAD BEARING PARTS: Check for worn, cracked or distorted
parts, such as suspension housings, outriggers, clevises,
yokes, hook blocks, suspension bolts, shafts, locking devices
and bearings on hoist (also on trolley, if so equipped).
5. MOTOR BRAKE: Check for excessive or uneven disc wear.
On direct acting, check for excessive magnet gap. Lubricate
linkage as required.
PRIOR TO TESTING, ALL SUPPORTING STRUCTURES,
ANCHORAGES, AND/OR SUSPENSIONS MUST BE
APPROVED BY THE APPOINTED PERSON FOR THE TEST
LOADS USED.
6. WIRING AND TERMINALS: See that all connections are tight.
Terminals are to be securely crimped to wires and the insulation
sound. Bent terminals can usually be straightened to provide a
tight t. Replace terminals or wire if necessary.
7. SHEAVES AND DRUMS: Inspect rope sheaves and drums for
excessive wear. When the groove of a sheave or rope drum
becomes worn excessively it should be replaced. Worn grooves
on the drum or sheave can greatly reduce the useful life of the
hoisting rope.
9. BEARING LUBRICATION: The motor, sheave, and outer drum
bearings are a pre-lubricated sealed design and normally will
not need to be lubricated.
10. INSPECTION CHECKLIST: Fill out inspection checklist at the
back of this manual, sign, date and le for future reference.
FUNCTION TESTING AFTER REPAIR
PRIOR TO TESTING, ALL SUPPORTING STRUCTURES,
ANCHORAGES, AND/OR SUSPENSIONS MUST BE
APPROVED BY THE APPOINTED PERSON FOR THE TEST
LOADS USED.
After repair or replacement of parts, function test hoist by operating
unloaded hoist into both upper and lower limits, rst with slowest
speed possible, then with increasing speeds up to maximum. Limit
switch mechanisms must be adjusted so they will trip in sufcient
time to prevent damage to any part of the hoisting arrangement.
See instructions for adjustment of limit switches. Then test
operation of hoist and brake by lifting 100% of rated load. (A normal
load lifted may be substituted if no load bearing parts were altered.)
If hoist is equipped with a load limiting device, and load bearing
parts have been altered, the rst test load should be only 100% of
rated load. The test should be prepared by the person responsible
and kept on le for future reference.

HOIST OPERATION & MAINTENANCE
9P/N: 11854801 REV. AC September 2017
WIRE ROPE INSPECTION
All wire rope should be inspected once a month and a signed and
dated inspection report maintained. The inspection checklists at the
back of this manual can be used to record these inspections. Wire
rope should be replaced if any of the following conditions are noted.
1. Twelve randomly distributed broken wires in one rope lay,
or four broken wires in one strand in one rope lay.
2. Wear of one-third (1/3) of the original diameter of outside
individual wires.
3. Kinking, crushing, birdcaging or any distortion of the
wire rope structure.
4. Evidence of heat damage.
5. Reductions from nominal diameter of more than
the following values:
New Rope Diameter Maximum Reduction
5/16 inch and under 1/64 inch
3/8 inch through 1/2 inch 1/32 inch
9/16 inch through 3/4 inch 3/64 inch
7/8 inch through 1-1/8 inch 1/16 inch
6. Rope clamps should be checked to ensure bolts
are properly torqued.
REPLACEMENT WIRE ROPE SHOULD BE THE SAME SIZE,
GRADE AND CONSTRUCTION AS THE ORIGINAL WIRE
ROPE. BEFORE REPLACING WIRE ROPE, READ REEVING
PROCEDURE. AFTER WIRE ROPE REPLACEMENT CHECK
FOR PROPER LIMIT SWITCH OPERATION.
ROPE PILE-ON HOISTING DRUM WILL SEVERELY DAMAGE
THE HOISTING ROPE. IF THIS CONDITION IS NOTED, THE
HOISTING ROPE SHOULD BE INSPECTED ACCORDING TO
THE ABOVE PARAGRAPH ON WIRE ROPE INSPECTION.
IF DAMAGED ROPE IS FOUND, CHECK DRUM AND FRAME
MEMBERS FOR DAMAGE.
HOW TO MEASURE WIRE ROPE
The correct diameter of a wire rope is the diameter of a
circumscribed circle which will enclose all the strands. It is the
largest cross-sectional measurement. The measurement should be
made carefully with calipers. The illustrations below show the correct
Wrong Way Right Way
Broken Wires Kinked Bird Cage
GENERAL INSTRUCTIONS
PROCEDURE FOR REEVING WIRE ROPE
ON DRUM
DOUBLE REEVED UNITS
Note: Rotary cam limit switch must be set for three (3) safety wrap.
1. The rope lays off the drum on the side closest to the equalizer
sheave/running sheave.
2. Anchor the rope in the drum on one side. Install rope retainer.
3. Stretch out rope to make sure there are no twists or kinks.
4. Reeve the free end of the rope through the bottom
block and all sheaves.
5. Anchor the free end of the rope in the other side of the drum.
Install rope retainer.
6. Push the “UP” button to reeve both sides of the drum, making
sure there is enough force on the rope to insure proper reeving
in all drum grooves.
Note: When the bottom block is raised to the upper limit, the block
should be at the midpoint of the ungrooved portion of the drum and
even with idler sheave. If this is not so, the unit is reeved incorrectly.
ALL UNITS WITH A LOWER LIMIT SWITCH MUST HAVE A
MINIMUM OF THREE WRAPS OF WIRE ROPE ON THE DRUM
WHEN THE BOTTOM BLOCK IS IN THE LOWEST POSITION.

HOIST OPERATION & MAINTENANCE
10 P/N: 11854801 REV. AC September 2017
COLUMBUS McKINNON
C O R P O R A T I O N
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
2/3/2015 APCCE
45487403
1:16
HOIST ASSEMBLY
200MM WHEEL BLOCKS
15T LODEKING LT
RSMS
Modeled:
Drawn:
Approved:
Design Authority:
Original project:
Original scale:
Format
B
Number:
Hoist PDE
Hoist PDE
2/3/2015
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.
COLUMBUS McKINNON
C O R P O R A T I O N
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
2/3/2015 APCCE
45487403
1:24
HOIST ASSEMBLY
200MM WHEEL BLOCKS
15T LODEKING LT
RSMS
Modeled:
Drawn:
Approved:
Design Authority:
Original project:
Original scale:
Format
B
Number:
Hoist PDE
Hoist PDE
2/3/2015
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.
REEVING TYPES
Yale powered wire rope hoists and winches are reeved in various
ways to gain desired advantages. Proper reeving insures maximum
life of the hoist drum, wire rope, and bottom block assembly while
obtaining the best characteristics of capacity, lift, and speed for the
basic unit.
Reeving is “double”, i.e. two ropes coming from the drum. Close
headroom hoists are double reeved. “Part” designates the number
of times the rope runs between the hoist and bottom block.
For example: With 2 part double reeving, the rope runs from the rope
drum to the bottom block, up to the equalizer sheave, back to the
bottom block, then back to the rope drum, indicating 4 “parts” of
rope supporting the load.
The drawings below show the characteristics of each principal
method of reeving.
Advantages of double reeved units include minimum lateral hook
drift (keeping load in the same approximate position in relation to
the drum and beam) and a lower hoist headroom requirement.
4 PART REEVING
10 TON CAPACITY
8 PART REEVING
20 & 25 TON CAPACITY
6 PART REEVING
15 TON CAPACITY

HOIST OPERATION & MAINTENANCE
11 P/N: 11854801 REV. AC September 2017
LUBRICANT SPECIFICATIONS
LUBRICANT SPECIFICATIONS AMBIENT TEMPERATURE
-20º to +50º F (-29 to +10ºC) 50º to 125º F (10º to 52ºC) 125º to 250ºF (52º to 121ºC)
CL No Specification
Cable Lubricant
Wire Rope Lubricant
Amoco® Oil Co. ------------------------------------------ Amovis® 5-X ------------------------------------------
Mobil® Oil Corp. ---------------------------------------- Mobilarma® 798 ----------------------------------------
Sun® Oil Corp. -------------------------------- Sunoco® Wire Robe Lubricant --------------------------------
Texaco® Inc. Crater A Texclad® 2
GO AGMA Lubricant No. 1 No. 2
General Oil
General Oiling to Prevent Rust-
ing an Provide Limited Lubrica-
tion for Points Not Considered
Normal Wear Points
Viscosity @ 100º F 193-235 SUS 284-347 SUS
Viscosity Index 60 Min. 60 Min.
Pour Point -20ºF (-29ºC) 10ºF (-12ºC)
Amoco® Oil Co. Rykon® Oil 46 American Industrial Oil® 68
Mobil® Oil Corp. --------------------------------------Mobil® DTE Oil Heavy--------------------------------------
Shell® Oil Co. Rotella® 10W Rotella® 10W-30
Sun® Oil Co. Sunvis® 932 Sunvis® 968
Texaco® Oil Inc. Rando® Oil 46 Rando® Oil 68
MPG NLGI Grease No.1 No. 2
Multipurpose Grease
Grease Lubricated Wear
Points Provided
6ASTM Worked
Penetration 310-340 265-295
Dropping Point 360ºF (182ºC) 360ºF (182ºC)
Base Lithium Lithium
Amoco® Oil Co. Amolith® Grease 1 EP Amolith® Grease No. 2 EP
Mobil® Oil Corp. Mobilith® AW1 Mobilith® AW 2
Shell® Oil Co. ------------------------------------------Retinax LC-----------------------------------------------
Sun® Oil Co. Presitge® 741 EP Sunoco® Multipurpose 2
Texaco Oil Inc. Multifak® EP 1 Multifak® EP 2

12 P/N: 11854801 REV. AC September 2017
COMPONENT, UNIT OR PART
AND LOCATION *RECOMMENDED
INSPECTION INTERVAL
CONDITION
(Check column best indicating condition when part
or unit is inspected. Use note column to the right if
condition is not listed below.)
CORRECTIVE ACTION NOTES
Location
Component, Unit
or Part
Monthly
Semi-Annual Good Adjustment Required Repair Required (Loose Parts Or Wires) Replacement Required (Worn Or Damaged) Lubrication Required (Low Oil Or Grease Rust Or Corrosion) Cleaning Or Painting Required
(Indicate corrective action taken during inspection
and note date. For corrective action to be done after
inspection, a designated person must determine that the
existing deficiency does not constitute a safety hazard
before allowing unit to operate. When corrective action
is completed, describe and note date in this column.)
DATE
LOCATIONHOIST
Motor 
Motor Brake 
Mechanical Load Brake 
Overload Clutch 
Couplings 
Gears, Shafts & Bearings 
Upper Block 
Lower Block 
Hook & Throat Opening Record Hook Throat Opening
Hoist Rope X
Rope Drum 
Guards 
Limit Switch 
CONTROL PANELS
& PUSHBUTTON
Trolley Panel 
Hoist Panel 
Pushbutton 
Wiring 
TROLLEY
Motor 
Brake (When so Equip.) 
Couplings 
Gears, Shafts & Bearings 
Frame 
Wheels 
Bumpers 
Guards 
Conductors 
Collectors 
RUNWAYS
Monorail Joints 
Monorail 
Main Conductors 
Main Collectors 
MISC
General Condition 
Load Attach. Chains 
Rope Slings & Connect. 
Change Gearcase Lub. 
Grounding Faults 
* See text for daily & weekly requirements
Inspection interval
Typical Inspection Schedule and Maintenance Report form. User must adjust
inspection interval and components to suit their individual conditions and usage.
Signed & dated report required - OSHA
X Magnetic particle or equivalent examination required.
INSPECTION SCHEDULE AND MAINTENANCE REPORT
CRANE SERIAL NO. (MFGRS.) _______________________________________________
CAPACITY _____________________________________________________________
TYPE __________________________________________________________________
VOLTAGE _______________________________________________________________
CUSTOMER CRANE IDENTITY NO. ____________________________________________
LOCATION IN PLANT ______________________________________________________
THIS INSPECTION IS
INSPECTED BY________________________________ DATE ______________________
MONTHLY SEMI-ANNUAL ANNUAL

HOIST OPERATION & MAINTENANCE
13 P/N: 11854801 REV. AC September 2017
DISASSEMBLY
BEFORE DOING MAINTENANCE WORK ON THIS HOIST,
READ THE FOLLOWING INSTRUCTIONS THOROUGHLY.
REFER TO THE REPLACEMENT PARTS SECTION FOR PARTS
IDENTIFICATION.
To completely disassemble the hoist, follow the disassembly
procedures in the order listed.
To disassembly any one specic part of the hoist, follow the
instructions for that specic section.
1. REMOVE HOIST ROPE, BOTTOM BLOCK
OR BOTTOM HOOK.
a. Remove or readjust rotary cam limit to negate lower limit
(see instructions (a) through (f)).
b. Operate hoist in down direction until no cable
remains on the drum. Remove rope clamps and
pull rope from the drum.
c. Remove power from the hoist.
d. Free the rope from the upper block
e. Remove shafts holding the sheaves in the yoke or frame
and remove cable (where applicable).
2. REMOVE MOTOR BRAKE (DIRECT ACTING).
DISCONNECT ALL POWER TO THE HOIST BY
DISCONNECTING THE POWER FEED LINE BEFORE
ATTEMPTING SERVICE OR REPAIR.
a. Disconnect encoder cable from encoder.
b. Remove fan shroud screws and remove shroud.
c. Loosen set screws holding encoder to shaft
and remove encoder.
d. Remove screws holding fan to shaft and remove fan.
e. Disconnect brake cable within motor terminal box
and remove cable from terminal box.
f. Remove four socket head screws holding
brake to motor. Remove brake.
3. REMOVE GEAR CASE.
a. hoist in down direction and clear all rope
from the hoist drum.
b. Block or support drum to prevent movement after the
outboard bearing support is removed. Remove (4) M20
SHCS and (2) M20 shoulder screws from the bearing support
and remove the stub shaft from the drum bearing. Be careful
that the drum does not move off the drive splined shaft.
c. Slide drum drive side end from spline shaft to remove the
drum. After blocking or supporting the gearbox, remove the
(8) M16 HHB.
d. The gearbox and motor assembly are now free from the
trolley frame, and may be removed by pulling the gearbox
out from the mating pilot on the frame.
THE GEAR CASE ASSEMBLIES CAN BE VERY HEAVY. IF
POSSIBLE, IT IS BEST TO SUPPORT THEIR WEIGHT PRIOR
TO REMOVAL.
4. REMOVE LIMIT SWITCH, TRAVELING NUT OR GEARED.
a. Geared Upper and Lower Limit Switch
1. Disconnect all power from hoist.
2. Remove the cover from the limit switch and disconnect
the wiring. Note the color coding or tag the wires so they
can be reconnected correctly. Loosen the cord tting and
remove the cord.
3. Remove the bolts and lockwashers that hold the limit
switch assembly to the bracket. Remove the limit switch
assembly from the bracket.
b. Upper Block Limit Switch
1. Disconnect all power from the hoist.
2. Remove bolts holding the limit switch bracket to the hoist
and remove the limit switch assembly.
3. Loosen the clamping screw holding the hub on the limit
switch shaft and remove the hub and lever assembly.
Note its position carefully so it can be reinstalled
correctly.
4. Remove the screws holding the limit switch to the
bracket.
5. Remove the limit cover and disconnect the wiring.
Note the color coding or tag the wires so they can
be reconnected correctly. Loosen the cord tting and
remove the cord from the limit switch.
5. REMOVE CONTROLS OR CONTROL BOX.
a. Remove all power from the hoist.
b. Disconnect and tag all wires coming into the control box.
c. Remove nuts, bolts and lockwashers holding control panel in
the box.
d. Remove control panel.
e. Disconnect all ex conduit, limit switch cord, push-button
cord and power leads from control box.
f. Remove nuts and lockwashers holding control box and
remove. Control box may be heavy and should be supported
before removing.
REASSEMBLY
The assembly sequence is basically the reverse of the disassembly
sequence previously described. The following special instructions
should be observed during reassembly.
1. Before the gear case is assembled, all internal parts should
be inspected for damage or excessive wear. Replace parts as
required.
2. Be sure the drum drive shaft is free of paint or other material
which would interfere with installation. Lubricate the shaft with
Never-Seez® to prevent galling. Reinstall inner and outer
retaining rings to prevent shaft movement.
3. Be sure the motor brake is properly adjusted before it is installed
on the motor.
4. Attach gear case to frame using (8) M16 x 70mm bolts (see
parts manual section for part number) torqued to 200 ft-lbs
max (275 N-m). Apply a medium strength thread locker such as
Loctite 243 on the bolts prior to installation
5. Prior to drum installation, lubricate drum splines with a
recommended Number 2 multipurpose grease as outlined in
the lubrication chart on page 11. Install the drum onto the drive
shaft splines taking care to support the drum.
6. Lubricate the drum stub shaft on the outboard bearing support
with a recommended Number 2 multipurpose grease as outlined
in the lubrication chart on page 11. Install outboard bearing
support ensuring that the shoulder screws are used in the correct
position. Torque the (4) M20 SHCS to 375 ft-lbs max (500 N-m).
Apply a medium strength thread locker such as Loctite 243 on
the bolts prior to installatio

HOIST OPERATION & MAINTENANCE
14 P/N: 11854801 REV. AC September 2017
Winding rope on rope drums with power can be hazardous.
Keep hands safe distance from drum; wear gloves and use
extreme care when winding rope.
7. Re-reeve as follows:
INSTALLING NEW ROPE:
1. Thread both ropes to drum from upper block side then secure
with rope clamps as follows:
a. Make sure that the rope clamp groove size, as marked on
top of the clamp above the groove, matches the rope size for
your hoist (12mm on LodeKing LT 10T, 15T, 20T and 13mm
on 25T.).
b. With the rope lying in the bottom of the drum groove, begin
by tightening the rope clamp at the tail end of the rope.
Torque the clamp bolt to 25-30 ft-lbs (34-40 N-m) for the
10T/15T/20T units, 60-70 ft-lbs (80-95 N-m) on the 25T.
c. Applying tension to the rope and keeping it properly seated
in the drum groove, install the remaining two clamps to the
specied torque above.
2. With all personnel clear of hoist - TURN ON POWER.
3. Operate hoist "UP" guiding six (6) wraps of new rope into drum
grooves with gloved hand.
4. With outer lower block covers removed, thread the wire rope
through the sheaves of the upper and lower block as shown on
Reeving Diagrams referenced on page 10 of manual.
5. Replace the lower block sheave covers.
6. Lubricate cable with recommended lubricant.
Geared limit switch must be reset after replacing wire
rope. Check limit switch operation carefully, without load,
before placing hoist in service. SEVERE DAMAGE AND/OR
A DROPPED LOAD COULD RESULT. Allow 3" for hook drift
in both directions. Do not allow less than three (3) complete
wraps of rope on drum with hook in lowest position.
The hoist must be removed from service and placed on the
ground for any maintenance that requires removal of the
output shaft assembly or drum.

HOIST OPERATION & MAINTENANCE
15 P/N: 11854801 REV. AC September 2017
TROUBLESHOOTING
LOAD DRIFTS OR DROPS
Possible Cause Remedy
Motor brake slipping* Adjust brake. Check for oil on brake discs.
Motor brake not closing* Adjust for proper clearance.
See brake instructions.
* With vector control, the inverter will fault and warning horn will sound in the
event of any brake related issues. If these conditions are observed (Brake slip
or failure to set), see the hoist inverter manual to troubleshoot inverter related
brake faults and the brake manual for proper adjustment of brake.
BRAKE COIL BURNED OUT
Possible Cause Remedy
Wrong coil Replace with proper voltage coil.
Motor brake too tight Adjust brake. See brake instructions.
HOIST DOES NOT OPERATE
Possible Cause Remedy
Blown or loose fuse Replace or tighten fuse
Tripped breaker Reset breaker
Lose terminal screws Check and tighten all loose screws
Low voltage
Check voltage at line side of mainline
contactor (when provided) or line side of
hoist fuse base
Low voltage or no voltage
to push button circuit
Check voltage at output side of transformer.
Wrong voltage tap may have been selected.
For example: 460 volt tap used when line
voltage is 230 volt. Check control circuit fuse.
Defective push button Check contact points at push button to see if
points touch. If not, replace.
Defective push button cord.
(Wire may be pinched,
broken or bare.)
Check for lack of continuity or short to ground.
Motor brake coil burned Replace. Check to make sure coil is proper
coil for voltage applied.
Defective stator Rewind stator
Rotor loose on shaft Replace
MOTOR OVERHEATS, EXCESSIVE
AMPERAGE DRAW
Possible Cause Remedy
Defective stator Replace or rewind stator
Worn motor bearings Replace
Bent rotor shaft Replace
Rotor dragging in stator
Tighten motor bolts. Check for foreign matter
between rotor and stator. Check for worn
motor bearings.
Stator loose in frame
Rewind stator if necessary.
Reposition and anchor in accordance with
motor manufacturers instructions.
Low voltage Check with local utility company and/or
increase wire size.
MOTOR NOISY
Possible Cause Remedy
Motor bolts loose Tighten
Rotor dragging in stator Check for bent rotor shaft or worn bearings.
Replace worn or damaged parts.
Motor bearings loose Replace bearings
TRANSFORMER OVERHEATS OR BURNS OUT
Possible Cause Remedy
Wrong tap used
on primary side
Replace transformer if necessary.
Primary tap must match line voltage.
Shorted transformer Replace
Shorted control circuit Correct short
HOIST SHOCKS OPERATOR
Possible Cause Remedy
Hoist not grounded Ground hoist
Power leads or control wires
shorted to hoist frame. Repair or replace
Grounded motor Replace
Slight electrical leakage
from any of the electrical
components on hoist.
Make sure hoist is properly grounded.

HOIST OPERATION & MAINTENANCE
16 P/N: 11854801 REV. AC September 2017
HOIST GEAR DRIVE
GENERAL INSTRUCTIONS
Recycling (keeping in mind the instructions in force):
– the elements of casing, gear pairs, shafts and bearings
of gear reducer must be transformed into steel scraps. The
elements in grey cast iron will be subjected to the same
treatment if there is no particular instruction;
– the worm wheels are made in bronze and must be
treated adequately;
– exhausted oils must be recycled and treated according to the
instructions.
The paragraphs marked with present symbol contain dispositions
to be strictly respected in order to assure personal safety and
to avoid any heavy damages to the machine or to the
system (e.g.: works on live parts, on lifting machines, etc.);
the responsible for the installation or maintenance must
scrupulously follow all instructions contained in present
handbook.
1 - GENERAL SAFETY INSTRUCTIONS
Gear reducers and gearmotors present dangerous parts because
they may be:
– live;
– at temperature higher than +50°C;
– rotating during the operation;
– eventually noisy (sound levels > 85 dB(A)).
An incorrect installation, an improper use, the removing
or disconnection of protection devices, the lack of
inspections and maintenance, improper connections may cause
severe personal injury or property damage. Therefore the component
must be moved, installed, commissioned, handled, controlled,
serviced and repaired exclusively by responsible qualified
personnel (denition to IEC 364).
It is recommended to pay attention to all instructions of present
handbook, all instructions relevant to the system, all existing safety
laws and standards concerning correct installation.
Attention! Components in non-standard design or with constructive
variations may differ in the details from the ones described here
following and may require additional information.
Attention! For the installation, use and maintenance of the electric
motor (standard, brake or non-standard motor) and/or the electric
supply device (frequency converter, soft-start, etc.) and accessories,
if any (ow indicators, independent cooling unit, thermostat, ecc)
consult the attached specic documentation. If necessary, require it.
Attention! For any clarication and/or additional information consult
Rossi and specify all name plate data.
Gear reducers and gearmotors of present handbook are normally
suitable for installations in industrial areas: additional protection
measures, if necessary for different employs, must be adopted and
assured by the person responsible for the installation.
IMPORTANT: the components supplied by Rossi must be
incorporated into machinery and should not be commissioned
before the machinery in which the components have been
incorporated conforms to:
– Machinery directive 2006/42/EC and subsequent updatings; in
particular, possible safety guards for shaft ends not being used
and for eventually accessible fan cover passages (or other) are
the Buyer’s responsibility;
– Electromagnetic compatibility (EMC)» directive 2004/108/ EC
and subsequent updatings.
When operating on gear reducer (gearmotor) or on components
connected to it the machine must be at rest: disconnect motor
(including auxiliary equipments) from power supply, gear reducer
from load, be sure that safety systems are on against any accidental
starting and, if necessary, pre-arrange mechanical locking devices
(to be removed before commissioning).
If deviations from normal operation occur (temperature increase,
unusual noise, etc.) immediately switch off the machine. The
products relevant to this handbook correspond to the technical
level reached at the moment the handbook is printed. ROSSI
MOTORIDUTTORI reserves the right to introduce, without notice, the
necessary changes for the increase of product performances.
2 - OPERATING CONDITIONS
Gear reducers are designed for industrial applications according
to name plate data, at ambient temperature 0 ÷40°C (with peaks
at -10°C and +50°C), maximum altitude 1 000 m.
Not allowed running conditions: application in aggressive
environments having explosion danger, etc. Ambient conditions
must comply with specications stated on name plate.
3 - HOW SUPPLIED
3.1 - RECEIPT
At receipt verify that the unit corresponds to the one ordered and
has not been damaged during the transport, in case of damages,
report them immediately to the courier.
Avoid commissioning gear reducers and gearmotors, that are even if
slightly damaged.
3.2 - NAME PLATE
Every gear reducer presents a name plate in anodised aluminium
containing main technical information relevant to operating and
constructive specications and dening, according to contractual
agreements, the application limits (see g. 1); the name plate must
not be removed and must be kept integral and readable. All name
plate data must be specied on eventual spare part orders.
3.3 - PAINTING
Products are painted according to the painting table shown on
page 20. Before adding further coats of paint (use dual-compound
paints only), properly protect the seal rings (which must neither be
damaged nor painted), degrease and sand the gear reducer (or
gearmotor) surfaces.

HOIST OPERATION & MAINTENANCE
17 P/N: 11854801 REV. AC September 2017
4 - STORING
Surroundings should be sufciently clean, dry and free from
excessive vibrations (veff ≤0,2 mm/s) to avoid damage to bearings
(excessive vibration should also be guarded during transit, even
if within wider range) and ambient storage temperature should be
0 ÷40°C: peaks of 10°C above and below are acceptable.
The gear reducers lled with oil must be positioned according to
the mounting position mentioned on the order during transport and
storage.
Every six months rotate the shafts (some revolutions are sufcient)
to prevent damage to bearings and seal rings. Assuming normal
surroundings and the provision of adequate protection during transit,
the unit is protected for storage up to 1 year.
For a 2 year storing period in normal surroundings it is necessary to
pay attention also to following instructions:
– generously grease the sealings, the shafts and the unpainted
machined surfaces, if any, and periodically control conservation
state of the protective anti-rust oil;
– for gear reducers and gearmotors supplied without oil: completely
ll the gear reducers with lubrication oil and the specied level
before commissioning.
For storages longer than 2 years or in aggressive surroundings or
outdoors, consult Rossi.
5 - INSTALLATION
5.1 - GENERAL
Before the installation, verify that:
– there were no damages during the storing or the transport;
– design is suitable to the environment (temperature, atmosphere,
etc.);
– electrical connection (power supply, etc.) corresponds to motor
name plate data;
– used mounting position corresponds to the one stated in name
plate.
Attention! When lifting and transporting the gear reducer or
gearmotor use through holes or tapped holes of the gear
reducer casing; be sure that load is properly balanced and
provide lifting systems, and cables of adequate section. If
necessary, gear reducer and gearmotor masses are stated
in Rossi technical catalogues.
Be sure that the structure on which gear reducer or gearmotor
is tted is plane, levelled and sufciently dimensioned in order
to assure tting stability and vibration absence (vibration speed
veff 3,5 mm/s for PN 15 kW and veff 4,5 mm/s for PN > 15 kW
are acceptable), keeping in mind all transmitted forces due to the
masses, to the torque, to the radial and axial loads.
For the dimensions of xing screws of gear reducer feet and the
depth of tapped holes consult the Rossi technical catalogues.
Carefully select the length of xing screws when using tapped holes
for gear reducer tting, in order to assure a sufcient meshing thread
length for the correct gear reducer tting to the machine without
breaking down the threading seat.
Attention! Bearing life and good shaft and coupling running
depend on alignment precision between the shafts.
Carefully align the gear reducer with the motor and the
driven machine (with the aid of shims if need be, for gear
reducers size ≥400 use level tapped holes), interposing
exible couplings whenever possible.
Incorrect alignment may cause breakdown of shafts and/or
bearings (which may cause overheatings) which may represent
heavy danger for people.
Do not use motor eyebolts when lifting the gearmotors. Position the
gear reducer or gearmotor so as to allow a free passage of air for
cooling both gear reducer and motor (especially at their fan side).
Avoid: any obstruction to the air ow; heat sources near the gear
reducer that might affect the temperature of cooling air and of
gear reducer (for radiation); insufcient air recycle and applications
hindering the steady dissipation of heat.
Mount the gear reducer or gearmotor so as not to receive vibrations.
Mating surfaces (of gear reducer and machine) must be clean and
sufciently rough (approximately Ra ≥6,3 μm) to provide a good
friction coefcient: remove by a scraper or solvent the eventual paint
of gear reducer coupling surfaces.
When external loads are present use pins or locking blocks, if
necessary.
When tting gear reducer and machine and/or gear reducer and
eventual ange B5 it is recommended to use locking adhesives on
the fastening screws (also on ange mating surfaces).
Before wiring-up the gearmotor make sure that motor voltage
corresponds to input voltage. If direction of rotation is not as
desired, change parameter B03-04 to change rotation.
If overloads are imposed for long periods or if shocks or danger of
jamming are envisaged, then motor-protection, electronic torque
limiters, uid couplings, safety couplings, control units or other
similar devices should be tted.
Motor is provided with thermal switch connected to the upward
motion (no thermal probes/thermistors). Motor is also protected
from overload via tuning to the VG+S4 inverter.
Use varistors and/or RC lters to limit voltage peaks due to
contactors.
When gear reducer is equipped with a backstop device1, provide a
protection system where a backstop device breaking could cause
personal injury or property damage.
Whenever a leakage of lubricant could cause heavy damages,
increase the frequency of inspections and/or envisage appropriate
control devices (e.g.: remote level gauge, lubricant for food industry,
etc.).
In polluting surroundings, take suitable precautions against lubricant
contamination through seal rings or other.
For outdoor installation or in a hostile environment (atmospheric
corrosivity category C3 according to ISO 12944-2), protect the gear
reducer or gearmotor with a proper dual-compound anticorrosion
paint; added protection may be afforded by applying water-proof
grease (especialIy around the rotary seating of seal rings and at shaft
end access points).
Gear reducers and gearmotors should be protected whenever
possible and by appropriate means from solar radiation and
extremes of weather: protection becomes essential when high
or low speed shafts are vertically disposed or when the motor is
installed vertical with fan uppermost.
For ambient temperature greater than +40°C or less than 0°C,
consult Rossi.
When gear reducer or gearmotor is supplied with water cooling by
coil or independent cooling unit, see ch 7.
1) The presence on gear reducer of backstop device is stated by the arrow near the low speed
shaft, indicating the free rotation, excluding shaft mounted gear reducers where B or C designs
are stated (see Rossi technical catalogues).

HOIST OPERATION & MAINTENANCE
18 P/N: 11854801 REV. AC September 2017
6 – LODEKING LT HOIST GEARCASE
LUBRICATION RECOMMENDATIONS
LodeKing LT hoist gearboxes are shipped from the factory prelled
with a high quality Mobilgear 600 XP 460 mineral oil based lubricant
in the following quantities:
Hoist Capacity Rossi Gearbox Quantity (gallons)
10T/15T/20T MR160 4.8
25T MR180 5
All capacities with Optional
Secondary Holding Brake MR180 Long Case 6.2
The unit should be lled from the orange breather/ller plug on
top of the case. Ensure that the unit has cooled sufciently before
removing the ll plug. A sight glass is provided on the side of the
transmission, behind the motor. Ensure that the oil level is halfway
up the provided sight glass. Exact oil quantity required to ll the unit
shall be determined by the sight gage. Do not overll the unit!
RECOMMENDED OILS:
Columbus McKinnon recommends 460 ISO viscosity grade oil,
either mineral or PAO based synthetic depending on operating
temperature. Acceptable oil types are listed below:
Manufacturer PAO Synthetic Oil
(ISO VG 460) Mineral Oil (ISO VG 460)
AGIP Blasia SX Blasia
ARAL Degol PAS Degol BG
BP Enersyn EPX Energol GP XP
Castrol Alphasyn EP Alpha SP
Fuchs Renolin Unisys CLP Renolin CLP
Klüber Klübersynth GEM4 Klüberoil GEM1
Mobil Mobil SHC Gear Mobilgear 600 XP
Shell Omala S4 GX Omala S2 G
Texaco Pinnacle Meropa
Total Carter SH Carter EP
Synthetic oil with a PAO basis and proper viscosity and additive
packages are recommended when it is necessary to increase oil
change interval, decrease operating oil temperature or increase the
ambient temperature range
OIL CHANGE INTERVAL:
Initial Oil Change shall occur at 1000 operating hours, or one year,
whichever occurs rst
Operating Oil
Temperature Oil Change Interval
˚F ˚C Mineral Oil Synthetic PAO Oil
< 149 < 65 4000 12500
149-176 65-80 2000 9000
176-203 80-95 1000 6000
203-230 95-110 Not Recommended 3000
Oil change intervals assume a pollution free environment. It may be
necessary to reduce the oil change intervals based on contaminants
introduced into the gearbox from the operational environment.
REGARDLESS OF OPERATING HOURS:
• Replace the mineral oil every three years after the initial oil change
• Replace or Regenerate the synthetic oil every 5 years
Do not mix different brands of synthetic oil! If a synthetic oil change
involves switching to a different lubricant manufacturer,
ensure that the gearbox is ushed completely before relling.
Regardless of oil base, Oil sampling and analysis is recommended
on a yearly basis as a preventative maintenance tool. An oil sample
analysis will indicate a trend in wear particles and contaminants (dirt
and water) within the gearcase, as well as give an indication of the
“health” of the oil additive packages. Consult your local oil supplier
for further details.
7 - COMMISSIONING
Carry out an overall check, making particularly sure that the gear
reducer is lled with lubricant.
Where star-delta starting is being used, input voltage must match
the motor lower voltage (connection).
For asynchronous three-phase motor, if the direction of rotation is
not as desired, invert two phases at the terminals.
Before running gear reducers tted with backstop device, make sure
that the direction of rotation in machine, gear reducer and motor all
correspond correctly.
Attention! One or more startings in the false direction, even
if short, could irremediably damage the backstop device,
the coupling seats and/or the electric motor.
A running-in period is advisable:
– of approx. 400 ÷ 1 600 h for gear reducers with worm gear pairs in
order to reach maximum efciency;
– of approx. 200 ÷ 400 h for gear reducers with bevel and/or
cylindrical gear pairs in order to reach maximum functionality.
The temperature of both gear reducer and lubricant may well
rise beyond normal values during running-in. After the running-in
period it may be necessary to verify the gear reducer fastening bolt
tightness.
8 - MAINTENANCE
8.1 - GENERAL
At machine rest, verify at regular intervals (more or less frequently
according to environment and use):
a) all external surfaces are clean and air passages to the gear
reducer or gearmotors are free, in order that cooling remains fully
effective;
b) oil level and deterioration degree (check with cold gear reducer
at rest);
c) the correct fastening screws tightening.
During the operation check:
– noise level;
– vibrations;
– seals;
– etc.
Attention! After a running period, gear reducer (excluding
the shaft mounted gear reducers) is subject to a light
internal overpressure which may cause burning liquid
discharge. Therefore, before loosening whichever plug wait until
gear reducer has become cold; if not possible, take the necessary
protection measures against burning due to warm oil contact. ln all
cases, always proceed with great care.
Maximum oil temperatures indicated in lubrication table (see ch.6.2)
do not represent a hindrance to the gear reducer regular running.
Oil change. Execute this operation at machine rest and cold gear
reducer.
Prearrange a proper drain oil collection, unscrew both the drain
plug and the ller plug in order to facilitate oil draining; dispose the
exhaust lubricant in compliance with the laws in force.
Wash the inside part of gear reducer housing using the same oil type
suitable for the running; the oil used for this wash can be applied for
further washings after proper ltering by 25 μm of ltration standard.
Fill in the gear reducer again up to level.
It is always recommended to replace the seal rings (see ch. 9.3)
When dismounting the cap (whenever gear reducers are provided
with), reset the sealing with adhesive on cleaned and degreased
mating surfaces.

HOIST OPERATION & MAINTENANCE
19 P/N: 11854801 REV. AC September 2017
8.2 - SEAL RINGS
It is always recommended that the seal rings are replaced with new
ones when they are removed or during periodic checks of gear
reducer; in this case, the new ring should be generously greased and
positioned so that the seal line does not work on the same point of
sliding contact as the previous ring.
Oil seals must be protected against heat radiation, also during the
shrink tting of parts, if applicable.
Durating depends on several factor such as dragging speed,
temperature, ambient conditions, ect.; as a rough guide; it can vary
from 3 150 to 25 000h.
8.3 - BEARINGS
Since there are many different types of bearings in a gear reducer
(roller, tapered roller, straight roller, etc.) and each bearing works with
different loads and speeds depending on the input speed, the nature
of the load of the driven machine, the transmission ratio, etc., and
with different lubricants (oil bath, oil splash, grease, oil circulation,
etc.), it is not possible to dene any periodical maintenance and
replacement of bearings in advance.
If a precautionally maintenance is required, undertake periodical
checks to verify noise level and vibration with the help of
appropiate diagniostic equipment and instruments. If the
measured values worsen even slightly it is necessary to stop gear
reducer or gear motor and after having inspected inside the unit
replace the bearings which are subject to breakdown.
8.4 - SOUND LEVELS
Most of the Rossi product range is cha racterised by sound
pressure levels L
pA (mean value of measurement, assuming nominal
load and input speed n1= 1 400 min-1, at 1 m from external prole of
gear reducer standing in free eld on a reecting surface, according
to draft proposal ISO/CD 8579) lower or equal to 85 dB(A).
The table indicates the pro ducts which can exceed a.m. threshold.
For further information about sound levels of every single product
see Rossi technical catalogues.
Machine / Train of gears iNSize
Parallel shaft R I ≤3,15 ≥160
R 2I ≥4≥200
R 3I all ≥320
R 41 all ≥400
≤160 ≥500
≥200 ≥630
Right angle shaft R CI all ≥320
R C2I ≤63 ≥400
≥71 ≥500
R C3I all ≥630
Right angle shaft R C 1≥250
8.5 PERIODIC BRAKE MAINTENANCE
Verify, at regular intervals, that air-gap and backlash g (see Fig. 9)
of release lever pullers, if any, are included between values stated
in Tab. 3 (remove the wear dust of friction surface, if any). It is not
necessary to set the backlash g if motor is equipped with manual
release with automatic clearance taking-up.
Excessive air-gap value makes brake noise level rise, miss of electric
release and decrease of braking
torque up to zero due to the clearance taking up of release lever
pullers; g dimension in Fig. 9 has always
to correspond to the values stated in Tab. 3; too high g value makes
difcult or inefcacious the use of release lever.
Adjust the air-gap (see Fig. 9) by releasing the nuts 32 and by
screwing the fastening screws 25 (it is necessary to act through a
hole of the ywheel, if present) in order to reach minimum air-gap
(see Tab. 3) measuring by a thickness gauge in 3 positions at 120°
near the guiding bushes 28. Tighten nuts 32 keeping in position
fastening screws 25. Verify the obtained air-gap value.
If the brake is provided (code «,RF» on name plate) with removable
thin spacers placed under the brake
fastening studs, adjust air-gap simply removing one series of thin
spacers after having partially loosen
(without disassembling) the brake xing bolts (see Fig. 11);
adjustment through thickness 25 gauge and brake dismounting are
no longer required. The brake is supplied with two series of thin
spacer of different color (yellow and red) to allow two adjustment
operations.
After several adjustments of air-gap, verify that brake disk thickness
is not lower than the minimum value stated in Tab. 3; if necessary,
replace the brake disk (refer to Fig. 9).
Release lever rod is not to be left permanently installed (to avoid
dangerous or inappropriate use).
Tightening torques Ms for terminal block connections
Ms
N m
Thread
M4 M5 M6 M8
Min 0,8 1,8 2,7 5,5
Max 1,2 2,5 4 8
Periodic Maintenance
Brake Size Motor Size mm Air-gap mm
BZ 07 132,160S 0,7 0,40 ÷ 0,40 7,5
1) Backlash of release lever pullers (if any)
2) Minimum thickness of brake disk.
11
Tab. 3. Manutenzione periodica
Periodical maintenance
Grand. freno Grand. motore g Traferro Smin
Brake size Motor size Air-gap
mm mm mm
1) 2)
BZ 12 63 0,5 0,25

0,4006
BZ 53, 13 71, 80 0,5 0,25

0,4006
BZ 04, 14 80, 90 0,6 0,30

0,45 6
BZ 05, 15 90, 100, 112 0,6 0,30

0,45 7
BZ 06S112 0,7 0,35

0,55 7,5
BZ 56 132 0,7 0,35

0,5507,5
BZ 06 132 0,7 0,35

0,5507,5
BZ 07 132, 160S 0,7 0,40

0,4007,5
1) Gioco dei tiranti della leva (eventuale) di sblocco.
2) Spessore minimo del disco freno.
1) Backlash of release lever pullers (if any)
2) Minimum thickness of brake disk.
Fig. 9.
Brake
Fig. 8. Collegamento freno (raddrizzatore)
Brake (rectifier) connection
t2c.c. (frenatura rapida)
t2d.c. (fast braking)
t2 (frenatura normale)
t2 (standard braking)
Raddrizzatore multitensione RM1, RM2 (colore gri-
gio), raddrizzatore per sblocco rapido RR5 (colore
rosso)
Multivoltage rectifier RM1, RM2 (grey color), rectifier
for quick release RR5 (red color)
Segnalazione usura freno
Brake wear signal
Segnalazione blocco/sblocco freno
Brake jam/release signal
Fig. 10. Freno con microinterruttore
Brake with microswitch
Fig. 11. Freno con traferro a
registrazione facile
Brake with easy adju-
stable air-gap
Freno HBZ - HBZ brake
Condizione di blocco
(freno non alimentato)
Jam condition
(brake not fed)
M
f0
Condizione di sblocco
(freno alimentato)
Release condition
(brake fed)
M
f= 0
Condizione
di freno
usurato
Worn brake
condition
Condizione
di freno
integro
Unworn
brake
condition
25
1) Bobina freno già collegata al raddrizzatore all'atto della fornitura.
2) Linea separata.
3) Morsettiera motore
1) Brake coil supplied already connected to rectifier.
2) Separate supply
3) Motor terminal block.
G = giallo / yellow N = nero / black B = bianco / white
11
Tab. 3. Manutenzione periodica
Periodical maintenance
Grand. freno Grand. motore g Traferro Smin
Brake size Motor size Air-gap
mm mm mm
1) 2)
BZ 12 63 0,5 0,25

0,4006
BZ 53, 13 71, 80 0,5 0,25

0,4006
BZ 04, 14 80, 90 0,6 0,30

0,45 6
BZ 05, 15 90, 100, 112 0,6 0,30

0,45 7
BZ 06S112 0,7 0,35

0,55 7,5
BZ 56 132 0,7 0,35

0,5507,5
BZ 06 132 0,7 0,35

0,5507,5
BZ 07 132, 160S 0,7 0,40

0,4007,5
1) Gioco dei tiranti della leva (eventuale) di sblocco.
2) Spessore minimo del disco freno.
1) Backlash of release lever pullers (if any)
2) Minimum thickness of brake disk.
Fig. 9.
Brake
Fig. 8. Collegamento freno (raddrizzatore)
Brake (rectifier) connection
t2c.c. (frenatura rapida)
t2d.c. (fast braking)
t2 (frenatura normale)
t2 (standard braking)
Raddrizzatore multitensione RM1, RM2 (colore gri-
gio), raddrizzatore per sblocco rapido RR5 (colore
rosso)
Multivoltage rectifier RM1, RM2 (grey color), rectifier
for quick release RR5 (red color)
Segnalazione usura freno
Brake wear signal
Segnalazione blocco/sblocco freno
Brake jam/release signal
Fig. 10. Freno con microinterruttore
Brake with microswitch
Fig. 11. Freno con traferro a
registrazione facile
Brake with easy adju-
stable air-gap
Freno HBZ - HBZ brake
Condizione di blocco
(freno non alimentato)
Jam condition
(brake not fed)
M
f0
Condizione di sblocco
(freno alimentato)
Release condition
(brake fed)
M
f= 0
Condizione
di freno
usurato
Worn brake
condition
Condizione
di freno
integro
Unworn
brake
condition
25
1) Bobina freno già collegata al raddrizzatore all'atto della fornitura.
2) Linea separata.
3) Morsettiera motore
1) Brake coil supplied already connected to rectifier.
2) Separate supply
3) Motor terminal block.
G = giallo / yellow N = nero / black B = bianco / white
Brake with easy adjustable air-gap

HOIST OPERATION & MAINTENANCE
20 P/N: 11854801 REV. AC September 2017
Trouble Possible Causes Corrective Actions
Excessive oil temperature Inadequate lubrication:
– excessive or insufficient oil quantity;
– unsuitable lubricant (diffe rent type, too
viscous, ex hausted, etc.)
Check:
– oil level (gear reducer at rest) or quantity
– lubricant type and/or state (see ch. 6.2 lubrication table); replace if necessary
wrong mounting position Change mounting position
Too tightened taper roller bearings Consult Rossi
Worm gear reducer with excessive load
during running-in
Reduce the load
Excessive ambient tempe rature Increase the cooling or correct the ambient temperature
Obstructed passage of air Eliminate obstructive material
Slow or missing air recycle Arrange auxiliary ventilation
Radiance Screen gear reducer and motor properly
Inefficiency of auxilia ry bearing lubrication
system
Check the pump and the pipes
Worn, faulty or badly lubricated bearings Consult Rossi
Inefficient or out of service oil cooling
system: obstructed filter, insufficient oil
(exchanger) or water (coil) flow rate, pump
out of service, water temperature 20 °C, etc.
Check pump, pipes, oil filter and safety devices efficiency (pressure switchs,
thermostats, flow indicators, etc.)
Anomalous noise One or more teeth with:
– dents or spallings
– excessive flanks roughness
Consult Rossi
Worn, faulty or badly lubricated bearings Consult Rossi
Taper roller bearings with ex cessive clearance Consult Rossi
Vibrations Check the fastening and the bearings
Lubricant leaking Seal ring with worn, bakelized, damaged or
false mounted seal lip
Replace seal ring (see ch. 8.3)
from seal rings Restore the raceway
Mounting position differs from the one
stated on the name pla te
Position the gear re ducer correctly
Oil leaking from filler plug Too much oil Check oil level/quantity
Incorrect mounting position Check mounting position
Inefficient vent valve Clean/replace filler plug with vent valve
Low speed shaft not rotating
even with high speed shaft/
motor running
Broken key Consult Rossi
Completely worn gear pair Consult Rossi
Lubricant leaking from
joints (covers or
half-casing joints)
Defective oil seals Consult Rossi
Water in the oil Defective cooling coil or heat exchanger Consult Rossi
Motor: see specific instructions.
NOTE
When consulting Rossi state:
– all data of gear reducer or gearmotor name plate;
– nature and duration of failure;
– when and under which conditions the failure occured;
– during the warranty period, in order not to loose validity, do not disassemble nor tamper the gear reducer or gearmotor without approval by Rossi.