JET TS050-230, TS100-230, TS200-230, TS300-230, TS500-230 Operating Instructions and Parts Manual

...

JET

Operating Instructions and Parts Manual

TS Series 2-speed Electric Chain Hoists

single fall model shown

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 “horse-

play” 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 limit switches 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.

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 TS 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.

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.

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 TS series hoist specifications ......................................................................................................................... 6

7.1 230 Volt models .......................................................................................................................................... 6

7.2 460 Volt models .......................................................................................................................................... 7

7.3 TS series hoist dimensions with MT trolley ................................................................................................ 8

7.4 Operating environment ............................................................................................................................... 8

8.0 Unpacking ...................................................................................................................................................... 9

9.0 Installation ...................................................................................................................................................... 9

9.1 Mounting top hook ...................................................................................................................................... 9

9.2 Power cable ................................................................................................................................................ 9

9.3 Lubrication ................................................................................................................................................ 10

9.4 Chain container ........................................................................................................................................ 10

10.0 Electrical connections ................................................................................................................................ 10

10.1 GROUNDING INSTRUCTIONS ............................................................................................................. 10

10.2 Inspecting hoist motion ........................................................................................................................... 11

11.0 Pre-operation inspection .................................................................................................................................. 11

11.1 Inspecting load chain .............................................................................................................................. 11

11.2 Inspecting hooks .................................................................................................................................... 11

12.0 Operation ................................................................................................................................................... 12

12.1 Controls .................................................................................................................................................. 12

12.2 General procedure ................................................................................................................................. 12

12.3 Magnetic brake function ......................................................................................................................... 13

13.0 Adjustments ............................................................................................................................................... 13

13.1 Replacing load chain .............................................................................................................................. 13

14.0 Mechanical classification (grade) ............................................................................................................... 16

15.0 Inspection and maintenance ...................................................................................................................... 17

15.1 Gearbox oil ............................................................................................................................................. 17

16.0 Inspection schedules .................................................................................................................................. 18

17.0 Allowable limits ........................................................................................................................................... 19

17.1 Hook wear limits (top and bottom) .......................................................................................................... 19

17.2 Chain wear limits .................................................................................................................................... 20

18.0 Chain container selection for TS series hoist ............................................................................................. 21

19.0 Pendant controllers for TS hoists ............................................................................................................... 21

20.0 Troubleshooting TS series Hoist ................................................................................................................ 22

21.0 Replacement Parts ..................................................................................................................................... 23

21.1.1 TS050,TS100 Motor Assembly and Housing – Exploded View .......................................................... 24

21.1.2 TS050,TS100 Motor Assembly and Housing – Parts List ................................................................... 25

21.2.1 TS050, TS100 Hook Assembly – Exploded View ............................................................................... 27

21.2.2 TS050, TS100 Hook Assembly – Parts List ........................................................................................ 28

21.3.1 TS050, TS100 Load Chain – Exploded View ...................................................................................... 29

21.3.2 TS050, TS100 Load Chain – Parts List ............................................................................................... 30

21.4.1 TS050, TS100 Gear Box – Exploded View ......................................................................................... 31

21.4.2 TS050, TS100 Gear Box – Parts List .................................................................................................. 32

21.5.1 TS050, TS100 Electrical Assembly – Exploded View ......................................................................... 34

21.5.2 TS050, TS100 Electrical Assembly – Parts List .................................................................................. 35

21.6.1 TS200,TS300,TS500 Motor Assembly and Housing – Exploded View ............................................... 36

21.6.2 TS200,TS300,TS500 Motor Assembly and Housing – Parts List ........................................................ 37

21.7.1 TS200,TS300,TS500 Hook Assembly – Exploded View ..................................................................... 38

21.7.2 TS200,TS300,TS500 Hook Assembly – Parts List .............................................................................. 39

21.8.1 TS200,TS300,TS500 Gear Box – Exploded View ............................................................................... 40

21.8.2 TS200,TS300,TS500 Gear Box – Parts List ....................................................................................... 41

21.9.1 TS200,TS300,TS500 Electric Assembly – Exploded View ................................................................. 42

21.9.2 TS200,TS300,TS500 Electric Assembly – Parts List .......................................................................... 43

22.0 Electrical connections ................................................................................................................................ 44

22.1 TS050 hoist wiring diagram .................................................................................................................... 44

22.2 TS100 hoist wiring diagram .................................................................................................................... 45

22.3 TS200/TS300/TS500 hoist – wiring diagram .......................................................................................... 46

22.4 TS050 hoist with MT050 trolley – wiring diagram ................................................................................... 47

22.5 TS100 hoist with MT100 trolley – wiring diagram ................................................................................... 48

22.6 TS200/TS300/TS500 hoist with MT200/MT300/MT500 trolley – wiring diagram ................................... 49

23.0 Warranty and Service ................................................................................................................................. 50

5.0 Product introduction

Your JET dual-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 TS series hoists are available in 230 volt, 3-phase or 460 volt, 3-phase power, as well as varied chain lengths. The magnetic disc brake provides dependable and rapid stopping of chain movement without hook drift, and

produces less wear on brake elements than standard mechanical braking systems, thus reducing maintenance. The hoist is equipped with upper and lower limit switches, and a slip-clutch to prevent overloading.

This hoist complies with FEM standards.

6.0 Glossary

Key terms helpful to the hoist operator: 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.

Electro-magnetic brake: A stopping device controlled by the application of electrical current to the coil of an electromagnet, which draws away an armature allowing rotation of the shaft. When the magnet is de-energized, the armature moves back toward the brake face and squeezes together friction discs – the torque is applied to the hub and stops shaft rotation.

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.”

7.0 TS series hoist specifications

Figure 7-1

7.1 230 Volt models

TS050-230

TS100-230

TS200-230

TS300-230

TS500-230

Capacity

1/2 ton (500 kg)

1 ton (1000 kg)

2 ton (2000 kg)

3 ton (3000 kg)

5 ton (5000 kg)

Lift

All models available in standard 10, 15 or 20 ft. lifts.

Custom lengths available up to 100 ft. for most models 1

Load Chain

(diameter x pitch)

in.

Ø .248 x .752

Ø .280 x .795

Ø .394 x 1.189

Ø .441 x 1.339

Ø 6.3 x 19.1

Ø 7.1 x 20.2

Ø 10 x 30.2

Ø 11.2 x 34

Number of falls

1 1 1 2 2

Lifting speeds

(ft/min)

High spd

Low spd 8 7 8 5

Pendant controls

Dependent upon lift and trolley use; see sect. 18.0.

Duty

Cycle

Time Rating

30 min.

Duty Rating %

H4 (40/20)

Max. starts

per hour

240

Motor

Horsepower High

1.5 2 5 5 5

Low

0.4

0.5

1.2

Pole

2/8

Cycle

60 Hz

Phase

Voltage

220 V

Current Draw

(amperage)

High spd.

6.9

16.8

Low spd. 4 5.6

8.4

Noise level

75 db

Gearbox capacity

1.2 L

1.4L

Dimensions (Figure 7-1)

22-7/16" (570mm)

24-7/16" (620mm)

28-1/8" (715mm)

10-5/8" (270mm)

11-13/16" (300mm)

13-3/8" (340mm)

12-3/16" (310mm)

12-5/8" (320mm)

14-3/4" (375mm)

6-1/2" (165mm)

7-1/16" (180mm)

8-11/16" (220mm)

14-3/4" (375mm)

16-1/8" (410mm)

20-7/8" (530mm)

7-1/2" (190mm)

7-11/16" (195mm)

10-5/8" (270mm)

7-5/16" (185mm)

8-11/16" (220mm)

10-1/4" (260mm)

19-11/16" (500mm)

21-5/8" (550mm)

40-3/16" (1020mm)

-----

41-5/16" (1050mm)

43-5/16" (1100mm)

Table 1

7.2 460 Volt models

Refer to Figure 7-1.

TS050-460

TS100-460

TS200-460

TS300-460

TS500-460

Capacity

1/2 ton (500 kg)

1 ton (1000 kg)

2 ton (2000 kg)

3 ton (3000 kg)

5 ton (5000 kg)

Lift

All models available in standard 10, 15 or 20 ft. lifts.

Custom lengths available up to 100 ft. for most models 1

Load Chain

(diameter x pitch)

in.

Ø .248 x .752

Ø .280 x .795

Ø .394 x 1.189

Ø .441 x 1.339

Ø 6.3 x 19.1

Ø 7.1 x 20.2

Ø 10 x 30.2

Ø 11.2 x 34

Number of falls

1 1 1 2 2

Lifting speeds

(ft/min)

High spd

Low spd 8 7 8 5

Pendant controls

Dependent upon lift and trolley use; see sect. 18.0.

Duty

Cycle

Time Rating

30 min.

Duty Rating %

H4 (40/20)

Max. starts

per hour

240

Motor

Horsepower High

1.5 2 5 5 5

Low

0.4

0.5

1.2

Pole

2/8

Cycle

60 Hz

Phase

Voltage

460 V

Current Draw

(amperage)

High spd.

3.5

5.5

8.4

Low spd. 2 2.8

4.2

Noise level

75 db

Gearbox capacity

1.2 L

1.4L

Dimensions (Figure 7-1)

22-7/16" (570mm)

24-7/16" (620mm)

28-1/8" (715mm)

10-5/8" (270mm)

11-13/16" (300mm)

13-3/8" (340mm)

12-3/16" (310mm)

12-5/8" (320mm)

14-3/4" (375mm)

6-1/2" (165mm)

7-1/16" (180mm)

8-11/16" (220mm)

14-3/4" (375mm)

16-1/8" (410mm)

20-7/8" (530mm)

7-1/2" (190mm)

7-11/16" (195mm)

10-5/8" (270mm)

7-5/16" (185mm)

8-11/16" (220mm)

10-1/4" (260mm)

19-11/16" (500mm)

21-5/8" (550mm)

40-3/16" (1020mm)

-----

41-5/16" (1050mm)

43-5/16" (1100mm)

Table 2

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

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.

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.

7.3 TS series hoist dimensions with MT trolley

MT Trolleys (purchased separately) are designed to pair with the TS hoists. Voltage of trolley must match voltage of hoist. See trolley manual for instructions on connecting the two.

Figure 7-2

Hoist model 230V

TS050-230

TS100-230

TS200-230

TS300-230

TS500-230

Trolley

230V

model no.

MT050

MT100

MT200

MT300

MT500

stock no.

140183

140185

140187

140189

140190

Hoist model 460V

TS050-460

TS100-460

TS200-460

TS300-460

TS500-460

Trolley

460V

model no.

MT050-4

MT100-4

MT200-4

MT300-4

MT500-4

stock no.

144183

144185

144187

144189

144190 A

15-3/16" (385mm)

15-9/16" (395mm)

17-1/2" (445mm)

4-15/16" (126mm)

6-1/4" (159mm)

7-5/16" (185mm)

12-13/16" (325mm)

14-3/16" (360mm)

15-3/4" (400mm)

7-1/16" (180mm)

7-5/16" (185mm)

7-11/16" (195mm)

2-15/16~4-15/16"

(75~125mm)

2-15/16~4-15/16"

(75~125mm)

3-15/16~5-7/8"

(100~150mm)

4-15/16~6-7/8"

(125~175mm)

4-15/16~6-7/8"

(125~175mm)

19-11/16" (500mm)

21-1/16" (535mm)

38-3/16" (970mm)

-----

39-3/8" (1000mm)

41-5/16" (1050mm)

Table 3

* The trolley can be extended for greater “E” widths than what are shown in the chart. See trolley manual for details.

7.4 Operating environment

Working temperature range: -5 to +40 °C (23 to 104 °F) Working humidity range: 85% or less Electric power supply: 3 phase, 60Hz, 220V

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 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.

Contents of shipping crate

1 Electric chain hoist 1 Chain container with fasteners 1 Power supply cord 1 Pendant control 1 Chain gauge (attached to pendant cord) 1 Top hook assembly 1 Bottom hook assembly with chain 1 Operating instructions & parts manual 1 Product registration card 1 Test certificate

9.0 Installation

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 18.0

TIP: If suspending from a trolley, it may be easier to remove top hook from hoist and attach it to trolley load plate, then re-attach hoist to the hook.

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

9.1 Mounting top hook

If the TS-series hoist will be used without a trolley, attach the top hook with the provided pin(s), lock washer(s), hex nut(s) and cotter pin(s).

If the TS-series hoist will be used with a JET MT trolley, do not attach the top hook. Instead mount the hoist to the trolley bottom using the provided fasteners through the aligned holes. See Trolley manual.

9.2 Power cable

All electrical connections must

be made by qualified personnel. Read sect. 10.0 before connecting this unit to power.

Hoist only: 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.

Hoist with MT trolley: The trolley will draw its power through the hoist. Connect trolley cable to hoist. Then direct hoist cable to the power source. See trolley manual for instructions.

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 9-1 for a recommended solution.

Figure 9-1

9.3 Lubrication

9.3.1 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 9-2. The oil level should be just below the edge of the hole.

Check the level again after the first 500 hours of operation, then check every 3 months. See sect.

14.1 for oil specifications. IMPORTANT: Before operating hoist, pull out the

rubber breather plug from the top fill plug (Figure 9-

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

Figure 9-2

9.3.2 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.

9.4 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. 17.0.

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, 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 hoist undercarriage,

using two bolts with lock nuts See Figure 9-3.

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.

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

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 TS series hoist is pre-wired for 220V, 3-phase or 460V, 3-phase power.

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 time-

delay 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/CSAlisted 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. 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.

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

3. On hoists with 3-Phase power supply, if the hook moves in opposite direction to that shown on control button, or if no motion occurs when UP button is pressed, then the power supply wires are incorrectly positioned.

Disconnect hoist from power, and switch any two of the three supply wires at the power source (excluding the ground wire). Do not

attempt to rewire the hoist circuit or pendant controls for this problem. Use the same

safety precautions when reversing two of the supply wires as was used when the wires were originally connected.

4. Reconnect power and test hoist movement again without load. Run hoist to maximum lifting height to ensure limiter devices are operating properly.

11.0 Pre-operation inspection

11.1 Inspecting load chain

Clean chain with non-acidic solution, and carefully inspect entire load chain. Replace damaged chain before using hoist. See section 16.2 for maximum pitch allowed for chain length. If the chain exceeds this amount, it must be replaced.

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

1. Seriously rusted or cracked.

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 11-2.

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.

11.2 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.

2. The vertical angle at neck of the hook reaches 10 (see Figure 11-3).

Figure 11-3

3. Chemical corrosion or cracks on the hook.

4. Excessive wear on the inside surface.

5. The throat opening has enlarged. (See sect.

16.1 for maximum allowable limits for the throat opening.)

NOTE: Excessive hook throat opening or twist indicates abuse or overloading of the hoist. If such deformation is discovered, inspect hoist, chain and all supporting members very carefully for additional indications of excessive hoist loading.

Do not attempt repair of a hook

by heat treating, bending or attaching anything by welding. Such procedures will weaken and may cause failure of the hook.

12.0 Operation

Read all safety instructions in sect. 1.0 before operating this hoist.

12.1 Controls

Refer to Figure 12-1.

Allow hoist to come to a full

stop before changing direction. Rapidly reversing or catching a falling load can overload the hoist system and cause failure in hoist and/or chain, resulting in injury or property damage.

Figure 12-1

To lift a load, press and hold the UP button. To lower, press and hold the DOWN button. The buttons are two-step: Lightly press a button for low speed; fully press for high speed.

Press and hold the button firmly; avoid excessive inching

Press the red emergency stop button to shut off power quickly; the button remains locked and prevents any movement of the hoist. To restart, rotate stop button clockwise until it disengages.

If hoist is connected to a manual trolley, move hoist by pushing on the suspended load. Move an unloaded hoist by pulling on the empty hook. Do NOT move hoist by pulling on control cord.

The 2-button pendant controls are standard when hoist is used by itself. The 4-button pendant controls are for use with the optional JET model MT dualspeed trolley. The buttons control both vertical lift and lateral travel, thus allowing one pendant control to be used for both hoist and trolley. All buttons are two-step. See chart in sect. 18.0.

Always keep hoist clean, and store in a clean, dry location.

Avoid lifting one load with two hoists. If this is unavoidable, apply equal weight to both hoists and use hoists with proper lift capacity. Capacity of

each hoist must be equal to the total load to be lifted.

12.2 General procedure

Follow this general procedure for hoisting loads:

1. Secure upper hook to the supporting structure.

2. Place load sling or chain in center of bottom hook, making sure the safety latch is secure.

Never load the hook in front of the safety latch. See Figure 12-2.

Figure 12-2

3. Press UP button (slow speed) and remove all slack in load chain. Increase tension in load chain until hoist is about to raise the load.

4. Check again that load is properly slung, is directly under hoist, and will not suddenly swing or twist.

5. Raise load an inch or two above ground and stop. Observe load for a few moments, looking for signs that load or hoist system is unstable, or other indications of a problem.

6. Check that chain is not twisted at bottom hook. All welds should face same direction (see Figure 11-1). For hoists with two or more falls of chain, make sure bottom hook is not capsized. This may cause the chain to twist.

7. Raise load to traveling height. Raise only to height necessary to safely clear all obstacles.

8. Lower load at destination. If both UP and DOWN commands must be used during lowering, pause for a moment between each reversal of load direction.

9. Slowly allow weight to shift from hoist to ground or new support. Do not approach load until all tension is out of chain and load is stable.

10. Press red stop button to lock out hoist movement until load has been unhooked.

11. Always leave bottom hook and pendant controls in a vertical, static position, never in a position that can produce swing or slip.

12.3 Magnetic brake function

The magnetic disc brake provides dependable and rapid stops, and produces less wear on parts than standard mechanical braking systems. It also provides an important safety measure – a power failure will result in immediate engagement of the brake.

13.0 Adjustments

13.1 Replacing load chain

Over time, the load chain will wear or elongate. This can cause damage to hoist, breakage, or nonengagement of the load sheave. The following procedures describe replacing the load chain for single and multiple fall hoists. These procedures

must be performed by qualified persons only.

It is recommended that after installing new chain, the first few lifts be limited to no more than 25-50% of rated load capacity. Thoroughly inspect new chain for twist before placing hoist into routine service.

IMPORTANT: Due to the internal space of hoist, additional length must be added to the nominal chain length, as shown in Table 4. For example, model TS050 with 10 ft. lift requires 11.65 ft. of chain.

Model

Additional length of chain

TS050

1.65 ft.

TS100

1.65 ft.

TS200

2.64 ft.

TS300

5.28 ft.

TS500

5.28 ft.

Table 4

13.1.1 Cutting chain

Use eye/face protection when

cutting chain.

Use a bolt cutter with special cutter jaws for cutting hardened chain. Cut only one side of the link at a time. When making the second cut, place a mat over the chain to catch the flying chain section.

13.1.2 Single fall chain hoist

1. Locate the flexible chain puller that was provided with your hoist.

2. Lower the load hook until only 1 to 2 feet of slack chain remains in the chain container.

3. Remove chain container.

4. On the slack end of the chain, remove the chain stop, spring, and limit block (Figure 13-1). Keep these handy for later re-installing.

Figure 13-1

5. Keep tension on chain and press DOWN on controller until slack end of old chain comes free of the hoist.

6. Insert chain puller through hoist as shown in Figure 13-2.

7. Connect hook of chain puller to the link on new chain (Figure 13-3), and pull chain through until it engages the sprocket. Do not let the chain

twist or bind as it is being pulled through the hoist.

Figure 13-2

Figure 13-3

8. Keep tension on the end of the new chain and press the DOWN button on the controller, until chain clears the hoist. Stop hoist when 1 to 2 feet of new chain remains on the slack side.

9. Install the limit block, spring and chain stop on the slack end of the chain.

10. Install chain container, making sure to install the self-locking nut on the screw. Do not fill chain container by hand.

11. Remove load hook from old chain and install on new chain end.

12. Test limit switches by raising and lowering hook. Inspect chain for any signs of twist or binding, and correct before continuing.

13. Lubricate new chain with light coat of oil.

13.1.3 Vertical and horizontal links

Vertical and horizontal are determined by the relationship to the load chain sheave. Vertical links will be guided by the center slit in the sheave. Horizontal links will engage the oval pockets on the sheave. See Figure 13-4.

Figure 13-4

13.1.4 Double fall chain hoists

1. Locate the flexible chain puller that was provided with your hoist.

2. Lower the load hook until only 1 to 2 feet of slack chain remains in the chain container.

3. Remove chain container.

4. On the slack end of the chain, remove the chain stop, spring, and limit block (Figure 13-2). Keep these handy for later re-installing.

5. Keep tension on chain and press DOWN on controller until slack end of old chain comes free of the hoist.

6. Insert chain puller through hoist as shown in Figure 13-2.

7. Connect hook of chain puller to the link on new chain (Figure 13-3) and move chain through until sprockets are engaged.

The link on the load side

end must be a vertical link, as shown in Figure 13-3. If it is a horizontal link, the chain will have a twist in it.

8. Press DOWN on controller while pulling chain through until it completely engages the sprocket and emerges from other side. Do not let the chain twist or bind as it is being pulled through the hoist.

9. Keep tension on the end of the new chain and press DOWN on the controller, until 1 to 2 feet of new chain remains on the slack side.

10. Install the limit block, spring and chain stop on the slack end of the chain.

11. Install chain container, making sure to install the self-locking nut on the screw. Do not fill chain container by hand.

12. Press UP button to further lower some of the slack end of chain into container, while keeping light tension on the load end of chain.

13. Attach the load hook using the chain puller, as shown in Figure 13-5.

14. Attach the load end of chain to the connecting pin on the hoist. Make sure the chain does not twist to accommodate the pin.

15. Test limit switches by raising and lowering hook. Inspect chain for any signs of twist or binding, and correct before continuing.

Figure 13-5

14.0 Mechanical classification (grade)

The JET TS-series hoists have been designed for grade 2m in the FEM regulations (FEM 9.5.11). See table 5. The life and safety of the electric hoist can only be guaranteed when the equipment is operated within its

prescribed grade. Average daily operating time and total operating time are determined by load distribution.

Load Spectrum

(Load distribution)

Definitions

Cubic mean value

Average daily

Operation time

(hours)

Total operating

time

(hours)

(light)

Mechanisms or parts thereof, usually subject to very small loads and in exceptional cases only to maximum loads.

k≦0.50

4 - 8

12500

(medium)

Mechanisms or parts thereof, usually subject to small loads but rather often to maximum loads.

0.50<k ≦0.63

2 - 4

6300

(heavy)

Mechanisms or parts thereof, usually subject to medium loads but frequently to maximum loads.

0.63<k ≦0.80

1 - 2

3200

(very heavy)

Mechanisms or parts thereof, usually subject to maximum or almost maximum loads.

0.80<k ≦1.00

0.5 - 1

1600

% operating time Load spectrum 1

% operating time Load spectrum 2

% operating time Load spectrum 3

% operating time Load spectrum 4

Table 5

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JET TS050-230, TS100-230, TS200-230, TS300-230, TS500-230 Operating Instructions and Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual