MODEL D4065/D4057 ⁄ 4 & 1 1 ⁄ 2 Ton RATCHET HOISTS 3 OWNER'S MANUAL Phone: (360) 734-3482 • Online Technical Support: email@example.com COPYRIGHT © AUGUST, 2010 BY WOODSTOCK INTERNATIONAL, INC. WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC. #13009TS Printed in China This manual provides critical safety instructions on the proper setup, operation, maintenance and service of this machine/equipment. Failure to read, understand and follow the instructions given in this manual may result in serious personal injury, including amputation, electrocution or death. The owner of this machine/equipment is solely responsible for its safe use. This responsibility includes but is not limited to proper installation in a safe environment, personnel training and usage authorization, proper inspection and maintenance, manual availability and comprehension, application of safety devices, blade/cutter integrity, and the usage of personal protective equipment. The manufacturer will not be held liable for injury or property damage from negligence, improper training, machine modifications or misuse. Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are: • Lead from lead-based paints. • Crystalline silica from bricks, cement and other masonry products. • Arsenic and chromium from chemically-treated lumber. Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: Work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles. D4065/D4057 Ratchet Hoist Manual SAFETY For Your Own Safety Read Instruction Manual Before Operating This Equipment The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of symbols and signal words which are intended to convey the level of importance of the safety messages. The progression of symbols is described below. Remember that safety messages by themselves do not eliminate danger and are not a substitute for proper accident prevention measures. Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury. It may also be used to alert against unsafe practices. NOTICE This symbol is used to alert the user to useful information about proper operation of the equipment. Safety Instructions for Ratchet Hoists 6. DO NOT USE UNDER THE INFLUENCE OF DRUGS OR ALCOHOL. 1. KEEP ALL SAFETY DEVICES IN PLACE and in working order. 2. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents. 7. KEEP ALL SAFETY DEVICES IN PLACE and in working order. 3. KEEP CHILDREN AND VISITORS AWAY. All children and visitors should be kept at a safe distance from work area. 8. LIFTING POWER. This ratchet hoist is designed to be comfortable for one person to lift the load using only hand power. Never use a motor, "cheater pipe", or other mechanical device on the hoist. 9. HEAD PROTECTION. Always wear a hard hat or similar head protection when using the hoist. 4. DO NOT FORCE TOOL. It will do the job better and safer at the rate for which it was designed. 5. USE THE RIGHT TOOL. Do not force tool or attachment to do a job for which it was not designed. -1- D4065/D4057 Ratchet Hoist Manual Safety Instructions for Ratchet Hoists 8. WARNING LABEL. Always make sure the warning label on the hoist is legible so that the operator can be aware of the immediate hazards of operating the hoist. If the label becomes damaged, replace it. 7. CRUSHING HAZARD. If the load should fall, it could cause death or serious personal injury to anyone underneath the hoist. Always make sure the operator and bystanders never move under the load. 8. OPERATION SPEED. Use a slow and steady pace when raising or lowering the load to avoid jerking or tangling the chains and load. 9. HEAD PROTECTION. Always wear a hard hat or similar head protection when using the hoist. 10.OPERATIONAL DIFFICULTY. If the lifting chain seems to require excessive force to lift the load, check for the following and resolve them before continuing: — Is the load heavier than the rated capacity of the hoist? — Are the chains or load entangled in any way? — Is an obstacle blocking the load or chains? — Are the chains and load not directly under the hoist? — Have the gears inside the hoist housing jammed? 1. KEEP ALL SAFETY DEVICES IN PLACE and in good working order. 2. LIFTING POWER. This ratchet hoist is designed to be comfortable for one person to lift the load using only hand power. Never use a motor or an additional mechanical device with this ratchet hoist to lift the load. 3. SAFETY HOOKS. Before lifting, inspect the safety hooks to make certain they are securely attached, and verify that the safety catches are operating correctly. 4. METAL FATIGUE. Before using, inspect the hooks, chains, and hoist housing to verify that the metal parts do not have cracks or other signs of potential failure. 5. DYNAMIC LOADING. Swinging or jerking the load will cause dynamic loading that could exceed the capacities of the hoist, which could result in the load falling. 6. VERTICAL MOVEMENT. The ratchet hoist is designed to only move the load straight up and straight down. Swinging or dragging the load could cause hoist failure. 7. CHAIN ENTANGLEMENT. Always make sure the chains are not twisted around each other before lifting. Keep body parts, long hair, and jewelry away from the chains and hooks to prevent entanglement during lifting. READ and understand this entire manual before using this hoist. Serious personal injury may occur if safety and operational information is not understood and followed. DO NOT risk your safety by not reading! -2- D4065/D4057 Ratchet Hoist Manual Additional Safety Precautions for Ratchet Hoists DO NOT attempt to lift a load in excess of the rated load capacity. DO NOT wrap the lifting chain around the load to lift it—use a separate chain. DO NOT drag the load or lift it when it is not directly under the ratchet hoist. DO NOT mishandle the hoist assembly. DO NOT allow the hook to become twisted around the chain. DO NOT exceed the maximum lifting or lowering distance. USE this and other machinery with caution and respect. Always consider safety first, as it applies to your individual working conditions. No list of safety guidelines can be complete—every shop environment is different. Failure to follow guidelines could result in death, serious personal injury, or damage to equipment. -3- D4065/D4057 Ratchet Hoist Manual INTRODUCTION Woodstock Technical Support This tool has been specially designed to provide many years of trouble-free service. Close attention to detail, ruggedly built parts and a rigid quality control program assure safe and reliable operation. If you need the latest edition of this manual, you can download it from http://www.shopfox.biz. If you have comments about this manual, please contact us at: Woodstock International, Inc. is committed to customer satisfaction. Our intent with this manual is to include the basic information for safety, setup, operation, maintenance, and service of this product. Woodstock International, Inc. Attn: Technical Documentation Manager P.O. Box 2309 Bellingham, WA 98227 Email: firstname.lastname@example.org We stand behind our tools! In the event that questions arise about your tool, please contact Woodstock International Technical Support at (360) 734-3482 or send e-mail to: email@example.com. Our knowledgeable staff will help you troubleshoot problems and process warranty claims. Specifications Refer to the table below to verify the operation specifications of the specific model of ratchet hoist that you purchased. The model number appears on the label attached to the side of the gear block housing. Be sure you understand the capacity and lift requirements for your particular model before using it! Description Maximum Load Capacity D4065 D4057 ⁄4 Ton 1 1⁄2 Ton 59" 59" 3 Maximum Lifting Chain Length No. of Load Chain Lines 1 Lifting Chain Link Thickness ⁄64" 15 Lifting Chain Hardness ISO 9002 Factory Net Weight -4- 1 ⁄16" 5 Grade 80 Grade 80 Yes Yes 15 lbs. 24 lbs. D4065/D4057 Ratchet Hoist Manual OPERATION To operate the ratchet hoist, do these steps: 4. Flip the lever on the ratchet handle to the neutral ("N") position. This allows the lifting chain to freely move through the gear block housing by either pulling on the lifting chain or rotating the handwheel. 1. Read and follow the safety precautions included in the front of the manual, wear protective head gear, and clear the area around the lifting operation. 5. Make sure the chains are not tangled, then attach the lifting hook to the load. 2. Secure the safety hook on top of the hoist housing to a structurally sound overhead beam that is capable of supporting the load weight. 6. Eliminate the slack in the lifting chain between the gear block housing and the load by pulling on the chain. Make sure that the overhead connection point conforms to the required local and state safety and building codes for the hoist and load used. 7. Flip the ratchet lever to the "UP" position, then pull on the ratchet handle until there is slight tension on the lifting chain. Note: The hoist can be mounted a beam trolley if the capacity of the trolley system is at least twice the maximum load capacity of the hoist. 8. Inspect the hoist and load to make sure that the lifting chain will stay vertical and will not twist during the lifting operation, that there is not a possibility of any type of entanglement, and that there are no obstacles in the path of the lift. 3. Position the load directly under the ratchet hoist. 9. While keeping to the side of the lifting path, continue to pull on the ratchet handle with a slow and steady pace. Always connect the ratchet hoist lifting hook to a separate lifting device attached to the load, such as straps, chains, or eye bolt. DO NOT wrap the hoist lifting chain and hook around the load in any way. If you do, the dynamic loads could exceed the capacity of the hoist, causing it to fail and drop the load. A falling load could cause death or serious crushing injuries. Note: The ratchet mechanism will suspend the load at the current position when you release the ratchet handle. 10.To lower the load, flip the ratchet lever to the "DOWN" position, then pull on the ratchet handle with a slow and steady pace. 11.When the tension between the hoist and the load is completely released, detach the hoist hook. -5- D4065/D4057 Ratchet Hoist Manual Cleaning Follow regular maintenance to keep the hoist in good working condition. To avoid serious injury from hoist failure, never attempt to repair a hoist that malfunctions or becomes damaged. Hoist repair or service must be done by a qualified technician only. To prevent the chains from jamming, clean away dirt and debris from the outside of the hoist housing and the chains. NOTICE The hazard of an improper repair job is that it could cause the hoist to fail and unexpectedly drop the load, which could crush or kill people below, or cause major property damage. For this reason, we strongly recommend replacing the hoist if it malfunctions or becomes damaged. DO NOT submerge the hoist housing in liquid of any kind or allow liquid to enter the brake cover during cleaning, or the braking mechanism may fail to work properly. Chain Lubrication When the chains are clean and dry, apply a thin coat of light machine oil to the links with an oiled shop rag to ensure smooth movement and prevent corrosion. To avoid contaminating the friction brake during maintenance, you must know the difference between the gear cover and the brake cover (see Figure 1). Storage The Gear Cover will be removed during routine maintenance. The Brake Cover should only be removed by a qualified technician; it encloses the friction brake and protects it from exposure to contaminants, such as liquids or lubrication, that will cause the brake to fail under load. Before storing the hoist, clean and lubricate the chains. Always store the hoist in a clean, dry, and protected area to prevent corrosion or damage. A malfunctioning or damaged hoist may drop its load and crush or kill people below, or cause major property damage. To reduce this risk, observe all care and maintenance noted in the manual. If hoist malfunctions or becomes damaged, replace it, or have it serviced by a qualified service technician. Gear Cover Can be removed by operator for gear lubrication. Brake Cover May be removed only by a qualified technician. Figure 1. Hoist housing cover identification. -6- D4065/D4057 Ratchet Hoist Manual Greasing Gears 3. Remove the two disc gears from the housing. Clean and grease the hoist gears every 6 months of normal use, or more frequently with heavier use. 4. Use mineral spirits, a stiff-bristled brush, and shop rags to clean the old grease and grime from the disc and splined gears. Items Needed Qty Wrench or Socket 13mm..................... 2 Mineral Spirits......................As Needed Stiff-Bristled Brush........................... 1 Shop Rags...........................As Needed Multi-Purpose Gear Grease.......As Needed To grease the hoist gears: Take care not allow the mineral spirits or lubricant to drip into the lower ratchet housing and onto the braking mechanism. 5. When the parts are dry, apply a medium coat of multi-purpose gear grease to the gear teeth. 1. Lay the hoist housing on a flat working surface with the brake cover facing down. 6. Re-assemble the components in the revers order that you disassembled them. 2. Remove the three lock nuts that secure the gear cover, then remove the cover (see Figure 2). 7. Test the lifting capabilities of the hoist with no load, then, if successful, with the rated maximum load for your hoist. Splined Gear Gear Cover — If you suspect any problems with the ratchet or brake mechanisms, immediately lower the load and resolve any issues before using the hoist again. Disc Gears Lock Nuts Figure 2. Gears exposed. -7- D4065/D4057 Ratchet Hoist Manual 102 133 128 129 104 147 110 -8- 125 124 146 130 145 144 140 141 127 139 138 126 121 All service, repair, or part replacement to this hoist MUST be performed by a qualified hoist service technician. Failure to heed this warning could result in hoist failure, which could cause death, serious personal injury, or property damage. 122 135 136 123 138 117 143 120 119 137 117 118 114 113 115 116 109 107 112 111 108 132 134 106 105 131 142 103 136 101 135 PARTS DIAGRAM D4065/D4057 Ratchet Hoist Manual PARTS LISTS D4057 Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 GEAR COVER DISC GEAR DRIVE SHAFT SPLINED GEAR GEAR SIDE PLATE LOAD SHEAVE GUIDE PLATE ROLLER BEARING RACE STRIPPER RATCHET SIDE PLATE PAWL TORSION SPRING 1 X 13 PAWL EXT RETAINING RING DISC HUB COMPRESSION SPRING 1 X 16 FRICTION DISK RATCHET DISK THREADED DISK BRAKE COVER CHANGE-OVER GEAR RATCHET HANDLE ASSEMBLY CHANGE-OVER PAWL SPRING SEAT 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 CHANGE-OVER SPRING 1.2 X 8.6 BUSHING HANDWHEEL LIFTING CHAIN G80 CHAIN RING NAME PLATE TOP HOOK ASSEMBLY TOP HOOK SHAFT BOTTOM HOOK ASSEMBLY CHAIN PIN HEX NUT M6-1 LOCK WASHER 6MM HEX NUT M6-1 LOCK WASHER 6MM HEX BOLT M6-1 X 10 SLOTTED HEX NUT M10-1.5 COTTER PIN LOCK NUT M6-1 WIRE SNAP RING GEAR SCREW M5-.8 X 10 LOCK WASHER 5MM RIVET INT RETAINING RING XD4057101 XD4057102 XD4057103 XD4057104 XD4057105 XD4057106 XD4057107 XD4057108 XD4057109 XD4057110 XD4057111 XD4057112 XD4057113 XD4057114 XD4057115 XD4057116 XD4057117 XD4057118 XD4057119 XD4057120 XD4057121 XD4057122 XD4057123 XD4057124 XD4057125 XD4057126 XD4057127 XD4057128 XD4057129 XD4057130 XD4057131 XD4057132 XD4057133 XD4057134 XPN01M XPLW03M XPN01M XPLW03M XPB04M XD4057140 XD4057141 XPLN03M XD4057143 XD4057144 XPLW01M XD4057146 XD4057147 D4065 Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 GEAR COVER DISC GEAR DRIVE SHAFT SPLINED GEAR GEAR SIDE PLATE LOAD SHEAVE GUIDE PLATE ROLLER BEARING RACE STRIPPER RATCHET SIDE PLATE PAWL TORSION SPRING 1 X 13 PAWL EXT RETAINING RING DISC HUB COMPRESSION SPRING 1 X 16 FRICTION DISK RATCHET DISK THREADED DISK BRAKE COVER CHANGE-OVER GEAR RATCHET HANDLE ASSEMBLY CHANGE-OVER PAWL SPRING SEAT 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 CHANGE-OVER SPRING 1.2 X 8.6 BUSHING HANDWHEEL LIFTING CHAIN G80 CHAIN RING NAME PLATE TOP HOOK ASSEMBLY TOP HOOK SHAFT BOTTOM HOOK ASSEMBLY CHAIN PIN HEX NUT M6-1 LOCK WASHER 6MM HEX NUT M6-1 LOCK WASHER 6MM HEX BOLT M6-1 X 10 SLOTTED HEX NUT M10-1.5 COTTER PIN LOCK NUT M6-1 WIRE SNAP RING GEAR SCREW M5-.8 X 10 LOCK WASHER 5MM RIVET INT RETAINING RING XD4065101 XD4065102 XD4065103 XD4065104 XD4065105 XD4065106 XD4065107 XD4065108 XD4065109 XD4065110 XD4065111 XD4065112 XD4065113 XD4065114 XD4065115 XD4065116 XD4065117 XD4065118 XD4065119 XD4065120 XD4065121 XD4065122 XD4065123 XD4065124 -9- XD4065125 XD4065126 XD4065127 XD4065128 XD4065129 XD4065130 XD4065131 XD4065132 XD4065133 XD4065134 XPN01M XPLW03M XPN01M XPLW03M XPB04M XD4065140 XD4065141 XPLN03M XD4065143 XD4065144 XPLW01M XD4065146 XD4065147 WARRANTY AND RETURNS Woodstock International, Inc. warrants this equipment to be free of defects from workmanship and materials for a period of 1 year from the date of original purchase. The liability under this warranty shall not exceed the purchase price paid for the products and is limited to credit for, or replacement of the defective part. We do not warrant or represent that the merchandise complies with the provision of any law or acts, and buyer assumes all risk and liability resulting from the use of the goods, whether using singly or in combination with other products. This warranty does not apply to defects or damages due directly or indirectly from misuse, abuse, negligence, accidents, repairs or alterations, or lack of maintenance of our products. We shall in no event be liable for death or injuries to persons or property or for incidental, contingent, special or consequential damages arising from the use of our products. This disclaimer applies to both during and after the term of this warranty. Any legal actions brought against Woodstock International, Inc. shall be tried in the State of Washington, County of Whatcom. Woodstock International, Inc. reserves the right to implement any changes in specifications or discontinue any products without notice.