NN ELECTRIC CHAIN HOIST OPERATION MANUAL & PARTS LIST SERIES: C YSs(b)-200 CJ] YST(D)-200 4] YSs(D)-250 | YST(D)-250 C) YSs(b)-300 YST(D)-300 C1 YSs(p)-500 CJ] YST(D)-500 [1 YSs(D)-750 Oo ] Yss(p)-1000 CHENG DAY MACHINERY WORKS CO., LTD.ORi 2538 (44nqs4o O fd. 2393) SAFETY-IMPORTANT The use of any hoist and trolley presents some risk of personal injury or property damage. That risk is greatly increased if proper instructions and warnings are not followed. Before using this hoist, each user should become thoroughly familiar with all warnings, instructions and recommendations herein, THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH IF NOT FOLLOWED COULD ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY OF YOURSELF AND OTHERS. READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL AND ANY PROVIDED WITH THE EQUIPMENT BEFORE ATTEMPTING TO OPERATE YOUR "BLACK BEAR” ELECTRIC CHAIN HOIST.1. FOREWORD This manual contains important information to help you properly install, operate and ‘maintain the Black Bear electric chain hoist for maximum performance, economy and safety Please study its contents thoroughly before puttin he electric chain hoist into operation. By practicing correct operation, procedures and by carrying out the preventative maintenance recommendations, you will be assured of dependable service, In order to help us to supply correct spare parts quickly, please always specify, (1) Hoist Model (2) Serial Number (3) Part Number, plus the description We trust that you will find this “Black Bear” electric chain hoist will give you many years of satisfactory service. Should you have any queries, please contact: (Please ask for a company’ s stamp from your local agent.)CONTENTS Safety — Important .. 1 L Foreword... 3 2.Main Specification. 4 2.1 Specification. 4 2.2 Mechanical Classification (Grade) and Life. esnenanannsserssabest 5 233 Safety Device..... 6 2.4 Main Specification and Dimensions of Hook Suspension Type Hoist... i 7 2.5 Optional Trolley Accessory. secteeeenseen are gt 8 3.Safety Rules, seccecvaneeese EEE Tana soe 10 4.lnstallaton,...... 13 41 Unpacking Information, 1B 4.2 Voltage. .oocsesecsnesssseseeee svessangeeiasetecceseussnseesestsmnnstssensenae 13 43 Installation... ssesceeseeee 13 5.Operation 16 6Maintenance and Inspection. ..........e Eieoereercent = 16 16 6.2 Inspection, "7 7-Troubleshooting.. 21 7.1 Wiring Diagrams. 24 72 Troubleshooting and Remedial Action........sssssssesessessceeceseense sess 28 8.Drawings and Parts List... ceectveseeenenssnt a | 9.Declaration OF ConformityMAIN SPECIFICATION 2.1 Specification The following specifications are common to all Black Bear electric chain hoists Table 2-1 Specifications Item Detail Working temperature range(’C) -5t0 +40 Working humidity range (%) 85 or less Hoist Ira Protection(Option) Push button 1P20 Electric power supply ‘Three Phase, 200-600V, 50/60 Hz. Single speed hoist 81 Noise Level ((B) Dual Speed hoist 81 WLL (working load limit) () | Nominal diameter (mm) | Pitch (tm) Chain size 2T(YSS),3T 10.0 30 2ST,ST, 7.57, 107 112 34 Remarks : (1) Contact an author -d Black Bear dealer for information on using the temperature or humidity range. hoist outside the wor 2) Intended use: This hoist has been designed for vertically lifting and lowering load under normal atmospheric conditions of work place. (3) Noise levels were measured at a distance of Im horizontally from the hoists during normal operation. (4) Push button protection grade IP 65 available.2.2 Mechanical Classification (Grade) and Life Safety and life for electric chain hoists are guaranteed only wi ‘operated in accordance with the prescribed grade. Black Bear electric chi n hoists have been desi 1Am in the FEM regulations (FEM 9,51 1). Details are provided in Table 2-2, ‘hen the said equipment is igned for grade 2m except YSF-series ‘Average daily operating time and total operating time are determined by load distribution. Table 2-2 Mechanical classifications oad Speci Cube (Load Definitions mean Average daily operating time (h) isibuion) value Mechanisms or parts , thereof, usually ies tion | bet vey sma so [02505] 051 | 12 | 24 | 48 | s16 exceptional cases only to maximum loads. “Mechanisms or parts 2 thereof, usually 0.50] «] [2] | >] | fi eae, § a er ao aS eee [| Torna sa go ag ee Ta © Geared Troitey Dimensions (mm)GT Kelas os om | EE ia om =] pe] | 3 |] Joe] RS | te, foe st rienisihaneerane ee ee ae : Dimensions / Specifications (mm) les] noun a se SE ESET totor wy Ee moae! |) a] clo] ey s | 3" [eonz[eotz| xu) ae Perf} so [roo 1a 27 PT8} ozs aa 2 ferro [504254 8 ar aa 7a 00 20 fratol a8 te 3 frre efeedarfzedzer] v2 [reset 22 Pal Oe Te) a0 el 08 TEL] 5 _fprcseareelordadas oo] roa rasa = PTE ns 2 75 fare feseraqacslar solzanaf roomed 12 | Te] Oe Ps Lo 10 Parsee e2 soar faeefarr sf soamd berate UV ES00- SON wTT HETS STA S042 wih moter of 4 5P © Motor Saddle Trolley f Dimensions / Specifications (mm) aay SATAY To] To] = Tx] SPE ‘ony “| Mose! Psonz [eonz | 2 fsrozef areal ™ 4? | 2 rar fer q ee 5 = Ft arr] ts9esq 050 sel a7 ra: 182, T Stoamb mr tT] x 2 mero sod aaa ta 75 beasre-rs0 rere apzarr 7°24 200|80| 1871220) —y rps faz] 2°8| roe Tt ee ale1sl ood 1200) 0] zads1—l oe 4 10 hasro-1o0q 2177 [206 7| - [os10-3apeqp ra] SFR, 100 — e042 wi pion oH ET, ~Cohz wit snan ota. MST: 300,MST-500 BOHZ/5OHZ with pinion of M8 5:207 1MST.750 60HZISOHZ win pison of M2 53157 82.5.1 Specification of hoist with motorized trolley. Dimensions/Specifications (mm) Capacity Aajustabte (ton) Span{mm 2_[ara00 | os |325|s67[asa]200] 100-150, | mra00_[1120|350[se2[4r7]246| 125-175, | mr-soo | v200|sassrafeaalass] 125-175, 75 | mr750_[1300)4s«[ras}ees]ari| 180200 10 [600] 435/580 [e2}seolar1] 150.200 modo] Hal ale|o 25.2: © Specification of hoist with GT/PT type trolley. Dimensions/Specifications (mm) = =o [adjustabr) ] ] tony Model # | A | 8] cf or| or] &| o [teetabe 2 [Stzoe| ses [ars ised vas | 22a ova fern dara] 100.150 | jroo] 263 [27a] er [vai f ara] — | 226 100.150 [cr-soof 1196] 286 [190 vas 750 [255 Jona dasa] 100-150 © [ers00f ize) 205 oo [uaal-zs1| | 253 = | 100-160 meant ru [or-so) 2:0] 206 [iszd 157 | 204 | ast [a0 faosal 25.175 jr-soo| 210] 2s6[ vo2] ss7] asi | — [ase 1253475,3. SAFETY RULES 4 USaH The hoist herein is not designed for, and should not be used for, lifting, supporting, or transporting personnel. Any modifications to upgrade , re-rate, or otherwise alter the hoist equipment must be authorized by either the original manufacturer or «4 qualified professional engineer. (1) Only the trained personnel are allowed to operate the hoist > A Do not use the hoist in explosive atmosphere. (3) Prior to each lifting operation, itis essential 10 make sure that (@) the comet lifting ling is being used (b) the lifting sling is located in the hook as shown below (Illus, 2) and that a safety lateh has been fitted, Mus. 2 ot lifting (a proper lifting frame or (©) the object to be hoisted is well secured for dit apparatus is strongly recommended for direct iting.)(4)Fiem and steady button operation is required, never push the button switeh intermittently (5) Always avoid excessive inching operation, (6) Always make sure the hoist motor completely stops before reversing, (1) Always leave the pendant button switeh cable and bottom hook load chain vertically static after completion of operation, never leave them at any position, Which may allow them swing or slip. (8) Sling must be applied to load evenly and centrally to ensure correct balance, Never lift any object which is insecure or out of balance, (9) Never use hoist to end or side pul a load, (lus. 3) (10) Never wrap around and hook back the load chain as a sling to lift a load. (Illus. 4) an A WARNING Do not use the hoist chain as a welding electrode.a A Never stand under a raised load (Illus. 5) (13) Lifting must always be personally attended, never leave a raised foad unattended. (14) Over-capacity-load lifting is hazardous and should not be undertaken, (15) Never lift load when the load chain is twisted. (16) Regularly inspect and check the condition of load chain, Do not operate with damaged chain,4, INSTALLATION 4.1 Unpacking Information ‘After removing the hoist from its packing box, carefully inspect the extemal condition of the electrical cables, contactor, gearbox and motor easing for damage. a ‘and ensure that these items are present ‘ach hoist is supplied as standard with the following accessories: 1. Chain bucket 1 set 2.Power cable 3 meters 3.Push button control switch | I piece Table 4-1 4.2 Voltage A Bum Af power supply deviates from standard by more than 0% abnormal operation or damage to the motor may result. It is imperative to ensure correct voltage supply before commencing operation. 4.3 Installation A RNG Connection to power supply before installation procedures having been completed is strictly prohibited.(1) Prior to installation check and ensure that the top hook assembly is securely attached to the hoist by means ofthe connecting pin (page 35, item 13) NOTE: Ifthe hoist is to be suspended from an electric trolley, assembly may be eased by firstly removing the top hook, just ataching hoist top hook to the trolley Joad plate, (2) Assemble chain bucket. lus. 6 (3) Connect power supply to hoist and oj iperate the push button switch. This operation must be carried out by a trained person yO we : conracror Bie EL WHE) WIRE ROPE 1 [bs ]j a 1 | Pade | a | 1) LE for] | Alexei os — gay Mlus. 7(4) Operation Test (A) Firmly push switch button to lower load chain until the Fimit spring touches the limit switch, Power should be cut off automatically (B) Firmly push @) switch button to check the collection of load chain into chain bucket. (© Check the emeryeney stop device function (if ited): While holding down cither Jor ution on the push button switch, Push the emergeney stop button, Check that the hook stops when the emergeney stop button is pushed. Also, check the hoist does not move in esponse to the push button switch. Finally, check that the emergency stop n-be resumed thereafter. If the equipment fails to pass another above checks, check the device pops out when tured to the right and that operation wiring and automatic locking function of the emergency stop device. (D) Check toad chain lubrication (It has been lubricated at our works, but the lubricant may dry out during transportation). Any readily available lubricant is recommended. It is further advisable to keep a small amount of lubricant in chain bucket to allow chain in oil bath, (E) Check chain position, Weld joints on links must face the same direction (Illus. 8), correct chain operation can only be achieved when all joints are vertically in fine, A Gti (illus. 9). The bottom hook on multi-fall hoist must never be rotated as shown below /p WELDING POINT SSS ~y— ALL WELDING POINTS SHOULD BE IN LINE hs. 8 Hus. 95. OPERATION After running test and checks have been completed, the hoist will be ready for normal operation A BW Since dealing with heavy loads may involve unexpected danger, all of the "SAFETY RULES" (Ref 3.) must be followed ard the operator must be aware of the following points while using the hoist. (1) The operator must have a elear and unobstructed view of the entire working atea before ‘operating the hos. (2) The operator must check that the entire working area is safe and secure before operating the hoist G) When using the hoist with a motorized trolley, the operator must take care to prevent excessive load swinging by sympathetic use of the trolley controls, 6. MAINTENANCE AND INSPECTION 4A BS Do not perform maintenance on the hoist while itis carrying a load except monthly checking for the brake or limit switch. A Een Before performing maintenance do not forget to affix tags to the power source and ‘the push button switch reading: “DANGER”, “EQUIPMENT BEING REPAIRED”. 6.1 Maintenance (1) Check the level of gear box lubricant after first 500 hours of operation, thereafter every 3 months and lubricant according NOTE: WE RECOMMEND USING A (2) Always keep the hoist unit dry and never misuse JBRICANT OIL EQUIVALENT TO ISO VG460. it ina manner likely to reduce its durability 16(3) When itis necessary to keep the unit outdoors, a protective covering should be fitted. 6.2 Inspeetion (1) Daily inspection: Before starting daily operation, check the following (a) Correct power supply. ()"Up", "Down’ and" (©) Correct motor performance. mergeney stop" (where fitted) test runs under no load (@) No abnormal or e cessive noise. (©) No malfunction of the bottom hook safety latch. (6 Proper function of moving/turning parts, limit switches and brake, (g) Well lubricated load chain. (2) Monthly inspeetion Chain Weati Cubie mean Using times Load Spectrum ™ Value | Now lubricated Lubricated Tah 30% 75000 175000 2 (Medium) 63% 35500 129500 3 (Heavy) 85% 30000 70000) 4 (Very heavy) [100% 15000) 5000 Above testing data under lifting height IM 1M pinpoint weoring test (100%Capacity) BadjIns pazynquoD 0 1 2 5 4 5 6 x10,000 Number of cycles "7A Always use the hoist manufacture's recommended parts when repairing a hoist. Distorted, elongated or worn chain link will not sit properly on the load sprocket wheel and may cause chain breakage and/or image to the hoist unit. To ensure safe and efficient operation, the chain links must be checked for their piteh (inside length), inside width and outside width monthly according to following table, Dia- Tnside | Tnside Meter | Load | Length} Width avin) | (ton) | (enim) | (enim) a ® | @ woo | 237 | 30 | 125 2 128] 5 " "2 lasror] 34 | 14 | 372 Table 6-2-a (b) Load hook: Check hook with care. If hook shows crack deformation or wear in excess of 5% of its original size, it should be replaced (Ref. following table) Cory FE Pig 23Ton LE ss | 34] as | 34 | 52 [43 sim [Ha] s[@l alae a a 10 Ton 7 100} 65 | 95 | 60 | 100) 68 T: Top hook Br: Bottom hook Table 6-2-b(©) Limit Switches: A REGIE A qualified electrician should perform this inspection. Check correct operation of the limit switehes. Clean thoroughly and apply a thin lubrication to ensure correct operation (3) Annual inspection ya WARNING Your dealer should be asked to perform this inspection. (a) Cheok gearing for any excessive wear or damage. (b) Replace gearbox lubricant completely. (©) Check brake lining and ratchet pawl for any wear or damage. (@) Check operation of pal spring. (©) Alter reassembly of above check, lifting a load several times to ensure good performance of the hoist before starting duty operation, ¢ 190 BUCKET SPECIFICATIONS KeyNo. | Bucket Chain teatn(n) | Bucks Size mm) — | Matai pore | 6 o Q < a oO E Oo = = >