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Manual may result in property damage, serious injury or death. ●Thank you very much for your purchase of Elephant products. ●Before using Elephant lever hoists, please read this instruction manual carefully to ensure that you fully understand the product and its proper use. ●Please store this instruction manual securely as it is required for maintenance, inspection, disassembly and assembly of the product. ELEPHANT CHAIN BLOCK CO.,LTD.
Index 1. Safety Information and Warnings 1.1 Terminology 1.2 Restrictions on the use of this Equipment are as follows : 1.3 Warning Tags, Labels 2.Regarding the personnel operating and using lever hoists 2.1 Names of Parts 2.2 Unpacking the Product 2.3 Specifications Table 2.3.1 YⅡ-25・YA-50 Dimensions 2.3.2 YⅡ-25・YA-50 Hook Dimensions 3.Pre-Operational Procedures 3.1 Chain 3.2 Lever Hoist Installation 3.3 Pre-Operational Inspection and Test Run 4.Precautions for Use 4.1 General Handling 4.2 Precautions before Operation 5.Lever Hoist Operation 5.1 About free chaining operation 5.2 How to adjust the length of the load chain 5.3 Lifting/Lowering Operation 6. Inspection of lever hoists 6.1 Definition 6.2 General 6.3 Inspection Category 6.4 Pre-use inspections 6.5 Normal inspection 6.6 Routine Inspection 6.7 Load Chain Inspection 6.8 Operational Tests 6.9 Load Tests 6.10 Inspection, Testing Methods and Reference Values Inspection records Breakdown Schematics Warranty −1−...
1. Safety Information and Warnings 1.1 Terminology This Instruction Manual contains safety information necessary for owners responsible for the installation, operation, maintenance and inspection of this Product, and for operators actually engaged in the operation of the Product. In order to fully comprehend the structure and operation of this Product, please make sure that you understand the contents of this Instruction Manual. The safety information provided within this Instruction Manual includes circumstances possibly leading to hazardous situations. The four terms Danger, Warning, Caution, and Notice are used to clearly indicate the seriousness of hazardous conditions.
●Repair and maintenance of this Equipment shall be conducted only with parts certified by ELEPHANT CHAIN BLOCK CO., LTD. NOTICE ●Owners and operators of this Equipment are responsible for ensuring that all personnel engaged in the installation, operation, inspection, test, and servicing of ...
No opere el polipasto cuando no pueda formar from forming a straight line from hook to hook in una línea recta de gancho a gancho en la dirección de la carga. the direction of loading. ELEPHANT CHAIN BLOCK CO., LTD. ELEPHANT CHAIN BLOCK CO., LTD. Figure 1 −4−...
2. Regarding the personnel operating and using lever hoists 2.1 Names of Parts Top hook Top hook Latch Latch Select lever Select lever Chain on load side Chain on load side Chain on no load side Chain on no load side Chain stopper Chain stop bolt Chain stopper Chain stop bolt Latch Latch Bottom hook Bottom hook Figure 2 Minimum head room and lift 2.2 Unpacking the Product ⑴Check that the box labeling and product matches your order. ⑵Please confirm the contents of the container. ⑶Make sure the product has not been damaged during transportation. ⑷Check that no accessories are missing or disengaged. ⑸Check the integrity and condition of screws, fittings, etc. for all components. 2.3 Specifications Table Table 1 Specifications Load chain Minimum Model Rated load Lift Hand force Self-weight Number of head room Diameter chain falls 250kg...
2.3.2 YⅡ-25・YA-50 Hook Dimensions ⑴Measure dimensions A, B, and C in Figure 4 below, and record the actual measurements at the time of purchase. Although limit dimensions may also be determined based on the reference standard values, it should be noted that there will be some dimensional errors due to the forging process. ⑵ If any of dimensions A, B, and C have reached the indicated limits, replace the hook with a new one. ⑶The opening of the hook will expand in the event loads exceeding the rated load are applied to the mouth, or if a concentrated load is applied to the tip section. ⑷Hooks with expanded openings lose their original strength and shock-absorbing capabilities, and should be replaced upon exceeding the limit. ⑸Never reuse hooks with expanded openings straightened by heating or repairing. Such attempts could cause extremely hazardous results. Hooks with flaws 1 mm or more deep or bent/twisted hooks should also be replaced. Table 3 Model Rated load 250kg 40.5mm 14mm 11mm YⅡ−25 551lbs 1.59in 0.55in 0.43in 0.5t 44.7mm 16mm 13mm YA−50 1,102lbs 1.75in 0.62in 0.51in ※Dimensions of the top and bottom hooks are the same. Exterior dimensions of the convex section Purchased Product ...
3.2 Lever Hoist Installation WARNING ⑴Never install lever hoists without sufficient expertise in the equipment. ⑵Make sure the location of equipment installation has sufficient strength to support the equipment under load. ⑶When suspending a load from the hook, be sure to hang it in the correct position at the center of the hook. ⑷Never suspend loads from the tip of a hook. ⑸Never use the hoist with the hook working as a fulcrum (the suspended hook is shifted from its vertical position). CAUTION ※Do not attach hooks in the manner illustrated in the figure ...
3.3 Pre-Operational Inspection and Test Run (continued) WARNING ⑹Make sure the equipment has been installed correctly. ⑺Make sure all nuts, bolts, and cotter pin are sufficiently secured in position. ⑻Understand the work to be done with the equipment and operate accordingly. ⑼Users are required to ensure this equipment has been safely installed and operated in accordance with the applicable provisions of ANSI/ASME B30.21 Lever Hoists standard and OSHA regulations, and that the maintenance and inspection requirements have been met. ⑽Before operating this equipment, make sure no interfering objects are present within its entire range of operation.
WARNING ⑷Operator are required to understand the adjustment, failure, and repair of this equipment. Operators unable to stop operation and take corrective action in the event of a malfunction are not to use this equipment. ⑸Operators should be attentive of potential malfunctions of the equipment which may require adjustment or repair, and must stop operation and contact a supervisor immediately in the event such a malfunction occurs. ⑹Individuals with restrictions in eyesight, field of vision, reaction time, or manual dexterity are not to operate this equipment. ⑺Individuals without sufficient bodily control, those with physical deficiencies, are emotionally unstable, have a history of seizures, are prone to seizures, or are otherwise likely to operate the equipment in a manner potentially hazardous to the operator or others are not to operate this equipment. ⑻Operator under the influence of drugs, medical drugs, or alcohol are not to operate this equipment.
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4.2 Precautions before Operation (continued) WARNING ⑼Never operate equipment by means of pipes, etc. inserted into the Equipment or by stepping on the Equipment with your feet. (Figure 8) ⑽Never apply loads exceeding the rated load on a single unit of this equipment when performing two-hoist lifting. (Figure 9) ⑾Never over-wind or over-lower loads. ⑿Never suspend a load with the tip portion of the hook. (Figure 10) ⒀When suspending loads from the hook, never operate the hook in such a way that a lateral Figure 8 load is applied to either the top or bottom hooks. ⒁Do not leave the load suspended for a long time. ⒂Do not connect the grounding from welding machines to the load chain. (Figure 11) Both hoists are for 0.5t loads ⒃Never allow welding electrodes to come in contact with the load chain. ⒄Do not remove caution labels or nameplates from the unit or use the unit with caution labels or nameplates in an illegible condition. ⒅Do not use the product if the nameplate affixed to the main unit is illegible. ⒆Make sure that all personnel are clear of the support load. ⒇Do not allow sparks from welding, etc. into come in contact with this equipment. Figure 9 When lifting or moving a load, notify surrounding workers. Never install this equipment without sufficient expertise in the equipment. Make sure the location of equipment installation maintains sufficient strength to ...
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4.2 Precautions before Operation (continued) WARNING Do not allow anyone to ride on suspended loads. Never use the lever hoist for human transport purposes. (Figure 12) Never reverse a suspended load without sufficient expertise in doing so. Do not suspend excessive loads. When maintaining the load in a suspended condition for a short period of time, be sure to leave the switch pawls in the lifting position. Never use the hoist or the hook to work as a fulcrum. Do not use damaged or deformed top/bottom hooks. Never use this equipment if the load chain is deformed or damaged. Do not operate the equipment with the load chain Figure 12 lodged against a steel plate or other corners. (Figure Do not operate the load chain by any means other than human power (do not use any tools or objects on the controls). Do not apply abrupt force to the load chain during idle operation. Suspend slings properly onto the hook. During lifting, temporarily pause winding once either the load chain or sling comes under tension. Keep the lever hoist unit and load chain clean and free of sand and other debris. Make sure the lifting height is sufficient for the intended work. Make sure the load chain is sufficiently lubricated. Figure 13 Do not modify this equipment in any way. Do not use with the load chain wrapped around the load. (Figure 14) Do not suspend the load chain directly from rope hook fixtures on trucks. Do not use the load chain as a suspension device. (Figure 15) Truck platform Figure 14 Figure 15 −12−...
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4.2 Precautions before Operation (continued) WARNING Do not hang hooks onto the rope hook fixtures of trucks in a manner subjecting the neck portion of hooks to strain when tying Truck down the cargo (could result in neck platform breakage). (Do not use hooks in a manner that it is subjected to lateral bending forces.) (Figure Instead, hook wire slings onto the rope hook ...
5. Lever Hoist Operation 5.1 About free chaining operation Lever hoist type YⅡ-25 / YA-50 in the no-load state, enables free chaining operation by operating the select lever. ※Free chaining operation is a state in which the load chain can be moved by releasing the brake when there is no load. 5.2 How to adjust the length of the load chain DANGER ⑴Never select the free chaining operation while the load chain is under load. Always select it when there is no load. WARNING ⑴Make sure that the select lever is set to the N position.
Operating procedure ①Move the select lever to the “DOWN” position. ②Move the lever 2-3 times. DOWN ③Set the select lever to “N” ④Slowly pull the load chain to the desired position. (If the load chain on the hook side is pulled strongly, the brake will be applied, The load chain will be fixed.) ※If the brake is engaged and the DOWN chain is fixed, move the select lever to(UP or DOWN)and rotate the lever to adjust the length of chain. NOTICE ⑴Do not pull the load chain strongly during free chaining operation. ⑵When the load chain is pulled strongly, the brake is applied and the load chain is fixed, 5.3 Lifting/Lowering Operation ⑴Adjust the position of the lower hook and the length of the load chain with the free chaining operation.
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⑼Even if it is in free chaining state, if a load is applied to the bottom hook, the brake will be activated instantly. ⑽When lifting, the load is always fixed by the pawls of the mechanical brake. ⑾When lowering the load, the lever is operated to loosen the mechanical brake and the load is lowered. When the lowering operation is stopped, the mechanical brake is instantly tightened and the brake is applied. Operating procedure Lifting ①Move the select ...
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Free DOWN chaining Lifting Lowering DOWN DOWN DOWN Figure 17 Figure 18 Figure 19 WARNING ⑴Make sure that the location where the top hook is hung to install this device has sufficient strength. ⑵When lifting one load with two units of this equipment, select equipment of which rated load that can lift the load with one unit of this equipment. ⑶Never wind up or wind down excessively. ⑷Inspect the lifting components for any abnormalities before use. Choose a method that does not overload the lifting components. NOTICE ⑴Before operating the lever, make sure that the lever hoists is not in free chaining state and that the position of the select lever is correct. ⑵When lowering a light load, if the load chain does not lower, lightly pull the chain on the load side to operate. −17−...
6. Inspection of lever hoists 6.1 Definition This inspection procedure is compliant with the provisions of the ANSI / ASMEB30.21 standard. The following word definitions, considered important, are from ANSI / ASME B30.21 and are relevant to the following inspection procedures: Inspection criteria reflecting dimensional and geometrical characteristics are provided separately. ●Normal Service Form of maintenance to be performed on equipment operated with randomly distributed loads within the rated load range and uniform loads of less than 65% of the rated load for 15% or less of the overall usage time. ●Heavy Service Form of maintenance to be normally performed on equipment used under static loads exceeding the level of normal service.
⒠Hoists not in use on a regular basis ⑴Hoists unused for a duration of one month or more but less than one year shall be inspected in accordance with the provisions of Section 6.5 prior to use. ⑵Hoists unused for a duration of one year or more shall be inspected in accordance with the provisions of Section 6.6 prior to use. 6.4 Pre-use inspections Minimum inspection requirements include the following items: ⒜Proper operability and appropriate adjustment of the operating mechanism, and any abnormal noise emission. ⒝Routine inspection of hooks in accordance with ASME B30.10. (item numbers 10-1.10.3 and 10-2.10.3) ⒞Application of load to the load chain without overall damage. Inspection items (refer to Section 6.7.) ⒟Load sheaves, idle wheels ⒠Proper installation of load chain terminal anchorage. ⒡Deformation, cracks, and/or other damage to the hoist unit and levers. ⒢Evidence of damage to the support structure 6.5 Normal inspection Minimum inspection requirements include the following items: ⒜Proper operability and appropriate adjustment of the operating mechanism, and any abnormal noise emission. ⒝Routine inspection of hooks in accordance with ASME B30.10. (item numbers 10-1.10.3 and 10-2.10.3) ⒞Application of load to the load chain without overall damage. Inspection items (refer to Section 6.7.) ⒟Load sheaves, idle wheels ⒠Proper installation of load chain terminal anchorage. ⒡Deformation, cracks, and/or other damage to the hoist unit and levers. ⒢Evidence of damage to the support structure 6.6 Routine Inspection ⒜Routine inspections can be performed at the location of usage, and disassembly of the hoist is not necessary. ⒝Covers and other parts of the structure may be released or removed for inspection, but the covers must be closed or replaced before the hoist is restored to its normal state.
6.7 Load Chain Inspection ⒜Load chains should initially be inspected with the hoist suspended in a vertical position and subjected to a load of approximately 50 pounds (23 kg), with the chain integrated into the hoist. ⑴With the designated load applied, operate the hoist in both lifting and lowering directions, confirming that the load chains and load sheaves operate to feed the chain smoothly out of ...
6.10 Inspection, Testing Methods and Reference Values Inspection/testing method and standard values are as follows: ※Some of part names and part numbers listed below differ depending on YII-25 or YA-50. Therefore, YII-25 or YA-50 is stated under some of part names and part numbers in the inspection item (part name). If the items have no statement of YII-25 or YA-50, they are common part names and part numbers. (Note: It does not mean a common part.) ※Although details of inspection and limit dimensions are specified for respective parts, users should determine the frequency of use and duration of service individually, replacing ...
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Inspection item (part name) Method Inspection/test details/standard values Measures part number Confirm engagement with the hook, the Visual Replace with a new part. Safety latch set repulsive force of the spring, and if there is inspection, (No.2) any damage or deformation. measurement Table 5 Rated load Engraving Dimension A Dimension B 35.0mm 17.2mm 250kg Engraving H−1 551lbs 1.37in 0.67in 45.0mm 22.0mm 0.5t C−3 1102lbs Figure 21 1.77in 0.86in Visual Inspect for pin diameter wear. Replace with a new part. Top hook pin inspection, ...
Inspection item (part name) Method Inspection/test details/standard values Measures part number Visual Inspect for wear of the chain stop bolt Replace with a new part. Chain stop bolt set inspection, diameter; damage or deformation of the ※Periodic replacemen (No.8) measurement retaining bolt; cracks in the hex nut is recommended Table 7 Dimension A Rated load Dimension A Dimension B Dimension C Engraving Engraving limit value 6.0mm 5.5mm 21.5mm 250kg M5XP0.8 551lbs 0.23in 0.22in 0.84in 6.0mm 5.5mm 21.5mm 0.5t M5XP0.8 1102lbs 0.23in 0.22in...
Inspection item (part name) Method Inspection/test details/standard values Measures part number Inspect for opening of ring and damage. E-ring for pawl Visual Replace with a new part. (No. 17) inspection Inspect for significant deformation and wear Gear cover Visual Replace with a new part. with bumps identifiable by hand. Inspect for (No. 1 8) inspection cracks, wear, or rattling of the metal clasped to the gear cover. Inspect for chipped gear teeth, bumpy wear Pinion shaft Visual Replace with a new part. or damage, and smooth rotation of the gear (No.19) inspection when passing through the disc hub and feed YA-50 gear. Inspect for significant deformation, wear with Washer for pinion shaft Visual Replace with a new part. bumps identifiable by hand. (No. 2 0) inspection Inspect for damage, wear, deformation, etc.
Inspection item (part name) Method Inspection/test details/standard values Measures part number Inspect for chipped teeth, wear in positions Ratchet wheel Visual Replace with a new part. engaging the pawls, damage (No. 3 0) inspection, Braking section to be free of any bumpy wear measurement Table 8 Dimension A Rated load Dimension A limit value 43.0mm 40.8mm 250kg 551lbs 1.69in 1.60in 45.0mm 42.7mm Dimension A : 0.5t Ratchet wheel diameter 1102lbs Figure 26 1.77in 1.68in Not to indicate wear of 5% or more in relation to above dimensional value. Inspect for chipped teeth, wear in positions Brake lining Visual Replace with a new part.
Inspection item (part name) Method Inspection/test details/standard values Measures part number Inspect for damage, wear, deformation, etc. Female screw Visual Replace with a new part. (No. 3 8) inspection Inspect for damage, wear, deformation, etc. Brake cover Visual Replace with a new part. (No. 45) inspection Inspect for damage, wear, deformation, etc. Stay bolt Visual Replace with a new part. (No. 51) inspection Inspect for damage, wear, deformation, etc. Ratchet pin Visual Replace with a new part. (No. 58) inspection Inspect for damage, wear, deformation, etc. Stay pipe Visual Replace with a new part. (No. 59) inspection Inspect for damage, wear, deformation, etc.
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Inspection item (part name) Method Inspection/test details/standard values Measures part number Inspect for damage or deformation of the top Lever-side plate set Visual Replace with a new part. hook pin hole and sheave hole. (No. 8 3) inspection, YⅡ - 25 measurement Top hook pin Table 11 hole position Dimension A Rated load Dimension A limit value A (Limit value) 8.0mm 8.5mm 250kg 551lbs 0.31in 0.32in 10.3mm 10.8mm 0.5t 1102lbs 0.40in 0.41in To be without wear of 0.5 mm (0.01 in) or more in relation to the above dimensional value. ...
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Inspection item (part name) Method Inspection/test details/standard values Measures part number Chain stopper Visual Inspect for expansion/contraction beyond the Replace with a new part. inspection, specified value. (No. 9 1) measurement Table 13 Rated load 37mm 15mm 250kg To be without 551lbs expansion/contra 1.45in 0.59in 0.03in ction beyond the dimension indicated on the left (to be without 50mm 15mm deformation due 0.5t to compression) 1102lbs 1.96in 0.59in 0.03in Figure 31 inspect for damage, legibilty Name plate...
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Inspection item (part name) Method Inspection/test details/standard values Measures part number Inspect for any damage, deformation, or Load chain Visual Replace with a new part. elongation beyond the specified value (No.53) inspection, measurement Table 14 Diameter (mm) Pitch (P×5) (mm) Rated load Standard value Limit value Standard value Limit value 4.3mm 4.0mm 60.3mm 62.1mm 250kg 551lbs 0.16in 0.15in 2.37in 2.44in 4.3mm 4.0mm 60.3mm 62.1mm 0.5t 1102lbs...
Inspection records YⅡ-25 YA-50 Model Date of inspection Tonnage Name of qualified person Production No. (Name of inspector) Lift Inspection Part Inspection contents Judgment Remarks (Part No., Part Name) Top hook set Check for openings in hook, twists, damage, etc. Between punches Hook thickness, vertical Hook thickness, horizontal Hole diameter of top hook pin Safety latch set Whether the hook is engaged, damaged, deformed, etc. Top hook pin Inspect for pin diameter wear. Bottom hook set Check for openings in hook, twists, damage, etc. Between punches Hook thickness, vertical Hook thickness, horizontal Hole diameter of chain stop bolt set Safety latch set Whether the hook is engaged, damaged, deformed, etc. Chain stop bolt set Check the bolt diameter for wear, damage, deformation, etc. Inspect for wear and deformation of the pin Gear side plate set (YⅡ-25) hole diameter in the respective parts Inspect for wear and deformation of the pin Lever side plate set (YⅡ-25)...
Inspection Part Inspection contents Judgment Remarks (Part No., Part Name) Load sheave Inspect for engagement with the chain, damage, deformation, etc. Chain guide set Inspect for damage, wear, deformation, etc. Chain stripper Inspect for damage, wear, deformation, etc. Disc hub Inspect for chipped gear teeth and other damage Ratchet wheel Inspect for chipped gear teeth and other damage Brake lining Inspect for wear, damage, deformation, etc. Check washer (YⅡ - 25) Inspect for damage, wear, deformation, etc. Lever set Inspect for proper operation of the changeover knob Lever grip Inspect for cracks in the rubber handle, deformation, etc. Inspect for damage, wear, deformation, etc. Bracket screw Female screw Inspect for damage, wear, deformation, etc. Brake cover Inspect for damage, wear, deformation, etc. Stay bolt Inspect for damage, wear, deformation, etc. Ratchet pin Inspect for damage, wear, deformation, etc. Stay pipe Inspect for damage, wear, deformation, etc. Plain washer (YⅡ - 25) Inspect for damage, wear, deformation, etc.
Ⅱ Breakdown Schematics and Parts Names: Models Y - 25 13 14 Symbols in Symbols in Symbols in Symbols in Breakdown Breakdown Breakdown Breakdown Schematics Schematics Schematics Schematics Parts Names Parts Names Parts Names Parts Names Set Individual Set Individual Set Individual Set Individual unit unit unit unit Top hook set Pawl Disc hub...
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Breakdown Schematics and Parts Names: Models Y - 50 Symbols in Symbols in Symbols in Symbols in Breakdown Breakdown Breakdown Breakdown Schematics Schematics Schematics Schematics Parts Names Parts Names Parts Names Parts Names Set Individual Set Individual Set Individual Set Individual unit unit unit unit Top hook set Gear cover Ratchet wheel Lever-side plate set 2...
Replacement parts installed after the expiration of the original warranty period shall be warranted (not including installation labor) only for a period of one year from the date of installation. If the product is found to be without defect or it is determined by ELEPHANT that the malfunction was caused by Customer s operating condition, the customer shall be responsible for the cost of returning the product. If ELEPHANT repairs the product according to the request ...
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The goods has passed rigid inspection by us ahead of delivery in accordance with our standard in terms of test load and all other respects in good and satisfactory condition. Inspector ELEPHANT CHAIN BLOCK CO.,LTD. 180 Iwamuro 2-chome, Osaka-Sayama-City, Osaka, Postal code 589-8502, JAPAN Phone : 072-365-7778 Fax : 072-365-7869...
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