JET BLVS018, BLVS025, BLVS050 Operating Instructions and Parts Manual

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Operating Instructions and Parts Manual

BLVS Series Electric Hoists

JET

1.0 IMPORTANT SAFETY

INSTRUCTIONS

WARNING: To avoid risk of injury:

1. Read and understand the entire owner's manual before attempting assembly or operation.

2. Read and understand the warnings posted on the machine and in this manual. Failure to comply with all of these warnings may cause serious injury.

3. Replace warning labels if they become obscured or removed.

4. This chain hoist is designed and intended for use by properly trained and experienced personnel only. If you are not familiar with the proper and safe operation of a chain hoist, do not use until proper training and knowledge have been obtained.

5. Do not use this chain hoist for other than its intended use. If used for other purposes, JET disclaims any real or implied warranty and holds itself harmless from any injury that may result from that use.

6. Do not install this chain hoist where explosive hazards may exist.

7. Give your work undivided attention. Looking around, carrying on a conversation and “horseplay” are careless acts that can result in serious injury.

8. Do not use to lift people, or loads over people. Warn others in the vicinity when lifting or transporting a load. Avoid swinging load and hook.

9. Do not exceed the rated lift capacity of the chain hoist.

10. Make sure limiter devices are operating properly. Do not use limit switches as routine operating stops; they are emergency devices only.

11. Verify that load chain is properly seated in load sheeve before operating hoist.

12. Do not use the load chain as a sling or wrap load chain around the load.

13. Do not use the load chain to side-pull a load.

14. Always inspect the chain hoist for damage prior to use. Do not use a chain hoist with twisted, kinked, worn or otherwise damaged chain. If the chain hoist is damaged, do not use until it has been repaired or replaced.

15. Do not use more than one chain hoist to lift or move a load. If this is unavoidable, each chain hoist must have the same capacity as the load to be moved.

16. Never allow the load chain to “set” over sharp edges. All lifts must be made with straight chain that is free of obstacles.

17. Do not use chain hoist unless load is centered between top and bottom hooks.

18. Protect load chain from weld splatter and other contaminants. Do not allow the hook or chain to be contacted by a live welding electrode.

19. Always take time to study the job to be performed and choose the safest method. Do not place yourself or other people in an unsafe position. Maintain constant awareness of the lifting environment.

20. Leave all internal maintenance to a qualified JET service center.

21. Disconnect hoist from power source before performing maintenance or opening the housing.

22. Do not leave a suspended load unattended.

23. Replace the chain with factory replacement chain only. Do not use any other type of chain.

24. Never use the chain hoist if either hook is stretched, deformed, or has a broken or missing safety latch. Always replace the safety latch and/or the hook before placing the chain hoist back into service.

25. Keep safety guards in place at all times when the hoist is in use.

26. Do not operate this hoist while tired or under the influence of drugs, alcohol or any medication.

27. This hoist is not designed for exposure to outdoor elements.

28. Understand and follow all procedures as set forth in American National Standards titled Overhead Hoists (Underhung), ANSI/ASME B30.16. This standard is available through the American Society of Mechanical Engineers at www.ASME.org.

WARNING: This product can expose you to chemicals including lead and cadmium which are known to the State of California to cause cancer and birth defects or other reproductive harm, and phthalates which are known to the State of California to cause birth defects or other reproductive harm. For more information go to http://www.p65warnings. ca.gov.

Familiarize yourself with the following safety notices used in this manual:

This means that if precautions are not heeded, it may result in minor injury and/or possible

machine damage.

This means that if precautions are not heeded, it may result in serious injury or possibly even

death.

2.0 Important notice

It is the responsibility of the owner/user to install, inspect, operate and maintain this hoist in accordance with OSHA regulations and ANSI/ASME B30.16, “Overhead Hoists (Underhung)”, along with any state or local codes/ordinances as applicable. If hoist is installed as part of a total lifting system (trolley, crane, monorail, etc.), or if below-the-hook lifting devices will be used, it is the responsibility of the owner/user to comply with any standards or regulations involving those additional elements of the system.

3.0 About this manual

This manual is provided by JET covering the safe operation and maintenance procedures for the JET BLVS series hoists. This manual contains instructions on installation, safety precautions, general operating procedures, maintenance instructions and parts breakdown for your hoist. It is not intended to be an exhaustive guide to the use of hoists or the broad subject of rigging, and cannot anticipate every system or lifting configuration in which this product may be used.

Retain all instructions and safety warnings for continued reference. If the hoist transfers ownership, the manual should accompany it.

If there are questions or comments, please contact either your local supplier or JET. JET can also be reached at our web site: www.jettools.com.

Read and understand the entire contents of this manual before installing hoist or

attempting operation, adjustment or maintenance. Failure to comply may cause serious injury.

4.0 Table of contents

Section Page

1.0 IMPORTANT SAFETY INSTRUCTIONS ....................................................................................................... 2

2.0 Important notice ............................................................................................................................................. 3

3.0 About this manual .......................................................................................................................................... 3

4.0 Table of contents ............................................................................................................................................ 4

5.0 Product introduction ....................................................................................................................................... 5

6.0 Glossary ......................................................................................................................................................... 5

7.0 BLVS series hoist specifications .................................................................................................................... 6

7.1 Operating environment ............................................................................................................................... 7

7.2 Wireless controller specifications ............................................................................................................... 7

8.0 Unpacking ...................................................................................................................................................... 8

8.1 Shipping contents ....................................................................................................................................... 8

9.0 Installation ...................................................................................................................................................... 8

9.1 Mounting top hook ...................................................................................................................................... 8

9.2 Lubrication .................................................................................................................................................. 8

9.3 Power cable ................................................................................................................................................ 8

9.4 Controller setup .......................................................................................................................................... 9

9.5 Chain container .......................................................................................................................................... 9

10.0 Electrical connections .................................................................................................................................. 9

10.1 GROUNDING INSTRUCTIONS ............................................................................................................... 9

10.2 Inspecting hoist motion ........................................................................................................................... 10

11.0 Pre-operation inspection .................................................................................................................................. 10

11.1 Inspecting load chain .............................................................................................................................. 10

11.2 Inspecting hooks .................................................................................................................................... 10

12.0 Operation ................................................................................................................................................... 11

12.1 Controls .................................................................................................................................................. 11

12.2 General procedure ................................................................................................................................. 11

12.3 Load brake function ................................................................................................................................ 12

13.0 Adjustments ............................................................................................................................................... 12

13.1 Replacing load chain .............................................................................................................................. 12

14.0 Transmitter/receiver synchronization ......................................................................................................... 15

15.0 Mechanical classification (grade) ............................................................................................................... 16

16.0 Inspection and maintenance ...................................................................................................................... 17

16.1 Gearbox oil ............................................................................................................................................. 17

17.0 Inspection schedules .................................................................................................................................. 18

18.0 Allowable limits ........................................................................................................................................... 19

18.1 Hook wear limits (top and bottom) .......................................................................................................... 19

18.2 Chain wear limits .................................................................................................................................... 20

19.0 Chain container selection for BLVS series hoist ........................................................................................ 21

20.0 Controllers for BLVS hoists ........................................................................................................................ 21

21.0 Troubleshooting BLVS series Hoist ........................................................................................................... 22

22.0 Replacement Parts ..................................................................................................................................... 23

22.1.1 BLVS018 and BLVS025 Hoists – Exploded View ............................................................................... 24

22.1.2 BLVS018 and BLVS025 – Parts List ................................................................................................... 25

22.2.1 BLVS050 Hoist – Parts List ................................................................................................................. 27

22.2.2 BLVS050 Hoist – Parts List ................................................................................................................. 28

22.3.1 BLVS018, 025, 050 Hoist – Exploded View ........................................................................................ 30

22.3.2 BLVS018, 025, 050 Hoist – Parts List ................................................................................................. 30

23.0 Electrical connections for BLVS series hoist .............................................................................................. 31

24.0 Warranty and Service ................................................................................................................................. 32

5.0 Product introduction

Your JET variable speed hoist is designed and constructed to provide consistent, long-term operation if used in accordance with the instructions set forth in this manual.

JET BLVS series hoists are variable speed, available in 120 volt, single-phase power, and varied chain lengths.

The mechanical load brake prevents slippage up to maximum load capacity. The hoist is also provided with overload protection and limit switches.

This hoist complies with FEM standards.

6.0 Glossary

Key terms the hoist operator should know:

Creep speed: Slow, constant, fixed rate of motion of a hoist.

Duty cycle: The amount of work a hoist can perform in a given period of time, generally measured by maximum run time and number of starts within that period. Duty cycle ratings are designated H1 through H5.

Duty class: Identifies the type of service for which a hoist is designed, designated A through F.

Headroom: Minimum distance between saddle of top hook to saddle of load hook, measured when load hook is at upper travel limit. Smaller headroom allows a hoist to fit in tighter work spaces.

Hook saddle: The inside arc of the hook which contacts the beam (top hook) or where the load sling is seated (load hook).

Toggle or “bump fire”: Rapid press and release of a control button to raise or lower load in intermittent steps. (A variable frequency drive in lowest speed range often eliminates the need for toggling.)

Overtravel limit device: A device for limiting upward or downward travel of the load hook at the extremities of its lift. (If activation of the device alters the electrical circuit within the machine, it is often called a “limit switch.”)

Load block: The assembly of hook or shackle, swivel, bearing, pins, sheaves and frame suspended by the chain.

Overload limit device: A mechanical or electrical device that prevents the hoist from lifting when excessive load is applied.

Rated Load, or Capacity: The maximum load weight, usually labeled as tonnage, which the hoist is designed to handle as designated by the manufacturer.

Reeving: The system in which a chain or rope travels around a running sheave.

Running Sheave: A sheave which engages the chain/rope and rotates as the load block is raised or lowered. Also called “load sheave” or “load sprocket.”

Variable frequency drive (“inverter”): A control system that converts fixed line voltage and frequency into a three-phase system with infinitely variable voltage and frequency, in order to regulate motor speed.

7.0 BLVS series hoist specifications

The specifications in this manual were current at time of publication, but because of our policy of continuous improvement, JET reserves the right to change specifications at any time and without prior notice, without incurring obligations.

Figure 7-1: All dimensions in inches. Shows OPTIONAL wired pendant; wireless remote comes standard.

BLVS018 BLVS025 BLVS050

DWG. Figure 7-1 I I II

Capacity

Lift All models available in standard 10 or 20 ft. lifts. Custom lengths up to 100 ft. some models 1

Load Chain

diameter x pitch

Number of falls 1 1 2

Lifting speeds

Pendant controls Wireless controller 2

Net weight

Shipping weight

Duty

Cycle

Motor

Current Draw (amperage) 6.0A 10.0 A 10.0 A

Gearbox capacity

Enclosure

ratings

Time Rating 15 min.

Intermittent Duty % 30%

Max. starts per hour 180

Noise level

Pushbutton control IP65

in. Ø .157 x .47

mm Ø 4.0 x 12

Low speed

High speed

10 ft. Lift 36.4 lb (16.5kg) 42.8 lb (19.4kg)

20 ft. Lift 38.6 lb (17.5kg) 47.4 lb (21.5kg)

10 ft. Lift 43.0 lb (19.5kg) 49.4 lb (22.4kg)

20 ft. Lift 45.4 lb (20.6kg) 54.0 lb (24.5kg)

Horsepower 0.4 HP (300 W) 0.8 HP (600 W) 0.8 HP (600 W) Pole 8P 8P 8P Cycle 60Hz Phase single Voltage 120 V

Hoist IP54

1/8 Ton (120kg)

0~10.5 ft/min

(0~3.2 m/min)

41 ft/min

(12.5 m/min)

1/4 Ton (240kg)

0~10.5 ft/min

(0~3.2 m/min)

41 ft/min

(12.5 m/min)

81 dB

0.5L

1/2 Ton (480kg)

0~5.25 ft/min

(0~1.6 m/min)

20.67 ft/min (6.3 m/min)

Table 1

Stock numbers vary based upon chain length. Determine needs, then see JET website for stock numbers. Note:

Some models are shipped in a plastic molded carrying case.

Optional wired pendants also available. See sect. 20.0.

Measured at 1m horizontally from hoist during normal operation. The specified values are emission levels and are not necessarily to be seen as safe operating levels. As workplace conditions vary, this information is intended to allow the user to make a better estimation of the hazards and risks involved only.

7.1 Operating environment

Working temperature range: -5 to +40 °C (23 to 104 °F) Working humidity range: 85% or less Electric power supply: Single phase, 100V

~240V(+/-10%), 60Hz

7.2 Wireless controller specifications

Frequency range 902.5 ~ 927.5 MHz Average power consumption 16mA@DC3V (default setting)

Modulation method 2 GFSK Radio-frequency power <10dBm (default setting)

Operating range 328 ft. (100 m) Operating temperature -4° ~ +131°F (-20° ~ +55°C)

Control system PLL Storage temperature -40° ~ +149°F (-40° ~ +65°C)

Antenna impedance

Typical command response time 50mS~100mS Dimensions 7.6x2.24x2 in. (193x57x51 mm)

Power supply LR6(AA)1.5Vx2 Weight (including battery) 0.72 lb (325 g) approx.

Antenna internal Housing material PA6 (30%GF)

50 

Enclosure rating IP65

Table 2

Read and understand the entire contents of this manual before installing hoist or attempting operation. Failure to comply may cause serious injury.

8.0 Unpacking

Remove hoist from its crate or case and carefully inspect its components for shipping damage. Report any damage immediately to your distributor and shipping agent. Do not discard any shipping material until hoist is installed and running properly.

8.1 Shipping contents

1 Electric chain hoist 1 Chain container with fasteners 1 Power supply cord 1 Wireless controller 1 Wrist strap (for controller) 1 Receiving antenna 1 Top hook assembly 1 Bottom hook assembly with chain 1 Hoist instructions & parts manual 1 Remote controller manual 1 Product registration card 1 Test certificate

9.2 Lubrication

9.2.1 Gear oil

Your hoist has been shipped with oil included in the gearbox. Before operating, verify the oil level by removing the fill plug on top of the hoist, shown in Figure 9-1. The oil level should be just below the edge of the hole.

Check the level again after the first 100 hours of operation, then check every 3 months. See sect.

16.1 for oil specifications.

IMPORTANT: Before operating hoist, pull out the rubber breather plug from the top fill plug (Figure 9-

1). Reinsert this plug if hoist is to be transported or placed in storage.

9.0 Installation

Hoist must remain disconnected from electrical supply during assembly and installation unless instructed otherwise.

Support for the hoist may be hook, clevis pin, trolley, or beam clamp. Whatever method of suspension is chosen, the support components must be rated equal to, or greater than the capacity of the chain hoist. Supporting structures (such as I-Beams) should be installed by properly licensed professional installers.

If you are using the hoist with a trolley, refer to the trolley manual for instructions on securing the control cord and maintaining proper slack in the cord during operation. Optional pendant cords for use with a trolley system are shown in section

20.0.

TIP: If suspending from a trolley, do not mount the top hook but install the hoist directly to the trolley if possible.

Make sure the suspension system used is properly grounded, in addition to the grounding of the hoist.

9.1 Mounting top hook

Attach the top hook with the provided lock bolt, hex nut and cotter pin (Figure 9-1).

Figure 9-1 (BLVS050 shown)

9.2.2 Chain lubrication

Periodically apply a light coat of 30W oil to the chain. This will create easier operation and prolong the chain’s life. For optimum results, clean chain with an acid-free solution before oiling.

9.3 Power cable

All electrical connections

must be made by qualified personnel. Read

sect. 10.0 before connecting this unit to power.

Connect the power cable leads to an extension and run the line to the electrical panel, or install a UL/CSA approved plug to draw from a receptacle.

IMPORTANT: The power cable should be directed so that it is safely out of the way of loads. If a trolley is used, power cable must not interfere with, or be pinched by, trolley travel. See Figure 9-2 for a recommended solution.

Figure 9-2

9.4 Controller setup

Screw the receiving antenna onto the bottom of the hoist. See Figure 9-3. The wrist strap can be placed on the wireless controller.

The wireless controller (transmitter) has been synchronized to your specific hoist by the manufacturer. If replacing a transmitter, see sect.

14.0 for instructions.

If using a wired pendant controller (optional accessory), the antenna is not needed. Connect the 12-pin male plug on the controller cable to the receptacle beneath the hoist, and clip the carabiner to the eye bolt to relieve stress on the plug connection.

See sect. 12.1 for controller operation.

resulting in serious personal injury or property damage.

To assemble chain container to hoist:

1. Hang hoist in position on the I-Beam or trolley. Do not install chain container yet. Allow slack side and load side of chain to hang freely from hoist.

2. Apply power to hoist and press DOWN button until limit switch is tripped.

3. Mount chain container to bracket on side of hoist (Figures 9-1 and 9-4), using the two socket head bolts and lock washers.

4. Place chain stop into container, and operate hoist to bring load hook up until upper limit switch is tripped.

5. Inspect chain to ensure that all non-loaded chain is completely in container.

HEX. RECESS BOLT

CHAIN BUCKET

LOCK NUT

Figure 9-4

Do not dump chain by hand

into the chain container. By not following the above steps, the chain can become twisted or kinked and can damage the hoist.

Figure 9-3: remote controller setup

9.5 Chain container

Your hoist is supplied with a chain container designed to fit the particular length of chain. If a different length chain is ever installed on this hoist, the chain container must be replaced by one of proper size. See chart in sect. 19.0.

The chain container should be installed after the power supply is connected to hoist.

Do not overfill chain container.

If chain should overfill and begin to fall, entire chain container may empty without warning,

10.0 Electrical connections

Electrical connections must

be made by a qualified electrician in compliance with all relevant codes. This machine must be properly grounded to help prevent electrical shock and possible fatal injury.

The BLVS series hoist is pre-wired for 120V, single-phase power only.

The hoist should be connected to a circuit with current overload protection, rated at minimum 120% of the full load amperage listed on the hoist’s nameplate. If fuses are used, they must be timedelay fuses rated “D”. Local codes take precedence over recommendations.

10.1 GROUNDING INSTRUCTIONS

In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock.

This hoist is not supplied with a power plug. Power supply cables may either be fitted with a UL/CSA-

listed plug rated for the appropriate phase and voltage, or “hard-wired” directly to a control panel. If hard-wired, make sure a disconnect is available for the operator.

If a plug is installed, it must have an equipmentgrounding conductor and a grounding prong. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances. Do not modify the plug – if it will not fit the outlet, have the proper outlet installed by a qualified electrician.

Improper connection of the equipment-grounding conductor can result in a risk of electric shock. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment-grounding connector.

If repair or replacement of the electric cord or plug is necessary, do not connect the equipmentgrounding conductor to a live terminal.

Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the tool is properly grounded.

Repair or replace damaged or worn cord immediately.

10.2 Inspecting hoist motion

1. Allow 15 seconds for start-up after connecting power supply.

2. Before closing circuit breaker and testing hoist, check that wiring has been complete. If hoist cannot be observed when circuit breaker is closed, station an observer within sight of hoist to report any movement when power is applied. Be prepared to disconnect power if hoist motor starts when power is applied – the hoist must remain motionless when power is applied. Find and correct any problems before continuing.

3. With no load on load hook, press UP button very briefly and observe hoist action. The hook should move upward.

4. Run hoist to maximum lifting height, then to maximum lowering point to ensure that limiter devices are operating properly.

11.0 Pre-operation inspection

2. Marks on the chain surface are deeper than 5% of the link’s diameter.

3. Links are twisted or deformed.

4. Links are stretched too long or considerably worn on the surface, especially at points where links contact each other.

Never extend load chain by welding a second piece to the original.

Do not operate hoist with

twisted, kinked or damaged load chain. Do not splice load chain.

Check that chain does not twist along its length from hoist to hook (Figure 11-1). If twist is present on units with multiple falls, the hook has been capsized; it must be passed back through the chain loop to remove all twist in the chain. See Figure 11-

Figure 11-1

Figure 11-2

The load chain supplied with

your JET chain hoist is designed, manufactured, and tested for proper fit and durability. Over a period of time, the chain may need to be replaced. For your own safety, use factory replacement chain only. Use of other than factory replacement chain may cause serious injury and/or damage to hoist.

A light coat of 30W oil applied periodically to the chain will create easier operation and prolong chain life.

11.1 Inspecting load chain

Clean chain with non-acidic solution, and carefully inspect entire load chain. Replace damaged chain before using hoist. Use provided chain gauge and refer to sect. 18.2. Replace worn chain.

Also replace the load chain if any of the following are identified:

1. Seriously rusted or cracked.

11.2 Inspecting hooks

It is important to check top and bottom hooks for proper opening and other signs of deformation or damage. Replace a hook immediately if any of the following problems are identified:

1. The safety latch is damaged or bent, or no longer has sufficient spring pressure to contact the hook tip.

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