Clarke CH2500C, CH4000C User guide

ELECTRIC HOIST

MODEL NO: CH2500C, CH4000C

PART NO: 7630388, 7630393

OPERATION AND MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC03/23 - rev 1

INTRODUCTION

Thank you for purchasing this CLARKE Electric Hoist.

Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safety of yourself
and that of others around you, and you can look forward to your purchase
giving you long and satisfactory service.

LIFTING OPERATIONS AND LIFTING EQUIPMENT REGULATIONS 1998

This hoist, depending on use, may fall within the scope of LOLER. It is the
owner’s responsibility to determine whether or not it does and, if so, to comply
with any applicable requirements in LOLER, for having the hoist thoroughly
examined.

GUARANTEE

This product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be
required as proof of purchase.

This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.

Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission. This guarantee does not effect your
statutory rights.

ENVIRONMENTAL PROTECTION

Through purchase of this hoist, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.

In effect, this means that this hoist must not be discarded with general waste.
Refer to the laws governing Waste Electrical and Electronic Equipment (WEEE)
at a recognised disposal facility.

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SPECIFICATIONS

CH2500C CH4000C

Part Number 7630388 7630393

Load Capacity (Single Cable) 125 kg 200 kg

Lifting Speed (Single Cable)

Lifting Height (Single Cable) 12 m 12 m

Load Capacity (Double Cable) 250 kg 400 kg

Lifting Speed (Double Cable) 5 m/min 5 m/min

Lifting Height (Double Cable) 6 m 6 m

Cable Length 12 m 12 m

Cable Diameter 3 mm 3.8 mm

Duty Cycle S3 20% - 10min S3 20% - 10min

Electrical Supply 230V @ 50Hz 230V @ 50Hz

Power Rating 540 W 950 W

Ingress Protection IP54 IP54

Sound Pressure Level 74.3 dB(A) 74.3 dB(A)

Sound Power Level 75.3 dB(A) 76.3 dB(A)

Sound Power Level Guaranteed 85dB 85dB

Uncertainty K 2 dB(A) 2 dB(A)

10 m/min 10 m/min

DO NOT LEAVE THE HOIST EXPOSED TO THE ELEMENTS AND AVOID DIRECT SUNLIGHT, DIRECT HEAT AND MOISTURE

THIS MACHINE IS FOR INDOOR USE ONLY

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

GENERAL SAFETY RULES

There is a serious risk of personal injury if you do not follow all instructions in this
guide.

1. This hoist must only be used by a competent person who understands these
instructions.

2. This hoist is for indoor, non-industrial use.

3. Keep children, animals and bystanders away from the work area.

4. DO NOT use this hoist if you are ill, tired, or under the influence of alcohol or
drugs.

5. Before use, always examine the hoist and its mountings to make sure that
they are in good condition. If you find any damaged or broken parts,
withdraw the hoist from service and renew or repair the part before further
use.

6. Before use, it is
important to make
sure that the steel
cable is correctly
wound around the
drum.

7. Wear protective clothing, gloves, footwear and hard hat.

8. DO NOT wear loose clothing, jewellery and tie back long hair.

9. Protect the equipment from frost or excessively high temperatures.

10. If the capacity of the hoist is exceeded, the cutout will operate. Let the
components cool down before continued use.

11. Make sure that the load is balanced, stable and that all personnel stay
clear of the raised load.

12. Make sure that the switches are in good condition.

13. Use this hoist for vertical lifts only.

14. Attach the hoist to a horizontal beam/box section that can hold the
weight of the load and the hoist.

15. When replacing parts, use only those supplied by Clarke International.
Consult the CLARKE service department for any spare parts required.

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ELECTRICAL CONNECTIONS

Plug must be BS1363/A approved.

Always fit

make sure that the outer sheath of

Neutral

(Blue)

Live

(Brown)

Earth

(Green and

a 13 Amp

the cable is firmly held by the clamp

fuse.

Yel low)

WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS FULLY
BEFORE CONNECTING THE HOIST TO THE MAINS SUPPLY.

This hoist is provided with a standard 13 amp, 230 volt (50Hz), BS 1363 plug, for
connection to a standard, domestic electrical supply. Should the plug need
changing, make sure that a plug of identical specification is used.

WARNING: THE WIRES IN THE CABLE ARE COLOURED AS FOLLOWS:
BLUE = NEUTRAL BROWN = LIVE YELLOW AND GREEN = EARTH

If the colours of the wires in
the power cable do not
correspond with the
markings on the terminals of
your plug, proceed as
follows.

• Connect the blue wire

to the terminal
marked N.

• Connect the brown

wire to the terminal
marked L.

• Connect the yellow and green wire to the terminal marked E or .

AN APPROVED RESIDUAL CURRENT DEVICE (RCD) WHICH HAS A TRIPPING
CURRENT OF LESS THAN 30MA MUST BE USED.

If you are not sure, consult a qualified electrician. DO NOT try to do any
repairs.

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UNPACKING

Unpack the box and make sure that the items in the list below are included.

• 1 x Hoist

• 1 x Hook / Pulley

•2 x Brackets

• 1 x Bag of fixings

• 1 x Instruction manual

If a part is damaged, consult your CLARKE supplier immediately.

INSTALLATION

Mount the hoist to a box section beam using the brackets supplied.

• The box section must be

able to support the weight
of the hoist plus the
maximum specified load.

If you are not sure, consult an
approved structural engineer.

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OPERATION

EMERGENCY STOP

LIFT

LOWER

PRE-USE INSPECTION

Unwind the cable and examine for fraying, corrosion etc.

Check the condition of all brackets and fastenings.

When in constant operation, the hoist should be inspected frequently.

HOIST CONTROL

LIFT/LOWER SWITCH

1. Press one side of the rocker switch
to lift the load.

2. Press the other side of the rocker
switch to lower the load.

3. To stop the hoist release the
switch.

NOTE: The load will not stop immediately when you release the switch. It

can continue for a 3-4 mm before the motor brake takes effect.

CAUTION: MAKE SURE THE HOIST HAS STOPPED BEFORE MOVING IN THE
OPPOSITE DIRECTION.

CAUTION: THIS HOIST IS FITTED WITH AN AUTO-STOP DEVICE. ENSURE THAT
WHEN THE CABLE IS AT ITS HIGHEST POINT AND THE AUTO-STOP IS
ACTUATED, THAT THE LIFT SWITCH IS RELEASED.

EMERGENCY STOP

Push the emergency stop to stop the hoist in an emergency.

• The emergency stop can be reset by turning it clockwise until it

‘pops’ out.

USING THE HOIST

WARNING: LIFTING OPERATIONS MUST BE PLANNED, SUPERVISED AND
CARRIED OUT SAFELY BY COMPETENT PERSONNEL.

1. Pay out the cable.

• Keep the cable in tension so that the coils on the drum remain

neatly in place.

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2. Attach the hook to the load. The hook must be placed -

• Directly above the centre of gravity of the load and in line with the

hoist.

• Make sure that no obstruction will prevent a clean lift.

HOIST CAPACITY

In the basic setup (shown on the
right) the lifting capacity is 125 kg,
(200 kg for the CH4000C)

It is possible to increase the capacity
to 250 kg (400 kg for the CH4000C). To
do this:

1. Loop the cable around the pulley
supplied.

2. Attach the hook to the hoist as
shown.

WARNING: ALWAYS LOWER IN A SLOW AND CONTROLLED MANNER, AND
ENSURE THAT THERE ARE NO OBSTACLES IN THE PATH OF THE LOAD’S
DESCENT.

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TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

When you press
the switch the
motor does not
operate.

Motor hums but
does not lift

Brake does not
operate and
load slips

The cable is
twisted, frayed or
kinked

If this does not solve your problem, please consult the CLARKE service
department.

The power cable is not
plugged in correctly

The cut out has operated Let the motor cool down

Power failure Check plug fuse

The motor is too hot Let it cool down

The load exceeds the
capacity of the hoist

The motor brake has
become stuck during
storage.

Brake is worn out. DO NOT use the hoist and

Cable is incorrectly wound
on the drum.

The cable has been stored
unwound or in poor
conditions.

Connect the power cable
correctly

Decrease the load

Consult your CLARKE dealer for
advice.

consult your CLARKE dealer.

Replace the cable.

Replace the cable.

MAINTENANCE

IMPORTANT: Only fully qualified personnel should attempt repairs.

1. Always visually inspect the hoist before use, to ensure that all parts are
correctly located and secure. Check for signs of damage or worn parts. Do

not use the hoist unless it is perfectly serviceable.

2. Check the cable for signs of fraying especially at the connecting parts.

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

COMPONENT PARTS - CH2500C

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COMPONENT PARTS CH2500C

No Description No Description

1 Hexagon Bolt 29 Internal Circlip

2 Bracket 30 Motor Brake Disc

3 Flat Washer 31 Tripping Spring

4 Spring Washer 32 Rotor

5 Support /Carriage Casing 33 Stator Casing Assembly

6 End Panel 34 Bearing

7 Locating Shaft 35 Front Cover

8 Gear Shaft 36 Paper Gasket

9 Flat Washer 37 Bearing

10 Silent Gear 38 First Gear

11 X-Head screw 39 Flat Key

12 Driven Gear 40 Gear Shaft

13 Turn Plate 41 Second Gear

14 Limit Switch 42 Bearing

15 Axle Sleeve 43 Gear Case

16 Limit Switch Plate 44 Socket Head Cap Screw

17 Nut 45 Bearing

18 X-Head Bolt 46 O-ring

19 Gear Cover 47 Flat Key

20 Fan Housing 48 Socket Head Cap Screw

21 Fan Blade 49 Drum Shaft

22 Hex Bolt 50 Limit Switch Arm

23 Locknut 51 Drum Inner Washer

24 Bearing 52 Wire Rope

25 Socket Head Cap Screw 53 Cable Drum

26 Bearing Sleeve 54 Wedge

27 Clamp 55 Drum External Washer

28 Rear Enclosure 56 Bearing

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No Description No Description

57 Straight Pin 78 Limit Switch

58 Driving Gear 79 Cable Entry

59 Aluminium Ferrule 80 Junction Box Cover

60 Block 81 Terminal

61 Rope Thimble 82 Junction Box Base

62 Hook Assembly Complete 83 Upper Limit Spring

63 X-head Bolt 84 Connecting Cable Sleeve

64 Plastic Limit Piece 85 Connecting Cable

65 Bolt 86 Socket

66 Bolt 87 Spade Connector

67 Spindle 88 Emergency Stop Button

68 Washer 89 Rocker Switch

69 Hook 90 Pendant Casing - Front

70 Pulley Wheel 91 Pendant Seal

71 Side Plate 92 Adjusting Locknut

72 Nut 93 Switch Base

73 Locknut 94 Emergency Stop Switch

74 Mains Plug 95 Cable Entry

75 Limit Shaft 96 Screw

76 Waterproof Gland 97 Pendant Casing - Rear

77 Plastic Closing Ring 98 Capacitor

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

COMPONENT PARTS - CH4000C

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

COMPONENT PARTS CH4000C

No Description No Description

1 Hexagon Bolt 29 Stator Casing Assembly

2 Bracket 30 Front Cover

3 Spring Washer 31 Paper Gasket

4 Flat Washer 32 Bearing

5 Support /Carriage Casing 33 First Gear

6 End Panel 34 Flat Key

7 Locating Shaft 35 Gear Shaft

8Gear Shaft 36Second Gear

9 Flat Washer 37 Bearing

10 Silent Gear 38 Gear Case

11 X-Head screw 39 Socket Head Cap Screw

12 Driven Gear 40 Bearing

13 Turn Plate 41 Circlip

14 Limit Switch 42 Flat Key

15 Axle Sleeve 43 Socket Head Cap Screw

16 Limit Switch Plate 44 Drum Shaft

17 Nut 45 Limit Switch Arm

18 X-Head Bolt 46 Drum Inner Washer

19 Gear Cover 47 Wire Rope

20 Fan Housing 48 Cable Drum

21 Fan Blade 49 Wedge

22 Hex Bolt 50 Drum External Washer

23 Rear Enclosure 51 Bearing

24 Bearing 52 Straight Pin

25 Motor Brake Disc 53 Driving Gear

26 Tripping Spring 54 Aluminium Ferrule

27 Spring 55 Block

28 Rotor 56 Rope Thimble

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No Description No Description

57 Hook Assembly 76 Limit Switch

58 X-head Bolt 77 Terminal

59 Plastic Limit Piece 78 Switch Plate

60 Bolt 79 Junction Box Base

61 Bolt 80 Connecting Cable Sleeve

62 Spindle 81 Connecting Cable

63 Washer 82 Socket

64 Hook 83 Spade Connector

65 Pulley Wheel 84 Emergency Stop Button

66 Side Plate 85 Rocker Switch

67 Locknut 86 Pendant Casing - Front

68 Nut 87 Pendant Seal

69 Mains Plug 88 Adjusting Locknut

70 Limit Shaft 89 Switch Base

71 Waterproof Gland 90 Emergency Stop Switch

72 Plastic Closing Ring 91 X-Head Screw

73 Switch Connector 92 Pendant Casing - Rear

74 Cable Clamp 93 Capacitor

75 Junction Box Cover

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DECLARATIONS OF CONFORMITY - CH2500C

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

DECLARATIONS OF CONFORMITY - CH2500C

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

DECLARATIONS OF CONFORMITY - CH4000C

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

DECLARATIONS OF CONFORMITY - CH4000C

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]