ELECTRIC CHAIN HOIST
Operating, Maintenance & Parts Manual
DU-905 3-Phase, 1000Kg.
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Table of Contents
Inspection & Maintenance
13
General Information
3
Preventive Maintenance
14
Safety Precautions
3
Hook Inspection
15
Chain Hoist Specifications
4
Chain
15
Application Information
6
Identification of Chain
16
Adverse Environmental Conditions
6
Chain Replacement with Chain
In Lifting Motor
17
Lifting of Hazardous Loads
6
Chain Replacement with no
Chain in Chain Hoist
17
Tandem Lifts and Multiple Lifts
6
Chain End Stop
18
Suspending Loads over People
6
Cutting Chain
18
Safety Information
6
Load Chain Cleaning
18
Installation
7
Overload Limiting Clutch
18
Power & Control System
Requirement
7
Limiting Clutch Adjustment
18
Preliminary Checks
7
Wiring
19
Rigging & Motor Handling
Instructions for Temporary
Installation
8
Wiring Diagrams
20
De-rigging the hoist
10
Power Cord Precaution
22
Chain Hoist Operation Instruction
11
Lubrication
23
General
11
Chain Hoist Repairs
24
Overload Limit Clutch
12
Recommend Spare Parts
24
Chain Bag
12
Explosive Art for DU-905 Chain hoist
25
Operating Notes
13
Part list for DU-905 Chain hoist
26
Trouble Shooting
27
2
General Information
All DUKE Electric Chain Hoists are thoroughly inspected and performance tested prior to shipment. If any
properly maintained hoist develops a performance problem due to a material or workmanship defect, as
verified by DUKE, repair or replacement of the unit will be made to the original purchaser without charge.
This repair/replacement policy applies only to DUKE Hoists installed, maintained and operated as outlined in
this manual, and specifically excludes parts subject to normal wear, abuse, improper installation, improper or
inadequate maintenance, hostile environmental effects and unauthorized repairs/modifications.
We reserve the right to change materials or design, if, in our opinion, such changes will improve our product.
Abuse, repair by an unauthorized person, or use of non-DUKE replacement parts voids the guarantee and
could lead to dangerous operation.
SAFETY PRECAUTIONS
Each DUKE Chain hoist is built in accordance with the specifications contained here in, and at the time of
manufacture complies with our interpretation of applicable sections of European FEM or equivalent to
American Society of Mechanical Engineers Code (ASME) B30.16 “Overhead Hoists,” the National Electrical
Code (ANSI/NFPA 70) and the Occupational Safety and Health Act (OSHA). Since OSHA states the National
Electrical Code applies to all electric chain hoists, installers are required to provide current overload
protection and grounding on the branch circuit section in keeping with the code. Check each installation for
compliance with the application, operation and maintenance sections of these articles.
Improper operation of a hoist can create a potentially hazardous
situation which, if not avoided, could result in death or serious injury.
To avoid such a potentially hazardous situation, the operator shall:
NOT operate a damaged, malfunctioning or unusually performing chain hoist.
NOT operate the chain hoist until you have thoroughly read and understood the manufacturer’s Operating and
Maintenance Instructions or Manuals.
NOT operate a chain hoist, which has been modified without the manufacturer’s approval.
NOT allow anyone under 18 years of age to operate the chain hoist.
NOT lift more than rated load for the chain hoist.
NOT operate a chain hoist unless it has been securely attached to a suitable support.
NOT use chain hoists with load chains that are knotted, twisted, kinked, damaged, or worn.
NOT use the chain hoist to lift, support, or otherwise transport people, without additional or mandatory local or national
safety precautions.
NOT let anyone stand beneath a moving load!
NOT move a load in any manner that can endanger persons.
NOT operate unless all persons are and remain clear of the supported load.
NOT operate unless load is centered under chain hoist.
NOT operate a chain hoist when it is restricted from forming a straight line from hook to hook in the direction of loading.
NOT use load chain as a sling, or wrap the load chain around load.
NOT apply the load to the tip of the hook or to the hook latch.
NOT apply load unless load chain is properly seated in the chain sprocket(s).
NOT apply load if bearing prevents equal loading on all load supporting chains.
NOT operate beyond the limits of the load chain travel
NOT use the chain hoist’s overload limiting clutch to measure load.
NOT leave a load supported by the chain hoist unattended unless specific precautions have been taken.
NOT allow the load chain or hook to be used as an electrical or welding ground.
NOT allow the load chain or hook to be touched by a live welding electrode.
NOT remove or obscure the warnings on the chain hoist.
NOT operate a chain hoist on which the safety placards or decals are missing or illegible.
NOT operate a chain hoist unless load slings or other approved single attachments are properly sized and seated in
the hook saddle.
NOT allow your attention to be diverted from operating the chain hoist.
NOT allow the chain hoist to be subjected to sharp contact with other chain hoists, structures, or objects
3
through misuse.
NOT adjust or repair the chain hoist unless qualified to perform such adjustments or repairs.
NOT attempt to lengthen the load chain or repair damaged load chain.
NOT drag the load chain and/or chain hook across dirty, sandy of abrasive surfaces (concrete floors).
NOT hold on to the load chain, which is dangerous for obvious reasons and hold on to the motor housing which is
dangerous as this can get very hot. Holding onto the power or control pigtails is certainly not advised as well.
Improper operation of a hoist can create a potentially
hazardous situation which, if not avoided, could result in
minor or moderate injury. To avoid such a potentially
hazardous situation, the operator shall:
DO make sure that the weight of the load to be suspended is known, and in accordance to the lifting
capacity of the chain hoist. In multiple lifts make sure a rigging plot is present.
DO make sure that the hoist operator is in good physical and mental condition.
DO check the chain hoist, suspension-hook, chain-hook, hook latches, as well as the load-chain itself,
prior to each time of use for any damage, deformation or malfunction.
DO make sure that the structure from which the DUKE chain hoist is suspended, as well as the slinging
equipment is able to safely absorb the force resulting from the weight of the load and the chain hoist
itself, multiplied by the dynamics of starting and stopping the lifting action. For the DUKE this is
approximate 1.4 times the static load.
DO check brake function by tensioning the chain hoist prior to each lift operation.
DO shut down a chain hoist that malfunctions or performs unusually and report such
malfunction.
DO make sure hook travel is in the same direction as shown on the controls.
DO maintain firm footing or be otherwise secured when operating the chain hoist.
DO guide the chain hoist to take up slack chain carefully without twisting or knotting.
DO make sure load is balanced and load holding action is secure before continuing lifting operation.
DO always keep your attention to the chain hoist and the load that it is supporting.
DO use hook latches. Latches are to retain slings, chains, etc. under slack conditions only.
DO make sure the hook latches are closed and not supporting any parts of the load.
DO make sure the load is free to move and will clear all obstructions.
DO make sure the power (and control) cables and connectors have proper stress relieves and are never fully
tight during lifting or lowering movement.
DO warn personnel of an approaching load.
DO avoid swinging the load or hook.
DO inspect the chain hoist regularly, replace damaged or worn parts, and keep appropriate records of
maintenance.
DO use a protective cover for the chain hoist to prevent exposure to rainfall when applied outdoors.
DO only use factory recommended parts when repairing the unit.
DO protect the load chain from weld splatter or other damaging contaminants.
DO lubricate load chain according to manufacturer’s recommendations.
DO transport the chain hoist in a flight case or other sturdy & protective facility.
CHAIN HOIST SPECIFICATIONS
The DUKE is a rugged and portable chain hoist designed for the demands of rigging applications. With its compact
construction and ability to operate inverted and it can be used to lift loads that are within its rated capacity. The
mechanical features of these hoists include an alloy liftwheel, Load Protector, hardened steel chain guides,
hardened steel load chain, hardened steel gear train, forged steel hooks, and lightweight steel frame. The electrical
features included hoist-duty motor, rugged geared brake, and voltage conversion terminal block.
DUKE chain-hoists come standard with handles to maneuver or guide the hoist in or out of a flight case, or
position it over the load.
4
Item No.
DU-905
Load capacity
1000kg
Lifting Speed 50/ 60Hz standard m/min
6/7
Operating voltage
380V-3P-50/60HZ
4150V-3P-50/60HZ
Motor power at 50/60Hz
2HP
Power consumption at operation
3.3Amp
Noise level
68db
Load wheel
5 pocket
Load chain DIN 5684
7,1 x 20,5mm
Falls of chain
1
Weight of chain per meter lift
1.04Kgs/per meter
Weight of body
40Kgs
Type of control
direct
Type of connector
CEE 16A-4p
Suspension with swivel hook
standard
5
APPLICATION INFORMATION
The DUKE is intended for professional use in rigging applications to lift and support material loads within its
rated capacity. It is designed as a component to be integrated into a rigging system. The user is responsible
for ensuring the adequacy and reliability of their controller and power supply and the whole lifting system and
operation as such. DUKE can not be held responsible for applications other than those for which the DUKE
hoist is intended. Prior to installation and operation, we caution the user to review his application for abnormal
environmental or handling conditions and to observe the applicable recommendations as follows:
ADVERSE ENVIRONMENTAL CONDITIONS
Do not use the chain hoist in areas containing flammable vapors, liquids, gases or any combustible dusts or
fibers. Do not use this chain hoist in highly corrosive, abrasive or wet environments. Do not use this chain
hoist in applications involving extended exposure to ambient temperatures below -20°C (-10°F) or above 50°C
(130°F.)
LIFTING Of HAZARDOUS LOADS
This chain hoist is not recommended for use in lifting or transporting hazardous loads or materials which could
cause widespread damage if dropped. The lifting of loads which could explode or create chemical or
radioactive contamination if dropped requires fail-safe redundant supporting devices which are not
incorporated into this chain hoist.
TANDEM LIFTS AND MULTIPLE LIFTS
Chain hoists – of any manufacturer unless otherwise stated - are basically designed to operate as a stand
alone type of machinery. When two (or more) chain -hoists are used to lift one single load the risks increase
considerably. Several countries around the world have legislation that in such cases it is mandatory to reduce
the allowable amount of load lifted to 75% or even 66% of the rated capacity of the chain hoist. DUKE
considers the application of the chain hoists in any other than stand alone situations as being the
responsibility of the operator or user. DUKE strongly advises operators to acquire sufficient knowledge of the
local, national or international rules and regulations when these types of lifting are applied.
SUSPENDING LOADS OVER PEOPLE
The suspension of loads over people demands the highest level of rigging knowledge, equipment, and
equipment maintenance. The DUKE must be installed and used in accordance to local and national standards
and regulations when suspending loads over people. These include the following important precautions.
It is preferred that the load always be tied off with an auxiliary chain or cable (‘secondary’ or ‘safety’) before
access to the area beneath the load is permitted.
As an alternative, the system may be designed in such way that malfunction or failure of one chain hoists load
bearing components does not cause load loss and/or overloading of any other chain hoists in the system.
Note that in such a system, chain hoist performance and function must be monitored visually or should be
monitored using load cells.
Never operate the chain hoist while people are under the load.
SAFETY INFORMATION
1. Follow all local electrical and safety codes, and applicable local standards.
2. The chain hoist must be securely and adequately grounded. The power cable includes a green/yellow lead
for grounding.
3. Be careful when touching the exterior of an operating motor; it may be hot enough to be painful or cause
injury. With modern motors this condition is normal if operated at rated load and voltage (modern motors
are built to operate at higher temperatures).
4. Protect the power and control cables from coming in contact with sharp objects.
5. Do not kink the electrical cables and never allow them to come in contact with oil, grease, hot surfaces, or
chemicals.
6. Make certain that the power source conforms to the requirements of your equipment.
7. Visually check the unit daily before operating chain hoist.
8. Cluttered areas and benches invite accidents.
9. The operator should not engage in any practice that will divert his attention while operating the chain hoist.
10. Before using the chain hoist, the operator should be certain that all personnel are clear of the load.
11. Do not operate chain hoist with loads exceeding its rated capacity.
6
12. Supporting frames or beams used as a chain hoist hanger must have a greater load capacity than the chain
hoist.
13. Do not attempt to operate chain hoist beyond normal maximum lift range.
14. Align chain hoist for a straight vertical pull. Avoid side pull or end pull.
15. Do not operate chain hoist with twisted, knotted, damaged or corroded chain.
16. Do not operate a damaged or malfunctioning chain hoist until necessary adjustments or repairs have been
made.
17. Do not use a chain hoist to lift people or to carry loads over people.
18. Do not leave a load suspended in the air unattended.
19. Always remove load before making repairs.
20. Do not remove or obscure capacity or warning decals.
INSTALLATION
POWER & CONTROL SYSTEM REQUIREMENTS
The DUKE hoist comes in a direct control. They must be connected to a power and control system that is
properly designed to operate the chain hoist and to handle the power consumption of the motor. DUKE hoists
are standard wired for 380V-3ph-50Hz operations. For other voltages the chain hoist motor can be re-wired
internally for ( 440V-3ph-50Hz and 220V-3ph-60Hz)
PRELIMINARY CHECKS
Before installing / starting to use the chain hoist, check the following:
General:
1.After unpacking the unit, carefully inspect for any damage that may have occurred during transit. Check for
loose, missing or damaged parts. Shipping damage claims must be filed with the carrier. Be sure that the
voltage labeled on the unit matches your power supply.
2. Make sure all supporting structures and attaching devices have the strength to safety absorb the weight of
the intended loads. If in doubt, consult a qualified structural Power cables to chain hoists must include a
ground conductor. If in doubt, consult a qualified structural engineer.
3. Chain hoists should not experience voltage drops of more than 10% of the supply voltage. It is critical to use
adequate sized power cable.
4. The user’s control board must be grounded in accordance with the electrical codes that are applicable in the
local area. Power cable to chain hoists must include a ground conductor. The power cable includes a
yellow/green ground conductor.
5. The installation area must provide safe operating conditions for the operator, including sufficient room for the
operator and other personnel to stand clear of the load at all times.
7
RIGGING & MOTOR HANDLING INSTRUCTIONS FOR TEMPORARY INSTALLATIONS RIGGING
1. Before each use, visually inspect the hoist and all load bearing parts of the hoist, like hook and chain.
2. Make sure the intended structural support component is able to safely absorb the chain hoist lifting capacity.
3. Attach the chain bag to the chain bag ring.
4. Put the chain into the chain bag and make sure there are no twists or knots in the chain in the chain bag.
5. Attach the chain hook to the main structural support member, either direct to an existing eyebolt or lug-plate, or
using a bracket or beam clamp. It is also possible to use a sling or bridle. Avoid slinging on sharp edges.
6. Connect the power (and control) cable and make sure these will have proper stress relieves and sufficient slack
in every direction of planned tilting of the load. Use Velcro or cable-strings to tie the cable to the hoist body or
lifting hook.
7. Lower the chain hook by letting the chain run out to the required height.
8. Put the load under the chain hook.
9. Attach the load to the chain hook, either to a lug plate, eyebolt or using one or more slings.
8
10.
11.
12.
Run the chain up until the load chain just taut.
Check all lifting and slinging connections, and lift the load until it is freely floating of the ground.
Visually check the whole lifting structure from chain hoist and cable through the load chain down to the load.
13. Remove all people from the area before you start lifting the load. Do not allow any people to stand under the
moving load.
14. Make sure you have a full visual view on the complete travel path of the load.
15. Lift the load to the required height.
16. Add a secondary in between support structure and the load when persons have to get under the load.
17. Make sure this secondary is as tight as possible, preferably using clutch-chains.
9
DE-RIGGING THE HOIST
1. Remove the secondary (when present).
2. Check the direction of travel. If the pre-selection switch on the controller is in the down-direction the chain
hoist should run in down-direction.
3. Check if both the lifting directions work properly (lifting and lowering).
4. Remove all people from the area before you start lowering the load. Do not allow any people to stand under
the moving load.
5. Make sure you have a full visual view on the complete travel path of the load.
6. Bring the load down until within reach for further dismantling.
7. Remove all parts of the load and slings attached the chain hook.
8. Disconnect the power and control cables.
9. Remove the chain hoist from the suspension structure and bring it down.
10. Put the chain hoist and the chain bag in their compartments of the flight case (when applicable).
11. Remove any bracket, beam clamp or sling from the main structure elements.
10
CHAIN HOIST OPERATION INSTRUCTIONS
General:
1. Check to ensure that the load point is in the line with the hoist head.
2. When applying a load, it must be directly in line with hoist. Avoid off-center loading of any kind.
3. Take up a slack load chain carefully and start load easily to avoid shock and jerking of hoist load chain. if there is
any evidence of overloading, immediately lower the load and remove the excess load.
4. Do not allow the load to swing or twist while lifting.
5. Do not allow the load and/or attachments to bear against the hook latch and/or hook tip. Apply load to hook bowl
or saddle only.
6. When installing a three phase chain hoist, check and make sure the chain hoist travels in the direction intended
when operating the controls. To correct improper motor travel, reverse any two wires (except the yellow/
green ground wire) at the power source. Do not change the connection in the chain hoist. Once the direction of
travel is verified to be correct, permanent connections can be made at the power source.
11
OVERLOAD LIMITING CLUTCH
The overload limiting clutch is designed to allow the intermediate gear to slip on an excessive overload. An
overload is indicated when the hoist will not raise the load. Also, some clutching noise may be heard if the hoist is
loaded beyond rated capacity.
This condition should be avoided by immediately releasing the “UP” button and reducing the load to within the rated
capacity of the chain hoist. When the excessive load is removed, normal hoist operation is automatically restored.
Caution: If the load being lifted exceeds the lifting capability of the overload clutch, the motor will continue
to run, causing overheating of both clutch and motor. Under no circumstance should the clutch be allowed
to slip for more than a few seconds.
CHAIN BAG
1. It is strongly recommend to use a chain bag with the DUKE. Chain bags like shown in below photo are
available from the manufacturer/supplier. The bags, which are colored black, fit closely to the chain
hoist and are as inconspicuous as possible. The bag comes with an acrylic bottom plate which distributes
the chain weight evenly.
2. Any other chain bags used should be capable of safely supporting the weight of the full length of
the load chain, and preferable have a drainage hole at the end side to prevent accumulation of
rainwater in case of outdoor use.
12
OPERATING NOTES
Points which must be observed at all times to maintain proper operations:
1.
Know the weight of the load to be lifted. Never overload the chain hoist.
2.
Do not operate if direction of travel is not the same as indicated on button being pushed. Make sure phases
are corrected until direction of travel is coherent with push button operation.
3.
Do not make side pulls with the chain hoist.
4.
Do not sling the chain hoist load chain around an attachment point. Use a separate and proper sling.
5.
Run the motor until the load chain is as good as taut.
6.
Check the load being held securely in the hook or sling chains, before it is raised.
7.
Never stand or allow people beneath a moving load.
8.
Do not move a load in such a manner as to endanger personnel.
9.
Do not move the load by intermittent use of the control button.
10.
Do not lower into areas where visibility is obscured unless a specific person is guiding the operation.
11.
Do not operate when chain hoist is not over the center of gravity of the load.
12.
Do not operate a damaged or malfunctioning chain hoist.
INSPECTIONS & MAINTAINANCE
To maintain continuous and satisfactory operation, a regular inspection procedure must be initiated to replace worn
or damaged parts before they become unsafe. Inspection intervals must be determined by the individual application
and are based on the type of service to which the hoist will be subjected to the degree of exposure to wear,
deterioration or malfunction of the critical components.
The type of service to which the hoist is subjected can be classified as Normal, Heavy, or Severe.
Normal Service: Involves operation with randomly distributed loads within the rated load limit, or uniform loads less
than 65% of rated load for not more than 25% of the time.
Heavy Service: Involves operating the hoist within the rated load limit which exceeds normal service.
Severe Service: Normal or heavy service with abnormal operating conditions.
Two classes of inspection- frequent and periodic – must be performed.
Frequent Inspections: These inspections are visual examinations by the operator or other designated personnel.
Records of such inspections are not required. The frequent inspections are to be performed monthly for
normal service, weekly to monthly for heavy service, and daily to weekly for severe service, and they should
13
Include those items listed in below.
Periodic Inspections: These inspections are visual inspections of external conditions by an appointed person.
Records of periodic inspections are to be kept for continuing evaluation of the condition of the hoist.
Periodic inspections are to be performed yearly for normal service, semi-annually for heavy service and quarterly
for severe service, and they are to include those items listed in below.
CAUTIONS: Any deficiencies are to be corrected before the hoist is returned to service. Also, the external
conditions may show the need of disassembly to permit a more detailed inspection, which, in turn, may require use
of nondestructive type testing.
PREVENTIVE MAINTENANCE
In addition to the above inspection procedure, a preventive maintenance program should be established to prolong the
useful life of the hoist and maintain its reliability and continued safe use. The program should include the periodic and
frequent inspections with particular attention being paid to the lubrication of the various components using the
recommended lubricants.
Minimum Frequent Inspections
TYPE OF SERVICE
Normal
Heavy
ITEM
Severe
Daily to weekly
Weekly to Monthly
Monthly
a)
Brake for evidence of slippage.
b)
d)
Control functions for proper operation.
Hooks for damage, cracks, twists, excessive throat
opening, latch engagement and latch operation.
Load chain for adequate lubrication, as well as
signs of wear or damaged links.
e)
Load chain for proper reeving and twists.
c)
Minimum Periodic Inspections
ITEM
TYPE OF SERVICE
Normal
Heavy
Severe
a)
All items in minimum frequent inspections
b)
External evidence of loose screws, bolts or nuts.
c)
External evidence of worn, corroded, cracked or
distorted hook block, suspension screws, gears,
bearings, chain stop and chain guide.
d)
External evidence of damage to hook retaining nut
and pin. Also check the upper suspension adapter
making sure it is fully seated in the hoist frame and
that both screws are tight.
External evidence of excessive wear of brake parts.
e)
f)
g)
h)
Checking the operation of the control station
making sure the buttons operate freely and do not
stick in either position.
Inspect the electrical cords and cables and control
station enclosure for damaged insulation.
Inspect the suspension hook for excess free play or
rotation. Replace worn parts as evidence by
excess free play or rotation.
14
HOOK INSPECTION
Hooks damaged from chemicals, deformations or cracks, or that have more than a 10 degree twist from the
hook’s unbent plane, excessive opening or seat wear must be replaced. Also, hooks that are opened and allow
the latch to not engage the tip must be replaced. Any hook that is twisted or has excessive throat opening
indicates abuse or overloading of the unit. Inspect other load sustaining parts, hook block screws, load pins and
hook block bodies for damage.
Check to make sure that the latch is not damaged or bent and that is operates properly with sufficient spring
pressure to keep the latch tightly against the tip of the hook and allow the latch to spring back to the tip when
released. If the latch does not operate properly, it should be replaced.
To Measure opening, depress latch against hook body as show.
Replace the hooks when opening is greater than 38mm.
Hook dimension
CHAIN
1. Clean chain with a non-caustic/non-acid type solvent and make a link by link inspection for nicks, gouges, twisted
links, weld splatter, corrosion pits, striations, cracks in weld areas, wear and stretching. Chain with any one of these
defects must be replaced.
2. Slack the portion if the chain that normally passes over the liftwheel. Examine the interlink area for the point of
maximum wear. Measure and record the stock diameter at this point of the link. Then measure stock diameter in
the same area on a link that does not pass over the liftwheel and compare these two measurements.
15
3. Also check chain for stretch using a larger caliper as show below to measure the outside length of a
convenient number of links about 11(pitchs). Measure the same number of links in a used section of chain and
calculate the percentage increase in length of the worn chain.
4. Chain is to be kept clean and lubricated. Visually check chain every time chain hoist is used. As oil needs to sit at
the bearing surface of each chain link, it is advised to submerge the chain in oil for 30 min. Take it out and let the
chain hang dripping for 24 hours before putting in the hoist.
IDENTIFICATION OF CHAIN:
FEC load chain can be recognized and determined original by the following marks on the chain
Chain specifications:
• diameter-7.1mm
• pitch-20.2mm
• grade-Grade 80
• type of marking-see sample picture below. Every 15 links.
• max. working load-1000kgs
• minimum breaking strength-6300kgs
• weight per meter- 1.12kg/m
For replacement load chains use FEC chain only.
16
CHAIN REPLACEMENT WITH CHAIN IN LIFTING MOTOR
1.
2.
3.
4.
5.
6.
7.
With the unit placing on workbench or motor up position, run the hook to its up
limit.
Remove the load block assembly from the old chain.
Make a “C” link, attach the new chain to the load end of the old chain.
Carefully jog the “UP” button and run the joined pieces of chain into the lifting
motor until about 40cm of new chain comes out the other side.
Remove the “C” link and the old chain. Remove the chain stop from the old chain
by a hex head screwdriver.
Attach the chain stop to the slack end of the new chain by capturing the 12th link
with the two stop halves. Be sure there are no twists in the chain.
Attach the load block on new chain by a hex head screwdriver.
CHAIN REPLACEMENT WITH NO CHAIN IN CHAIN HOIST
1.
2.
3.
4.
5.
6.
7.
8.
With the unit placing on workbench, run the hook to its up limit.
Remove the load block assembly from the old chain.
Remove the chain stop from the old chain.
Carefully jog the “UP” button and detach the old chain out of the lifting
motor.
Insert the new chain into the load sheave.
Feed the new chain into the chain hoist by jogging the “DOWN” button.
Allow about 40cm of chain below the chain hoist on the slack end.
Attached the chain stop and load block assembly. Be sure there are no
twists in the chain.
17
Make a “C” link
CHAIN END STOP
The end stop on the dead-end chain should be mounted on the 11th link. (No less than 11 links should be in between
the dead-end and the chain stop).
CUTTING CHAINS
FEC load chain is hardened and therefore difficult to cut. The following methods are recommended when cutting
a length of new chain from stock or cutting worn chain.
a) Use a grinder and nick the link on both sides, then secure the link in a vise and break of with a hammer.
Cutting chain by Nicking
b)
Use a bolt cutter with special cutter jaws for cutting
hardened chain.
Cutting chain with a Bolt Cutter
LOAD CHAIN CLEANING
Clean the load chain with acid-free solvent and coat with new ISO VG-320 or equivalent gear oil. Wipe excess Oil to
prevent dripping. Never apply grease to the chain.
OVERLOAD LIMITING CLUTCH
The parts of limiting clutch are mounted free on the gear input shaft. The adjustable slip clutch, fitted as an overload
safety device. This device has been calibrated at the factory and is engineered for low maintenance and also serve as
an overload protection.
LMITING CLUTCH ADJUSTMENT
1.
2.
3.
4.
Hook a load of 1.25 times the nominal load into the hoist.
Remove the cover no.1 and fasten any 2 nuts back into gear cover side.
Tighten the adjustable clutch nut by torque spanner set in 20.3Nm.
Raise the load and check if the movement and noise. The slipping clutch is now adjusted.
Tighten this adjustable nut
Torque spanner set to 20.3Nm
18
WIRING
3-phase units(220V/380V) are wired for 380V as standard unless otherwise specified when ordering.
Conversion of multiple voltage units can be done simply and quickly as follows.
1. Disconnect chain hoist from power supply and remove motor cover.
2. Find the 2 ways terminal block, Relay rectifier, 3 wires
power input wires tag with different number.
3. Make sure that all of the screw clamps on the terminal block
are tightened. Tug on the connected wires to ensure they are
securely connected and match the diagram to ensure proper
wiring.
4. Check the operation of the chain hoist, ensuring that the direction of travel is connect.
Important: Always refer to the wiring diagram located on the inside of the motor cover when performing electrical repairs.
Make sure all terminals are securely fastened and check for damaged insulation.
SIGNS OF INADEQUATE ELECTRICAL POWER:
The hoist must be supplied with adequate electrical power in order to operate properly. The signs of low voltage are:
•Noisy hoist operation due to brake and /or chattering.
•Dimming of lights or slowing of motors connected to the same circuit.
•Heating of the hoist motor and other internal components as well as heating of the wires and connectors in the circuit
feeding the hoists.
•Failure of the hoist to lift the load due to motor stalling.
•Blowing of fuses of tripping of circuit breaker
19
20
21
Low voltage may also be caused by using an undersized cord and/or connectors to
supply power to the hoist. The following chart should be used to determine the size
wires in the extension cord in order to minimize the voltage drop between the power
source and the hoist.
Three phase hoists
Length of extension
cord
Minimum wire size
Up to 50 feet (15M)
#16AWG (1.6mmsq)
80 feet (24M)
#16AWG (1.6mmsq)
120 feet (36M)
#14AWG (2.0mmsq)
200 feet (61M)
#14AWG (2.0mmsq)
300 feet (91M)
#12AWG (2.7mmsq)
POWER CORD PRECAUTIONS:
The following are the conductor color code for mains cable, break ins, break outs
and multi cable:
MAINS CABLE
Wire
Color
Pin
L1/R1
Red
1
L2/S2
White
2
L3/T3
Black
3
Ground
Yellow/Green
GND
22
LUBRICATION
Proper lubrication is necessary to ensure a long and reliable chain hoist life. Refer to the
following and the RECOMMENDED LUBRICATION SCHEDULE for lubrication points, type of
lubricant, and frequency of lubrication. Note: If the chain hoist is used in an atmosphere
containing abrasive dust, frequent cleaning and oiling may be necessary.
Figure &
reference no.
Component
Type of lubricant
( use only new lubricant)
Type of service and frequency of lubrication
NORMAL
HEAVY
SEVERE
Monthly
Weekly
Figure 48
Load Chain
ISO VG(HD)-320 gear oil
Occasionally
Figure
13/18/29
&38
Gearing
Moly extreme pressure
grease
At periodic inspection
(yearly replacement is advised)
Figure 44
Load hook
bearing
Moly extreme pressure
grease
23
Yearly
Monthly
Weekly
CHAIN HOIST REPAIRS
Note: If you do not have an experienced mechanic to do your repair work, we recommend
that you send your chain hoist to an approved service station for repairs. Use authorized
repair parts only.
RECOMMENDED SPARE PARTS
To insure continued service of the DUKE hoist, the following is a list of parts that are
recommended to be kept on hand at all time to replace parts that have worn or failed.
Parts Number
Part Name
Quantity for each hoist in
service
Parts No.55
Magnetic Contactor
2
Parts No.11
Brake Coil
1
Parts No.57
Regulator
1
24
Explosive Art for DU-905 3-phase 1 ton chain hoist:
25
Parts list for DU-905 3-phase 1 ton chain hoist:
DU-905 PARTS DESCRIPTION
1
Gear end housing
33
Chain Guide
2
Nut
34
Chain
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
21-1
22
23
24
25
26
27
27-1
28
29
30
31
31-1
31-2
32
Brake assembly attaching screws
Brake Frame
Brake Disc
Fixing spring
Nut
Brake intermediate plate
Spring
Screw
Brake coil
Brake base plate
Bearing
Drive shaft key
Drive shaft
Bearing
Gear
Bearing
Rod of gear shaft
Fixing base of gear shaft
Bearing
Key
Gear Shaft
Gear hub
Rod of gear shaft
Bearing
Gear
Chain Guide Shaft
Bearing
Gear frame
Screw
Screw
Side Cover
Screw
Screw
Limit Cover
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
49-1
50
51
52
53
54
55
56
57
58
59
60
61
62
62-1
70
71
72
Limit disconnector
Limit switch base
Screw
Ring
Loose end link
Lifting hook block
Screw
Nut
Lifting hook
Chain stop block
Chain bag
Fix Rod
Fix Rod
Fix Rod
Suspension hook
Hook base block
Motor frame
Motor frame screws
Motor
Screw
Circuit board
Magnetic Contactor
Circuit board holder
Regulator
Power Cord
Cable gland
Motor end housing
Control Cord
Control switch w/o cord
Emergency Stop Guard
Limit switch ass'y
Fix Spring
Chain Guid Spring
26
Trouble
TROUBLE SHOOTING FOR CH-1000 CHAIN HOIST
Probable Cause
Check and Remedy
1. Lifting motor does not
respond to pushbutton
A) Power failure in supply line
B) Wrong voltage or frequency
A) Check circuit, breakers, switch
and connection in power supply line
B) Check voltage and frequency of
power supply against the rating on
the nameplate of the motor.
C) Improper connections in
chain hoist of push button
C) Check all connections at line
D) Brake does not release
2. Hook does not stop
promptly
A) Chain hoist overloaded
B) Brake not holding
3. Hook moves in wrong
direction
A) Three phase reverse
B) Improper connection
4. Chain hoist hesitates
to lift when energized
A) Chain hoist overloaded
connectors and on terminal block.
D) Check brake coil connection for
open or short circuit. Check wiring for
relay rectifier.
A) Reduce load within rated capacity
of chain hoist.
B) Check brake and it may be
necessary to replace discs.
A) Reverse any two wires (expect the
ground wire) at the power source.
B) Check all connections against
wiring diagram.
A) Reduce load within rated capacity
of chain hoist.
B) Worn overload limiting clutch B) Check and adjust limiting clutch
C) Low voltage
C) Determine cause of low voltage
and bring up to within plus or minus
10% of the voltage specified on the
motor. Measure voltage at the lifting
motor in terminal block power input.
5. Hook raises but will
not lower
A) “Down” circuit open
B) Broken conductor in
pushbutton cable
27
A) Check circuit for loose
connections.
B) Check each conductor in the cable.
If one is broken, reduce entire cable.
6. Hook lowers but will
not raise
A) Lifting motor overload
B) Low voltage
C) “UP” circuit open
A) Reduce load to within rated
capacity of chain hoist.
B) Determine cause of low voltage
and bring up to within plus or minus
10% of the voltage specified on the
motor. Measure voltage at the lifting
motor in terminal block power input.
C) Check circuit for loose
connections
D) Broken conductor in
pushbutton cable
D) Check each conductor in the
cable. If one is broken, replace
entire cable.
E) Worn overload limiting clutch E) Adjust or replace overload
clutch assembly.
F) Loose screw clamps
F) Ensure that screw clamps are
tightened on the terminal blocks.
7. Motor overheats
A) Excessive load
A) Reduce load to within rated
capacity of chain hoist
B) Low voltage
B) Determine cause of low
voltage and bring up to within plus
or minus 10% of the voltage
specified on the motor. Measure
voltage at the lifting motor in
terminal block power input.
C) Frequent starting or reversing C) Excessive inching, jogging or
reversing should be avoided since
this type of operation will
drastically shorten the life of
motor and brake.
D) Brake dragging
D) Replace brake assembly
8. Lack of proper lifting
speed
A) Chain hoist overload
A) Reduce load to within rated
capacity of chain hoist
B) Brake dragging
B) Replace brake assembly
28
C) Low voltage
C) Determine cause of low
voltage and bring up to within plus
or minus 10% of the voltage
specified on the motor. Measure
voltage at the lifting motor in
terminal block power input.
D) Overload limiting clutch
intermittently slipping
D) Adjust or replace overload
limiting clutch assembly.
9. Motor brake noise or
chatter
(while starting chain hoist)
10. Motor brake “buzz”
(anytime
chain hoist is running)
A) Brake needs replacement
A) Replace brake assembly
B) Low voltage
B) Determine cause of low
voltage and bring up to within plus
or minus 10% of the voltage
specified on the motor. Measure
voltage at the lifting motor in
terminal block power input.
A) Brake needs replacement
A) Replace brake assembly
B) Broken brake coil
B) Replace the brake coil and
check the relay rectifier.
30