Elephant C21 Instruction Manual

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Instruction Manual and Safety Instructions

Manually operated chain hoist

Elephant chain hoist model C21

Model No. :

Serial Number :

Date of initial use :

※The above information needs to be ﬁlled in by the purchaser.

Owners (operators) are required to completely understand the

installation, operation, maintenance and inspection of the

equipment described within this instruction manual prior to

use. Failure to understand or comply with the contents of this

Manual may result in property damage, serious injury or

death.

●Thank you very much for your purchase of Elephant products.

●Before using Elephant manually operated chain 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.

for Owners (Operators)

Rated load: 0.5t to 5t

(1,102 to 11,023lbs)

WARNING

ELEPHANT CHAIN BLOCK CO.,LTD.

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Summary of Contents for Elephant C21

Page 1 Manual may result in property damage, serious injury or death. ●Thank you very much for your purchase of Elephant products. ●Before using Elephant manually operated chain 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.
Page 2 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 manual chain hoists 2.1 Names of Parts 2.2 Unpacking the Product 2.3 Speciﬁcations Table 2.3.1 C21 Dimensions 2.3.2 C21 Hook Dimensions 3. Pre-Operational Procedures 3.1 Chain 3.2 Manual Chain Hoist Installation 3.3 Pre-Operational Inspection and Test Run 4. Precautions for Use 4.1 General Handling 4.2 Precautions before Operation 5. Manual Chain Hoist Operation 5.1 Lifting/Lowering Operation 6. Inspection of Manual Chain hoists 6.1 Deﬁnition 6.2 General 6.3 Inspection Category 6.4 Preoperation inspections 6.5 Frequent inspection 6.6 Periodic Inspection 6.7 Load Chain Inspection 6.8 Operational Tests 6.9 Load Tests 6.10 Inspection, Testing Methods and Reference Values 7. Disassembly,Assembly and Adjustment 7.1 Tools and Equipment/Consumables used for Disassembly/Assembly 7.2 Assembly of Model C21 7.3 Is this a malfunction!? First check for (commonly found assembly errors) Inspection records Breakdown Schematics −1−...
Page 3 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.
Page 4 ●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 ...
Page 5 No opera el polipasto cuando no pueda formar una linea the direction of loading. recta de gancho a gancho en la direccion de la carga. ELEPHANT CHAIN BLOCK CO., LTD. ELEPHANT CHAIN BLOCK CO., LTD. Figure 1 −4−...
Page 6 2. Regarding the personnel operating and using manual chain hoists 2.1 Names of Parts Top hook Latch Wheel cover Gear cover Hand chain Load chain Chain stop bolt Bottom hook Latch C21 3t C21 5t Head room and lift Figure 2 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 Hand chain Minimum Model Rated load Lift Hand force Self-weight Number of length head room Diameter chain falls 0.5t 4.3mm 275mm 255N 6.1kg...
Page 7 2.3.1 C21 Dimensions C21−0.5 C21−1 C21−1.5 ︵ C21−2 ︶ C21−3 C21−5 ︵︵︶︶ Figure 3 Table 2 Model Rated load 0.5t 275mm 131mm 54mm 77mm 121mm 30mm 36mm 17mm 13mm 24mm C21−0.5 1102lbs 10.82in 5.15in 2.12in 3.03in 4.76in 1.18in 1.41in 0.66in 0.51in 0.94in 310mm...
Page 8 2.3.2 C21 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. ⑵If 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 0.5t 44.7 mm 17.0 mm 13.0 mm C21−0.5 1102lbs 1.75 in 0.66in 0.51 in 51.0 mm 22.0 mm 16.0 mm C21−1 2204lbs 2.00in 0.86 in 0.62 in 1.5t 55.0mm 26.0 mm 21.0 mm C21−1.5 3306 ｌｂｓ...
Page 9 3. Pre-Operational Procedures 3.1 Chain WARNING ⑴Do not put a load on the load chain on the no-load side. Make sure that no load is applied to the no-load side. ⑵Before operating the equipment, make sure the load chain is not twisted or tangled. Hook for 3t (2 falls) and 5t (3 falls) are multiple falls hook. Make sure the hooks are not reversed. Be sure to correct any problems before using this equipment. (Figure 5, Figure 6) Figure 5 Do not operate equipment in this state! Correctly oriented chain Twisted chain due to reversed hook Figure 6 −8−...
Page 10 3.2 Manual Chain Hoist Installation WARNING ⑴Never install manual chain 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). ⑹When using with a trolley, never pull diagonally. Unreasonable force is applied to the trolley. Please move the trolley directly under the load.
Page 11 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 laws and regulations of the country, the applicable provisions of ANSI/ASME B30.16 Overhead Underhung and Stationary Hoists standard and OSHA regulations, and that the maintenance and inspection requirements have been met.
Page 12 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.
Page 13 4.2 Precautions before Operation (continued) WARNING ⑹Never operate the hoist in such a manner as to let the load drop even a slight distance. (Figure 11) ⑺Never cut, splice, or weld the load chain. ⑻Do not operate the chain hoist if the load cannot be suspended from the center portion of the hook. ⑼Do not use this equipment as a sling suspension device. Also, do not use with the load chain wrapped around the load. ⑽Never apply loads exceeding the rated load on a single unit of this equipment when performing two-hoist lifting. Figure 11 (Figure 12) ⑾Never over-wind or over-lower loads. ⑿Never suspend a load with the tip portion of the hook. (Figure 13) Both hoists are ⒀When suspending loads from the hook, for 1 ton loads never operate the hook in such a way that a lateral 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 14) 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. Figure 12 ⒅Do not use the product if the nameplate aﬃxed to the main unit is illegible. ⒆Make sure that all personnel are clear of Building the support load.
Page 14 4.2 Precautions before Operation (continued) WARNING Do not allow anyone to ride on suspended loads. Never use the manual chain hoist for human transport purposes. (Figure 15) Never reverse a suspended load without suﬃcient expertise in doing so. Do not suspend excessive loads. 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 lodged against a steel plate or other corners. (Figure 16) Do not operate the load chain by any means other than human power (do not use any tools or objects Figure 15 on the controls). Suspend slings properly onto the hook. During lifting, temporarily pause winding once either the load chain or sling comes under tension. Keep the manual chain 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. Do not modify this equipment in any way. Do not use with the load chain wrapped around the load. (Figure 17) Do not hang the hook in a way that places a burden on the neck (neck breakage). (Do not use the hook with lateral bending force.)Attach the wire sling to the rope hook ﬁrst and then tighten the load. Figure 16 (Figure 18) Truck platform Figure 17 Figure 18 −13−...
Page 15 4.2 Precautions before Operation (continued) WARNING Do not suspend the load chain directly from rope hook ﬁxtures. Do not use the load chain as a suspension device. (Figure 19) Do not pull diagonally. (Move the chain block directly above the load before lifting.) Move the chain block directly above the load before lifting it. When using with a trolley, never pull diagonally. Unreasonable force is applied to the trolley. Please move the trolley directly under the load. Do not let the trolley or chain block collide with stoppers or structures. Do not operate or move the load chain, hand chain, or load by hooking it on other structures. Do not suspend a load on the load chain on the no-load side. Also, make sure that no load is applied to the no-load side. Do not bind the hand chain. (keep it natural) (Figure 20) Truck platform Figure 19 Figure 20 CAUTION ⑴When operating this equipment, be sure to maintain a ﬁrm foothold, and otherwise ensure safe working conditions (for performance of operations). ⑵Always check the brake function before using this equipment. ⑶Make sure the latch for the hook is properly attached. The latch helps prevent slings, chain slings, and other slinging tools and loads from being released. ⑷Make sure all obstacles are removed from the vicinity of the load. ⑸Avoid shaking either the load or the hook. ⑹Make sure the hook is moving in the predetermined direction. ⑺Inspect this equipment periodically and replace any damaged or worn parts. Maintain records of the inspections.
Page 16 5. Manual chain hoist Operation 【Wheel cover side】 Lowering Lifting To lower the load, please To lifting the load, please pull hand chain on the left pull hand chain on the right side from the wheel cover side from the wheel cover side (counterclockwise). side (clockwise). Hand chain DANGER ⑴Do not operate this equipment who does not understand the contents of the instruction manual and caution plate.
Page 17 6. Inspection of Manual chain hoists 6.1 Deﬁnition This inspection procedure is compliant with the provisions of the ANSI / ASME B30.16 standard. The following word deﬁnitions, considered important, are from ANSI / ASME B30.16 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.
Page 18 6.4 Preoperation inspections Minimum inspection requirements include the following items: ⒜Proper operability and appropriate adjustment of the operating mechanism, and any abnormal noise emission. ⒝Periodic 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 Frequent inspection Minimum inspection requirements include the following items: ⒜Proper operability and appropriate adjustment of the operating mechanism, and any abnormal noise emission. ⒝Periodic 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 Periodic Inspection ⒜Periodic 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.
Page 19 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 (23kg), 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 ...
Page 20 6.10 Inspection, Testing Methods and Reference Values Inspection/testing method and standard values are as follows: Inspection and testing methods for C21 parts (*Refer to the breakdown schematics for part numbers.) ※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 the necessary parts with new parts or new products in order to prevent accidents and enhance the operational safety factor. ※Please note, some of the parts are forged and may have slight dimensional errors. The following dimensions are limit values based on reference standard values. （The instruction manual states that you should measure the dimensions at the time of product purchase and record the actual measurements (initial dimensions)） Inspection item (part name) Method Inspection/test details/standard values Judgement, Measures part number ・Inspect opening of the hook, hook thickness Top hook set Visual Replace with a new part. and wear in vertical/horizontal dimensions. inspection, （No.1）・Inspect diameter of the top hook pin-hole measurement for elongation. Inspection/test details/ ・Inspect the hook for bends, twists, damage, ...
Page 21 Inspection item (part name) Method Inspection/test details/standard values Judgement, Measures part number ・Inspect the hook to see if it has a Visual Replace with a new part. Safety latch set safety latch. inspection, （No.3）・Conﬁrm engagement with the hook. measurement ・Conﬁrm the repulsive force of the spring, and if there is any damage or deformation. Table 5 Rated load Marking Dimension A Dimension B 45.0mm 22.0mm Marking 0.5t C−３ 1102lbs 1.77in 0.86in 48.0mm 22.0mm F−４ 2204lbs 1.88in 0.86in 54.0mm 31.0mm 1.5t F−５...
Page 22 Inspection item (part name) Method Inspection/test details/standard values Judgement, Measures part number ・Inspect the opening of the hook, hook Visual Replace with a new part. Bottom hook set thickness and wear in vertical/horizontal inspection, （No.17） dimensions. measurement ・Inspect elongation of the chain stop bolt hole. ・Inspect the hook for bends, twists, damage, etc. and smooth hook rotation. ・Dimensions are not to exceed the limit value. ・Inspect the hook cover joint for any openings. ・Inspect for visible scratches or deformation. Inspection/test details/ ・Inspect for loosen rivets or bolts. standard values （Continued）・Inspect the chain attachment hole for 5 ton to see if it is deformed into an oval shape. ・Inspect bottom hook sheave 3t, 5t that engages with the （to be continued on the right） chain (pocket part) for Table 6 stepped wear, scratches, and deformation. Reference ・Inspect for signs of Rated load Position standard Limit Value obduction by the chain.
Page 23 Inspection item (part name) Method Inspection/test details/standard values Judgement, Measures part number ・Inspect for wear of the chain stop bolt Visual Replace with a new part. Chain stop bolt set diameter. inspection, ※Periodic replacement （No.26）・Inspect for damage or deformation of measurement is recommended chain stop bolt. ・Inspect for cracks in the hex. castle nut. ・Inspect for deterioration of the cotter pin. Table 7 Dimension A Rated load Dimension A Dimension B Dimension C Marking limit value Marking 6.0mm 5.5mm 21.5mm 0.5t M5XP0.8 1102lbs 0.23in 0.21in 0.84in 8.5mm 8.0mm 31.5mm M6XP1 2204lbs...
Page 24 Inspection item (part name) Method Inspection/test details/standard values Judgement, Measures part number ・Inspect for damage or deformation of the Gear side plate set Visual Replace with a new part. top hook pin hole and stay bolt holes. inspection, （Ｎo． 31）・Inspect metal for cracks, wear, or measurement looseness. Table 9 Dimension A Rated load Dimension A Position of limit value Top hook pin 10.3mm 10.8mm 0.5t 1102lbs 0.40in 0.42in A (Limit value) A (Limit value) 12.3mm 12.8mm 2204lbs 0.48in 0.50in 14.3mm 14.8mm 1.5t Hole for Stay bolt 3306lbs...
Page 25 Inspection item (part name) Method Inspection/test details/standard values Judgement, Measures part number ・Inspect for damage, wear, deformation, Hex. Nut Visual Replace with a new part. etc. （Ｎo． 38） inspection ・Inspect for damage, wear, deformation, Spring washer Visual Replace with a new part. etc. （Ｎo． 39） inspection ・Inspect for chipped teeth on pawls, Pawl Visual Replace with a new part. bumpy wear and damage （Ｎo． 43） inspection ・Inspect for smooth rotation ・Inspect for opening of ring and E ring Visual Replace with a new part. damage （Ｎo． 45） inspection ・To be without wear on the surfaces Pawl spring Visual Replace with a new part.
Page 26 Inspection item (part name) Method Inspection/test details/standard values Judgement, Measures part number ・Inspect for damage, wear, deformation, Washer for pinion shaft Visual Replace with a new part. etc. （Ｎo． 60） inspection ・Inspect for chipped gear teeth, bumpy 2nd/3rd gear set Visual Replace with a new part. wear or damage, deformation. （Ｎo． 61） inspection ・Inspect for chipped gear teeth, bumpy Load gear Visual Replace with a new part. wear or damage, deformation. （Ｎo． 64） inspection ・Inspect the part that engages with the Load sheave Visual Replace with a new part. chain (pocket part) for stepped wear, （No.65） inspection scratches, and deformation. ・Inspect for signs of obduction by the chain Locations with possibility of ...
Page 27 Inspection item (part name) Method Inspection/test details/standard values Judgement, Measures part number ・Inspect for scratches, cracks, and Friction disc Visual Replace with a new part. surface roughness. （Ｎo． 77） inspection, ・Braking section to be free of any measurement bumpy wear ・Inspect the surface for oil or dirt Table 12 Dimension A Rated load Dimension A Dimension B Dimension C limit value 2.5mm 2.3mm 43.0mm 26.2mm 0.5t 1102lbs 0.098in 0.090in 1.69in 1.03in 2.5mm 2.3mm 53.5mm 32.0mm 2204lbs 0.098in 0.090in 2.10in...
Page 28 Inspection item (part name) Method Inspection/test details/standard values Judgement, Measures part number ・Inspect for any damage, deformation. Load chain Visual Replace with a new part. ・Inspect for elongation beyond the （No.79） inspection, Wear inspection point speciﬁed value. measurement ・Inspect for rust Table 13 Diameter (mm) Pitch (P×5) (mm) Rated load Standard value Limit value Standard value Limit value 4.3mm 4.0mm 60.3mm 62.1mm 0.5t 1102lbs 0.16in 0.15in 2.37in 2.44in 5.6mm 5.3mm 85.6mm 88.2mm Figure 34 diameter 2204lbs 0.22in...
Page 29 7. Disassembly, Assembly and Adjustment 7.1 Tools and Equipment/Consumables used for Disassembly/Assembly Prepare the following tools and supplies : 1. Wrench 2. Phillips screwdriver 3. Nippers 4. Pliers 5. Hexagonal wrench 6. Radio pliers 7. Snap ring pliers 8. Plastic hammer 9. Brush 10. Grease （NLGI. No. 1） 11. Oil （ NLGI. No. 00） 12. Waste cloth ※Apply gear grease （NLGI. No. 1） and load chain oil （ NLGI. No. 00） . ※Use the following tools to disassemble and reassemble the hoist. Be sure to work carefully. 1. Wrench 2. Phillips screwdriver 3. Nippers 4. Pliers −28−...
Page 30 5. Hexagonal wrench 6. Radio pliers 7. Snap ring pliers 8. Plastic hammer 9. Brush −29−...
Page 31 WARNING Incorrect disassembly and assembly may cause death or serious accidents. Disassembly and assembly should be carried out by a specialist or by someone with specialized knowledge speciﬁed by the operator. ※Apply gear grease (NLGI. No. 1) and load chain oil (NLGI. No. 00). 7.2 Assembly of Model C21 ㉟Wheel side plate set Prepare ㉟ Wheel side plate set ※Pawl pin side facing down. Load sheave ㉟Wheel side plate set Apply grease Load sheave Attach a greased Load sheave to the rotating part of the side plate on the ㉟ Wheel side plate set. ㉟Wheel side plate set Load sheave Complete status of which greased Load sheave attached to the rotating part of the ㉟ Wheel side plate set. −30−...
Page 32 Chain guide ㉟Wheel side plate set Chain guide Install the Chain guide to the ㉟ Wheel side plate set. Align the protrusions of the Chain guide with the hole of the ㉟ Wheel side plate set. Condition of the Chain guide attached to the ㉟ Wheel side plate set. Chain guide pin ㉟Wheel side plate set Chain guide pin Attach the Chain guide pin to the ㉟ Wheel side plate set. ※ Chain gude pin is attached for 1.5t and more capacities only. −31−...
Page 33 Chain guide pin ㉟ Wheel side plate set with Chain guide pin attached like this. ※ Chain gude pin is attached for 1.5t and more capacities only. Chain stripper ㉟Wheel side plate set Chain stripper Insert the Chain stripper into the ㉟ Wheel side plate set. (Place the rounded surface on the load side.) ㉟Wheel side plate set Condition of Chain stripper attached to the ㉟ Wheel side plate set. Chain stripper −32−...
Page 34 Gear side plate ㉟Wheel side plate set ㉛Gear side plate set Combine the ㉟ Wheel side plate set and the ㉛ Gear side plate set. (It can be easily installed by ﬁxing the Chain stripper by hand.) Chain stripper ㉛Gear side plate set ㉟Wheel side plate set Condition of ㉟ Wheel side plate set combined with the ㉛ Gear side plate set. Load gear Recessed part Apply grease Load gear Load sheave Attach the Load gear to the Load sheave with resessed part facing up. −33−...
Page 35 Load gear Condition of the Load gear combined with the Load sheave Washer for pinion shaft Washer for pinion shaft Load gear Install the Washer for the pinion shaft on the center of the Load gear. (Set the ﬂat part of the Washer for pinion shaft to the Load gear side.) Load gear Washer for pinion shaft Condition of Washer for the pinion shaft installed on the center of the Load gear. −34−...
Page 36 Pinion shaft Pinion shaft Grease Load gear Apply grease to the shaft part of the Pinion shaft and insert it into the center of the Load gear Pinion shaft Load gear Condition of the Pinion shaft inserted into the center of the Load gear 2nd/3rd gear Mountain side 2nd/3rd gear There are 2 kinds of 2nd/3rd gears. They are Mountain side gear and Grease Valley side gear . Set the Pinion shaft in the center, facing each other so that the marks on the mountain side and the marks on the valley side are in a straight line. Firstly, install the 2nd/3rd gear mountain side. Apply grease to the metal part and gear part of the side plate. Gear combination Rated load Mountain side Valley side 0.5t 1t Ⅰ 1.5t 3t 2t 5t −35−...
Page 37 Pinion shaft 2nd/3rd gear Mountain side The state where the 2nd/3rd gear mountain side is installed. Align the mark on the mountain side with the center of the Pinion shaft. 2nd/3rd gear Valley side Install the 2nd/3rd gear valley side. Grease Apply the grease to the gears and metal part of the side plate Mountain side gear Valley side gear Ⅰor or The state where the 2nd/3rd gear valley side is attached. Align the mark on the 2nd/3rd gear valley side with the center of the Pinion shaft. Gear combination Rated load Mountain side Valley side 0.5t 1t Ⅰ 1.5t 3t 2t 5t Make sure that the 2nd/3rd gear marks are aligned with the Pinion shaft. ※After installation, rotate the gear and ...
Page 38 Gear case set Gear case set Hole part Align the three holes in the Gear case set with the three stay bolts, attach the Gear case set, and cover the gears. Stay bolt Stay bolt Gear case set Condition of the Gear case set attached to the positions of three stay bolts to cover the gears. Stay bolt ㊴Spring washer ㊳Hex. Nut Gear case set Attach ㊴ Spring washer and ㊳ Hex nut to the stay bolts to ﬁx Gear case set on the ㉛ Gear side plate set. Stay bolt ㉛Gear side plate set −37−...
Page 39 ㊳Hex. Nut Stay bolt Condition of Gear case set ﬁxed to ㉛ Gear side plate set with ㊳ Hex nuts. ㊳Hex. Nut Pawl spring ㉟Wheel side plate set Apply grease Pawl pin ㊻Pawl spring B ㊻Pawl spring A Attach the ㊻ Pawl spring A,B to ratchet pin on the ㉟ Wheel side plate set. ㉟Wheel side plate set ㊻Pawl spring A, B Location to incert Insert part of the long parts of the ㊻ Pawl spring A,B into the holes in the ㉟ Wheel side plate set. −38−...
Page 40 Pawl ㊺E-ring ㊸Pawl Pawl pin Grease Attach the ㊸ Pawl and ㊺ E-ring to the ratchet pin on the ㉟ Wheel side plate set. ※Apply grease to the ratchet pin. ㉟Wheel side plate set ㊸Pawl Condition of ㊸ Pawl attached to pawl pin of ㉟ Wheel side plate set ㉟Wheel side plate set Disc hub Disc hub Pinion shaft ㊸Pawl Install the Disc hub on the Pinion shaft. Since the mounting part of the Pinion shaft is a screw,turn the Disc hub by hand and tighten until it stops moving. If you screw in the Disc hub, it will hit the ㊸ Pawl, so please spread the ㊸ Pawl when installing. Shape of Disc hub for 0.5t is diﬀerent from for 1ton and more capacities. As for their diﬀerence, please see Breakdown Schematics. −39−...
Page 41 Pinion shaft Disc hub Condition of Disc hub attached to Pinion shaft Ratchet wheel Friction disc Friction disc Install the Friction disc, Ratchet wheel and Friction disc on the Disc hub on this order. ※Make sure that Ratchet wheel and Pawl are engaged correctly. ※Apply very small amount Apply grease of grease on the inside of Ratchet wheel the Ratchet wheel. Disc hub Friction disc Condition of the Friction disc, Ratchet wheel and Friction disc attached to Disc hub on this order. Ratchet wheel −40−...
Page 42 Top hook set ❶Top hook set Align the holes in the ❶ Top hook set with the holes in the gear-side and wheel-side side plates, and ﬁx them with the ㉚Top hook pin ㉚ Top hook pin. ※The top hook pin has a marking, please insert from marking side. Rated load Marking 0.5t 1.5t/3t 2t/5t ❶Top hook set ㉚Top hook pin Condition of the ❶ Top hook set attached Brake cover ㉟Wheel side plate set Brake cover Install the Brake cover according to the shape of the ㉟ Wheel side plate set. −41−...
Page 43 Brake cover Condition of Brake cover attached Hand wheel Hand wheel Cut section Pinion shaft Install the Hand wheel cut section side up on the Pinion shaft(opposite the brake lining) Turn the Hand wheel by hand and tighten until it stops. Pinion shaft Hand wheel R pin Insert the R pin into the hole of the Pinion shaft to ﬁx the movement of the Pinion shaft. Tighten the Hand wheel again. Remove the R pin after tightening. −42−...
Page 44 Hand wheel Completion status of No. . Check washer Install the Check washer Hand wheel with the roundness on the Hand wheel side through the Pinion shaft. Check washer There are 2 large and small cutouts(fan-shaped items) on the Check washer mounting part of the Hand wheel. Either side is ﬁne, so please install it on the right side of the center of the notch. ※If it is installed all the way Pinion shaft to the right side, the brake will not be released. Condition of the Check washer attached to the right of the center of the notch in the Hand wheel. −43−...
Page 45 Castle nut Pinion shaft Castle nut Hand-tighten the Castle nut onto the Pinion shaft. If the groove of the Castle nut exceeds the hole of the Pinion shaft, see below A. If the groove of the Castle nut does not reach the hole of the Pinion shaft, see below B. If the groove of Castle nut matches the hole of the Pinion shaft, see below C. A If the groove of the Castle nut exceeds the hole of the Pinion shaft, Hole of Pinion shaft If the Castle nut is tightened and the groove of the Castle nut exceeds the Adjust hole hole of the Pinion shaft, loosen the position Castle nut and align the groove of the Castle nut with hole where the R pin will be inserted. Hole of Pinion shaft The ﬁgure to the left shows that aligning the groove of the Castle nut with the hole position of the Pinion shaft(the hole position where the R pin is inserted) after loosing the Castle nut. Hole of Pinion shaft One groove (Matching position)
Page 46 B If the groove of the Castle nut does not reach the hole of the Pinion shaft, Hole of Pinion shaft If the Castle nut groove does not reach Matching position the hole in the Pinion shaft when the Castle nut is tightened, loosen the Castle nut and align the groove of the Castle nut with the hole where the R pin will be inserted. Hole of Pinion shaft The ﬁgure to the left shows that aligning the groove of the Castle nut with the hole position of the Pinion shaft(the hole position where the R pin is inserted) after loosing the Castle nut. One groove (Matching position) Hole of Pinion shaft Once the Castle nut groove and Pinion shaft hole position (the hole position where the R pin is inserted) are aligned, loosen the Castle nut by one groove, and then align the groove of the Castle nut with the hole position of the Pinion shaft(the hole position where the R pin is inserted). C If the groove of Castle nut matches the hole of the Pinion shaft, One groove (Matching position)
Page 47 Completed installation of the Castle nut Castle nut R pin R pin Insert the R pin into the adjusted slotted hole of Pinion shaft so that Castle nut will not be loosen. R pin Lay down the R pin inserted in the hole of Pinion shaft to the side (for 1ton and more capacities) ※ R pin can not be laid down to the side for 0.5t −46−...
Page 48 Load chain Hand wheel side Gear side Place the gear case side to the left and the Hand wheel side to the right so that the Load sheave can be seen. Put the end of Load chain into the Load sheave with the welded part of the Load chain Load chain facing up(Vertical link). Turn the Hand wheel so that the Load chain can be sent to the other side(no load side). Welded part With the Load chain attached. Load chain −47−...
Page 49 Chain stop pin ㊿Chain stop pin Fix the end of Load chain on the no-load side with the ㊿ Chain stop pin. Then, using Clip for the Clip ㊿ Chain stop pin to prevent it from coming oﬀ. Load chain ※Insert the ㊿ Chain stop pin from hand wheel side. No-load side ㊿Chain stop pin Clip Condition of the Load chain on the no-load side installed Load chain −48−...
Page 50 Bottom hook set Load chain load side Attach the ⓱ Bottom hook set to the Load chain on ㉖Chain stop bolt set the load side using the ㉖ Chain stop bolt set. Install the ⓱ Bottom hook set so that the welded side of the second link from the ⓱Bottom hook set end is on the nut side of the ㉖ Chain stop bolt. ※Apply screw lock to the 0.5t screw. Complete status of which the ⓱ Bottom hook set is attached to the Load chain on the load side Note 1) For 0.5t, U nut is used for ㉖ Chain stop bolt set, ⓱Bottom hook set For 1 t and more capacities, spring washer, castle nut, cotter pin are used for it. 0.5t 1t or more Cotter pin Secure the ⓱ Bottom hook set and Load chain with cotter pin so that they do not come oﬀ. Cotter pin Bend a cotter pin Insert a cotter pin Bend a cotter pin −49−...
Page 51 Hand chain Hand wheel Hand chain Attach Hand chain to the Hand wheel. Insert the hand chain into hand wheel notch and turn the hand wheel to attach it. Condition of Hand chain attached to the Hand wheel. Hand wheel cover Hand wheel cover Attach the Hand wheel cover to prevent the Hand chain from coming oﬀ the Hand wheel. −50−...
Page 52 Hand wheel cover Condition of the Hand wheel cover attached to prevent the Hand chain from coming oﬀ the Hand wheel. ㊴Spring washer ㊳Hex.nut Secure the Hand wheel cover with the ㊴ Spring washer and ㊳ Hex.nut so that Hand wheel cover does not come oﬀ. Condition of Hand wheel cover secured with the ㊴ Spring washer and ㊳ Hex.nut so that Hand wheel cover does not come oﬀ. −51−...
Page 53 Assembly completed Assembly completed Check the appearance and check the movement of the product with no load. Load the bottom hook and pull Hoisting check the hand chain in the direction of the arrow. Is the brake slipping? Are there any abnormal sounds? Is there a clacking sound when winding up? Is there any weight in the operation of the hand chain? If there is any abnormality, please reassemble. If there is no abnormality, please check the lowering. Lowering check Is the brake slipping? Are there any abnormal sounds? Is there any weight in the operation of the hand chain? If there is any abnormality, please reassemble. If there are no errors, the process is complete. −52−...
Page 54 Complete −53−...
Page 55 7.3 Is this a malfunction!? First check for (commonly found assembly errors) ・Check again according to the instructions below before calling for repairs: When in this situation: The cause and target of inspection is: How to ﬁx: ①Hand chain does not move Ratchet wheel in the brake Reassemble ratchet wheel either up or down. section is not assembled correctly. correctly. Ratchet wheel is Make sure the pawl and the There is no audible pawl assembled backwards and is not ratchet wheel are engaged, and engaging sound. engaged with the pawl. also check for the clicking sound when the ratchet wheel is turned. Pawl Pawl Ratchet wheel Ratchet wheel ②Hand chain does not move The pawl and ratchet wheel are Disassemble, clean and lubricate either up or down. not engaged. the brake, pawl, and pawl spring There are dirt, corrosion on pawl parts. Replace pawl spring and check There is no audible pawl and pawl pin. engaging sound. Check the spring failure. the spring force. ③Hand wheel does not The mark on the mountain side ...
Page 56 When in this situation: The cause and target of inspection is: How to ﬁx: ⑤Brake does not work. Brake parts are not assembled Assemble brake parts correctly correctly. so that the pawl engages the There is no clicking sound Pawl spring is damaged. ratchet wheel. of the pawl engaging. Conﬁrm the clicking sound of Load is slipped down. ratchet wheel meshing with the pawl before use. Ratchet wheel Friction disc Friction disc Ratchet wheel Ratchet wheel Disc hub Disc hub ⑥Brake does not work. The brake is not working because Attach the check washer to the the check washer is located to right side of the center of the Load is slipped down. the left of the center. hand wheel cutout (fan shape). Check washer Check washer ⑦The hand wheel does not The brake does not release Attach the check washer to the turn in the lowering because the check washer is right side of the center of the direction. installed all the way to the right.
Page 57 Inspection records Model Date of inspection Tonnage Name of qualiﬁed person Production No. (Name of inspector) Lift Inspection Part (Part No., Part Name) Inspection contents Judgment Remarks Top hook set Check for openings in hook, twists, damage, etc. Actual value 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. Bottom hook set Check for openings in hook, twists, damage, etc. Actual value 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. Actual value Top hook pin Inspect for pin diameter wear.
Page 58 Inspection Part (Part No., Part Name) Inspection contents Judgment Remarks Chain stop pin Inspect for damage, wear, deformation, etc. Clip Inspect for opening of ring and damage Gear case set Inspect for damage, wear, deformation, etc. Name plate Inspect for damage, deformation, legibility. Pinion shaft Inspect for chipped gear teeth and other damage Castle nut Inspect for damage, wear, deformation, etc. R pin Inspect for damage, wear, deformation, etc. Check washer Inspect for damage, wear, deformation, etc. Washer for pinion shaft Inspect for damage, wear, deformation, etc. 2nd/3rd gear set Inspect for chipped gear teeth and other damage Load gear Inspect for chipped gear teeth and other damage Load sheave Inspect for engagement with the chain, damage, deformation, etc. Chain guide Inspect for damage, wear, deformation, etc. Chain guide pin （1.5t or more） Inspect for damage, wear, deformation, etc. Chain stripper Inspect for damage, wear, deformation, etc. Hand wheel cover Inspect for damage, wear, deformation, etc. Warning sticker Inspect for damage, legibility.
Page 59 Breakdown Schematics and Parts Names: Models C21 0.5t to 5t C21 3t C21 5t Note 3 : Shape of Disc hub for 0.5t is diﬀerent from for 1ton and more capacities. Disc hub Attach chain For 0.5t For 1t or more stopper to sixth link Note 1 : U nut is used for No.26 chain stop bolt 0.5ton. Spring washer, castle nut, cottor pin are used for chain stop bolts 1ton and more capacities. 0.5t For 1t or more split pin Note 2 : No.69 Chain guide pin is used for 1.5ton and more capacities. Symbols in Symbols in Symbols in Symbols in Breakdown Breakdown Breakdown Breakdown Schematics Schematics Schematics Schematics Parts Names Parts Names Parts Names Parts Names Individual Individual Individual Individual unit...
Page 60 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...

This manual is also suitable for:

C21-0.5 C21-1 C21-1.5 C21-2 C21-3 C21-5