Jet Tools L-100 User Manual

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Operating Instructions and Parts Manual

L-100 Series Hand Chain Hoists

For L100-200 serial no. 15070001 and higher For L100-300 serial no. 15070043 and higher For L100-1500 serial no. 15070088 and higher

JET

1-ton model shown

1.0 IMPORTANT SAFETY INSTRUCTIONS

WARNING – To reduce 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 tool and in this manual. Failure to comply with all of thes e war nin gs may cause serious injury and/or damage to property.

3. Replace the warning labels if they become obscured or are missing.

4. Keep visitors a safe dist ance from the work area. Keep children away.

5. Give your work undivided attention. Look ing around, carrying on a conversation and “horse-play” are car e les s a c ts that c an res u lt in serious injury.

6. Provide for adequate space surrounding work area and non-glare, overhead lighting.

7. 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.

8. 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.

9. Do not use to lift people or loads over people.

10. Do not exceed the rated capacity of the chain hoist.

11. Do not use more than hand power to pull t he hand chain.

12. Do not use the load chain as a sling; this may cause damage to the chain.

13. Always inspect the chain hoist for damage prior to use. If the chain hoist is damaged, do not use until it has been repaired or replaced.

14. Do n ot use more than one chain hoist to lif t or move a load. If this is unavoidable, each chain hoist must have the s ame capacity as the load to be moved.

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

16. If the hand c hain is difficult to operate, then the load exceeds the capacity of the chain hoist. Select a chain hoist of larger capacity.

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

18. 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.

19. Stand to one side of the load being lifted and make sure no one else is standing underneath when lifting a load. Should a load slip, it will descend at a high rate of speed and can cause serious injuries to anyone standing directly underneath.

20. Leave all internal m aintena nce to a qualif ied JET Service Center.

21. Replace the chai n with factory replacement chain only. Do not use any other type of chain.

22. If welding near the hoist, do not allow the chain or hook to be touched by a live electrode. Prevent weld splatter upon the chain.

23. 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.

24. Understand an d follow all pr ocedures as set forth in American National Standards titled

“Performance Standard for Hand Chain Manually Operated Chain Hoists.” ANSI/ASME HST-2; and “Overhead Hoists (Underhung),” ANSI/ASME B30.16. These

standards are available through the American Societ y of Mechanical E ngineers, www.ASME.org

WARNING: This product can expose you to chemicals including lead, which is known to the State of California to cause cancer and 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 tool damage.

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

even death.

2.0 Table of Contents

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

2.0 Table of Contents ................................................................................................................................... 3

3.0 Introduction ............................................................................................................................................ 4

4.0 Specifications ......................................................................................................................................... 5

5.0 Using the Chain Hoist ............................................................................................................................ 6

5.1 Prior to Operation ............................................................................................................................... 6

5.2 Hooking the Load ............................................................................................................................... 7

5.3 Raising the Load................................................................................................................................. 7

6.0 Hand Chain – Cutting and Ins talli ng ...................................................................................................... 8

7.0 Load Chain and Bottom Hook ................................................................................................................ 9

7.1 Load Chain Inspect io n (all m odels ) .................................................................................................... 9

7.2 Load Chain Removal (all models) ...................................................................................................... 9

7.3 Attaching Load Chain to Load Chain Sprocket (all models)............................................................... 9

7.4 Load Chain and Bottom Hook Installation ........................................................................................ 10

7.5 Chain Installation: 0.5- to 2-Ton Hoists ............................................................................................ 10

7.6 Chain Installation: 3- to 5-Ton Hoists ............................................................................................... 10

7.7 Chain Installation: 10- to 20-Ton Hoists ........................................................................................... 11

8.0 Overload Protection ............................................................................................................................. 11

9.0 Inspection and Maintenance ................................................................................................................ 12

10.0 Load Limits ......................................................................................................................................... 13

10.1 Load Chain ..................................................................................................................................... 13

10.2 Hooks (Top & Bottom) .................................................................................................................... 13

11.0 Troubleshooting JET® Manual Chain Hoists ...................................................................................... 14

12.0 Timing Marks for Gear Replacement ................................................................................................. 15

13.0 Replacement Parts ............................................................................................................................. 15

13.1.1 L-100 Chain Hoist Parts Breakdown ........................................................................................... 16

13.1.2 Parts List: L100-25 Chain Hoist (0.25 Ton) ................................................................................. 17

13.1.3 Parts List: L100-50 Chain Hoist (0.5 Ton) ................................................................................... 19

13.1.4 Parts List – L100-100 Chain Hoist (1 Ton) .................................................................................. 21

13.1.5 Parts List – L100-150 Chain Hoist (1.5 Ton) ............................................................................... 23

13.1.6 Parts List – L100-200 Chain Hoist (2 Ton) .................................................................................. 25

13.1.7 Parts List – L100-300 Chain Hoist (3.0 Ton) ............................................................................... 27

13.1.8 Parts List – L100-500 Chain Hoist (5 Ton) .................................................................................. 29

13.1.9 Parts List – L100-1000 Chain Hoist (10 Ton) .............................................................................. 31

13.1.10 Parts List – L100-1500 Chain Hoist (15 Ton) ............................................................................ 33

13.1.11 Parts List – L100-2000 Chain Hoist (20 Ton) ............................................................................ 35

14.0 Warranty and Service......................................................................................................................... 37

3.0 Introduction

This manual is provided by JET covering the safe operation and maintenance procedures for a JET Model L-100 Series Chain Hoist. This manual contains instructions on installation, safety precautions, general operating procedures, maintenance instructions and parts breakdown. This hoist has been designed and constructed to provide consistent, long-term operation if used in accordance with instructions set f orth in this manual. If there are a ny questions or comm ents, please contact either your local supplier or JET. JET can also be reached at our web site: www.jettools.com.

The L-100 Chain Hoist complies with ANSI/ASME B30.16 and HST-2 standards.

4.0 Specifications

5.0 Using the Chain Hoist

5.1 Prior to Operation

1. Support for the hoist may be hook, clevis pin, trolley, or beam clamp. Whatever method of suspension is chos en, the s upport componen ts must be rated equal to, or greater than the capacity of the chain hoist.

2. If the chain hoist has not been used for an extended period of time, check for proper operation before putting into service.

3. The brak e mechanism must be kept c lean and free from dirt, wat er, and oil. Never allo w oil to penetrate the brake mechanism. Always keep your chain hoist clean and s tore in a clean, dry location.

4. Although oiling the chain is not mandatory, a light coat of 30-weight oil applied periodically to the chain will create easier operation and prolong the life of the chain.

5. Check the chain for damage and elongation. Replace damaged chain b efore us ing the chain hoist.

The load chain suppl ied with your JET chain hoist is designed, manuf actured, and tested f or pro per fit and durability. Over a peri od of tim e, the chain ma y 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 the hoist.

6. T he top and bottom hooks on your JET chain hoist are designed to open to warn of an overload. Both top and bo ttom hooks for 0.5 to 5 ton hoists have two indicator points ( A, Figure

1) cast into the hook for m easurem ent. Refer to Table 2 (page 13) to de term ine if a hook needs to be replaced.

Hooks for 10- and 20-ton hoists do not have indicator points. Measurements are made at the jaw opening (B, Figure 1).

7. It is important to check top and bottom hooks for proper opening. If the safety latch no longer contacts the hook opening, replace the hook.

Never side load the top or bottom hook; this practice is dangerous and could lead to serious injury.

8. If the vertical angle at the n eck of the bo ttom or top hook reaches 10°, replace the hook (see Figure 2).

Figure 1

Figure 2

5.2 Hooking the Load

1. Secure the upper hook.

2. Place the bottom hook securely into the object to be lifted.

3. Place ropes or chain in the c enter of the bo ttom hook, making sure the safety latch is secure. Never load the hook in front of the saf ety latch. See Figure 3.

4. Avoid lifting one load with two ho ists. If this is unavoidable, appl y equal weight to both hoists and use hoists with the proper lift capacity.

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

5. Check that the chain is not twisted at the bottom hook. All welds should face the same direction (Figure 4).

6. For hoists with two or more falls of chain, m ake sure the bottom hook is not turned over. This may cause the chain to twist.

5.3 Raising the Load

To raise the load, pull the right side of the hand chain (A, Figure 5) clockwise.

To lower the load, pull the left side of the hand chain (B, Figure 5) counterclockwise.

Figure 3

Figure 4

Important: Make sure the hoist has an adequate length of load chain to rais e or lower the load in a safe manner. Do not attempt to lower the hoist beyond its limit.

Figure 5

6.0 Hand Chain – Cutting and

Installing

To cut the hand chain in order to increase or shorten:

To change the length of th e hand chain, the chain must be cut and links added to increase the over all length or links removed to decrease the length. This is done as follows:

1. Insert one link lengthwis e into the vise (Figure

6). Be sure that the s ide opposite the we ld lies completely below the surface of the vise jaw (about 1/3 of a link). This prevents nicking or cutting the lower part of the link.

2. Using a hack saw, cut through th e up per p ar t of the link at the weld.

3. Loosen the link, r eposition the link verticall y at the edge of the vise with the level of the cut above the vise jaw (Figure 7).

4. Tighten the vise jaw.

5. Using an adjustable wrench, twist the link horizontally from fr ont to ba ck . ( Figur e 8) Ope n just far enough to ins ert (or remove) a second chain link.

Figure 6

Figure 7

Note: Chain length is now ready to lengthen or shorten.

6. Insert or remove the second end link at the opening in the first end link.

7. Using an adjustable wrench, twist the link horizontally until the li nk is in the or ig ina l c l osed position. See Figure 9.

Do not push the link inward

from the curved ends. This will distort the lin k. Check that the link is closed and free of twist.

8. If installing entire ne w chain, insert the end of the hand chain into the groove at t he top of the hand chain wheel (see Figure 10). Rotate the hand chain wheel and pull the chain through.

9. Re-weld the link at the cut.

10. Grind off excess on the weld so that it is smooth.

Figure 8

Figure 9

7.0 Load Chain and Bottom

Hook

7.1 Load Chain Inspection (all models)

Over time, the load chain will wear or elongate. This can cause dam age to the hoist, breakage, or non-engagement of the load sheave.

Do not operate the hoist with a

twisted, kinked or damaged load chain. Do not splice the load chain. Check the chain for excessive wear or stretch. Failure to comply may cause serious injury.

1. Test the hois t under load in both the liftin g and lowering directions, obser ving the operation of chain and sprockets. Chain should feed smoothly into and away from the sprock ets .

2. If the chain binds, jumps, or is noisy, make sure it is clean and properl y lubricated . If the trouble persists, inspect the chain and mating parts for wear, distortion, or other damage.

3. Clean th e chain before i nspection. Exam ine for gouges, nicks, weld splatter, corrosion, and distorted links. Slacken the chain and move adjacent links to one s ide, looking for wear at the contact points. If you see wear or suspect stretching, measure the chain as follows:

7.3 Attaching Load Chain to Load

Chain Sprocket (all models)

Install the new load chain onto the load chain sprocket as follows, referring to Fig. 10:

1. Position the load chain sprocket by rotating the hand chain wheel so that t he wide and narrow grooves show.

2. Insert the load chain into t he sprocket grooves so that the chain wi ll win d u p an d back over the sprocket. Welds must face away from the sprocket.

3. Rotate the hand chain wheel so that the load chain falls six to eig ht inches at th e back of the sprocket.

• Select an unworn, unstretched length of chain (i.e. at the slack end).

• Suspend the chain vertic ally under tension and, using a caliper type gauge, measure the outside length of several links about 12 to 24 inches.

• Measure the s ame number of links in us ed sections and calculate the percentage of the increase in length.

4. If the length of used chain exceeds 2-1/2 percent of the unused chai n, replace the cha in. (See “Load Limits” on pag e 13 for specific link measurements.)

Do not add to the load chain.

Replace the entire ch ain. Failure to compl y may cause serious injury.

7.2 Load Chain Removal (all models)

Remove the old load chain as follows while referring to Figure 11:

1. Remove the cotter pin (A) and the chain anchor pin (C) on the chain anchor (D), allowing the end of the chain to fall free.

2. Pull the hand chain (Fig. 5) until the load chain is completely removed from the gear assembly.

Figure 10

Referring to Figure 11:

4. Insert one end of the chain link (B) into the chain anchor (D).

5. Insert the chain anchor pin (C) through the chain anchor (D) and chain link ( B) and secure with the cotter pin (A).

Figure 11

Continue with Load Chain and Bottom Hook Installation on th e f ol low ing pag e, proc eed in g t o the section that applies to your hoist: 1/2- to 2-Ton hoists, 3- to 5-Ton hoists, or 10- to 20-Ton Hoists.

7.4 Load Chain and Bottom Hook

Installation

The following procedure assumes that the load chain has been attached to the chain anchor (A,

Figure 12) and fed thr ough the load chain sprocket as described in the previous section. This section completes the load chain and bottom hook installation.

7.5 Chain Installation: 0.5- to 2-Ton

Hoists

Referring to Figure 12:

1. Remove the lock nut and bolt from the lower hook (D).

2. Insert the last chain link (C) into the lower hook slot.

3. Re-insert the bolt through the lower hook slot and chain link.

4. Re-attach the lock nut to the bolt and tighten.

7.6 Chain Installation: 3- to 5-Ton

Hoists

Referring to Figure 13:

1. After installing the load chain into the load chain sprocket (B), run the remaining chain through your hand to remove any twist. The last link of the chain must be in the same direction as the first. If not, cut off the last link.

2. Insert the last link into the pulley of the lower hook (C).

3. Pull the load chain through and up from the underside of the pulley (C, D).

4. Remove the c otter pin and chain anc hor pin in the upper hook slot (E).

5. Insert the last link into the upper hook slot.

6. Check that the load chain is not twisted.

0.5 to 2 Ton

Figure 12

7. Re-position the chain anch or pin back through the upper hook slot an d the last chain link and secure with the cotter pin.

3 to 5 Ton

Figure 13

7.7 Chain Installation: 10- to 20-Ton

Hoists

Referring to Figure 14:

2. Insert the last link into the left side p ulle y of the lower hook (C).

3. Pull the load chain through and up from the underside of the pulley (C, D).

4. Insert the last link into the right hand pulley of the upper hook, moving the chain up, then around and down (D, E). Check that the load chain is not twisted and w elds face away from the pulley.

5. Insert the last link into the right side pulley of the lower hook, pulling around, then up from the underside of the pulley (E, F). Check that the load chain is not twisted and welds face away from the pulley.

6. Remove the cotter pin and chain anchor pin in the upper hook slot (G).

7. Insert the last link into the upper hook slot.

8. Check that the load chain is not twisted.

Re-position the ch ain anchor pin back through the upper hook slot and the la st chain link and secure with the cotter pin.

10 Ton

Figure 14

8.0 Overload Protection

Some models of the L-100 Hoist have overload protection in the form of a slip clutch (these are identified by “WO” in the model number). The slip clutch is effective at 160% +/- 20% of the rated hoist capacity.

The slip clutch will allow the hand chain pulley to move without lifting the lo ad, if the load is too heavy for the hoist. The sl ip clutch has been pre-adjusted at the factory and should not require any adjustment by the user. If future adjustment or repair to the slip cl utch sho uld ever be needed, th is must be done by qualified personnel.

9.0 Inspection and

Maintenance

Read and follow ANSI Inspection and Maintenance Instruct ions. Know the meaning of Frequent Inspection, Periodic Inspection, Normal Service, Heavy Service, and Severe Service. It is the customer’s responsibility to understand and follow all ANSI and JET inspection and maintenance instructions.

All repairs and adjustments

are to be performed by trained and experienced personnel using procedures that are approved for t he hoist system being serviced. Failure to comply may cause serious injury.

All safety related def iciencies

discovered in the inspection are to be corrected before the hoist is to be placed back into service. Failure to comply may cause serious injury.

Check for internal damage

whenever external damage has occurred. Failure to comply may cause serious injury.

1. Clean hoist after each use and oil lightly. NOTE: Do not get oil on brake system.

2. Do not drop or drag the hoist.

3. Store the hoist in a clean and dry environment.

4. While not mandatory, periodically oiling the chain with SAE 30 oil will increase its life.

5. Leave all repairs and adjustm ents of internal parts to qualified repair personnel.

6. Inspect the load chain and the lower hook after lifting a maximum weight load.

7. This hoist uses special alloy hoisting chain and does not interchange with any other manufacturer. All replacement chain must be purchased from your JET distributor or from JET directly by calling 800-274-6848.

8. Check and inspect the brake system frequently.

9. Annuall y, the hoist should be disas sembled, inspected, and cleaned by trained and experienced person nel only. Contact a JET authorized service center by calling your dealer or visiting our web site at jettools.com.

10. After servicing, test the hoist with no load, then test the hoist with a load.

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