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c) Continue to disassemble the hoist and inspect the liftwheel,
chain guides, motor housing and gear housing. If any of these
components are worn or damaged, premature failure of the new
chain may result. Parts can be easily identified by accessing the
Parts List.
d) If the liftwheel pockets, particularly the ends, are worn or scored,
replace liftwheel. If chain guides and housings are worn, cracked,
or damaged, these parts should also be replaced.
e) Reassemble hoist with the new load chain inserted over the
liftwheel. Position chain with the weld on upstanding links away
from liftwheel and leave approximately 1 foot (0.3 m)0.3 m of
chain hanging free on loose end side.
NOTE To simplify handling when reassembling the hoist,
a short undamaged piece of the old chain may be used
as a "starter chain". Position this piece of chain in the
same manner as explained above for the "new chain" and
complete the reassembly of the hoist. See Method #2 below
for more details on using starter chain.
f)
Reinstall the loose end chain stop and bumper.
g) Attach the hook block and bumper to new load chain.
Method #2
a) Detach loose end chain stop and lower hook block from the
chain.
b) Treat the old load chain in hoist as a "starter chain", and use the
loose end link to serve as a temporary coupling link.
c) Connect the starter chain in the hoist, and the new load chain to
be installed. Ensure proper orientation of the new chain with the
welds facing away from the liftwheel.
d) Under power, reeve the new load chain through the liftwheel
area, replacing the starter chain in unit. Run enough chain
through to attach loose end chain stop.
e) Reinstall the loose end chain stop and bumper.
f)
Attach the hook block and bumper to new load chain.
MAINTENANCE
LOAD LIMITER
The load limiter should operate for the normal life of the hoist without
service. The device has been calibrated at the factory for a specific
model of hoist.
WARNING
The lubricants used in and recommended for
the hoist may contain hazardous materials that
mandate specific handling and disposal procedures.
TO AVOID CONTACT AND CONTAMINATION:
Handle and dispose of lubricants only as directed in applicable
instructions in the lubricant manufacturer's safety data sheets and
in accordance with applicable local, state and federal regulations.
MECHANICAL LOAD LIMITER DESCRIPTION
The mechanical clutch is designed to prevent overloading the hoist
beyond the determined safe limit. It is a direct acting type capacity
limiter with a force limit factor of 1.6. The clutch is calibrated from the
factory and should only be adjusted by a qualified person.
ELECTRONIC LOAD LIMITER DESCRIPTION
The "overcapacity" feature aims to prevent a user from lifting ~125%
rated load by using measured current through the sense resistors
and comparing it to a pre-defined amp draw threshold (set to 46 A in
memory).
A 46-Ampere threshold is set based on empirically collected data for
the measured average current when lifting a 100% load, then a 1.25×
multiplier is applied.
BatteryStar
TM
Once user begins to move a load and the motor ramps up to full
speed, overcapacity function will start to calculate. If this threshold
is exceeded, the tool will shut down and flag the overweight LED on
the Remote Control. The overload condition will clear on the Remote
Control once the user releases the Directional Button UP/DOWN.
This feature is not safety critical and is secondary to the Safety
Critical mechanical clutch (set to 160%).
MECHANICAL CLUTCH ADJUSTMENT PROCEDURE
This procedure shall only be performed by a qualified person.
1. Ensure any load is safely on the ground and battery is removed
prior to beginning work on the hoist. If hoist is suspended, it is
helpful to leave chain slightly tensioned.
2. Use a small, flat-blade screwdriver or a similar tool to remove the
clutch adjustment nut cover (1).
3. With an appropriate groove nut socket (2) and a ratchet (3),
tighten the clutch adjusting nut to increase the slip point or loosen
it to decrease the clutch slip point.
4. To check the clutch slip point, the electronic load limiter must be
disabled. To disable the electronic load limiter, (see "Electronic
Load Limiter Disablement Procedure", page 15).
5. Check and record the clutch slip point using either an appropriate
load cell or test load. Ensure the maximum output force is
between 110% and 160% of the rated load. If the slip point is out
of range, readjust and repeat this step.
6. Re-enable the electronic load limiter, (see "Electronic Load
Limiter Disablement Procedure", page 15) and replace the
clutch adjustment nut cover (1).
1
Clutch Adjustment Nut
Cover
2
Groove Nut Socket
(BGS-Technic 8337-5 or
equivalent)
ELECTRONIC LOAD LIMITER DISABLEMENT PROCEDURE
This procedure shall only be performed by a qualified person.
1. Ensure any load is safely on the ground and a charged battery is
installed to begin electronic load limiter disablement procedure.
2. Depress the STOP Button.
3. Open the rear battery compartment door and locate the Pairing
Button as shown below.
15
WARNING
1 3
3
Ratchet
WARNING
P/N: 192097707YLEM June 2024
1 2
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