Operating Instructions and Parts Manual AL100 Series Aluminum Hand Chain Hoists 1-ton model shown JET 427 New Sanford Road La Vergne, Tennessee 37086 Ph.: 800-274-6848 www.jettools.com Part No.
1.0 IMPORTANT SAFETY INSTRUCTIONS 15. Never allow the load chain to “set” over sharp edges. All lifts must be made with straight chain that is free of obstacles. WARNING – To reduce risk of injury: 1. Read and understand the entire owner’s manual before attempting assembly or operation. 16. If the hand chain is difficult to operate, then the load exceeds the capacity of the chain hoist. Select a chain hoist of larger capacity. 2. Read and understand the warnings posted on the tool and in this manual.
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 ..........................................
3.0 Introduction This manual is provided by JET covering the safe operation and maintenance procedures for a JET Model AL100 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 forth in this manual.
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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 chosen, the support components 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 brake mechanism must be kept clean and free from dirt, water, and oil.
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 center of the bottom hook, making sure the safety latch is secure. Never load the hook in front of the safety latch. See Figure 3. 4. Avoid lifting one load with two hoists. If this is unavoidable, apply 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. Figure 3 5.
6.0 Hand Chain – Disassembling and Installing To open the master link (part #7 on the parts list in the “Replacement Parts” section) on hand chain in order to increase or shorten: To change the length of the hand chain, the master link must be open and hand chain links added to increase the overall length or links removed to decrease the length. This is done as follows: 1. Insert the master link into the vise (Figure 6). Figure 6 2.
7.0 Load Chain and Bottom Hook 7.3 Attaching Load Chain to Load Chain Sprocket (all models) 7.1 Load Chain Inspection (all models) Install the new load chain onto the load chain sprocket as follows, referring to Figure 10: 1. Position the hoist body upside down, so that the outlets for the load chain are showing. Over time, the load chain will wear or elongate. This can cause damage to the hoist, breakage, or non-engagement of the load sheave. 2.
Continue with Load Chain and Bottom Hook Installation, proceeding to the section that applies to your hoist: 1/2- to 2-Ton hoists or 3- to 5-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 through the load chain sprocket as described in the previous section. This section completes the load chain and bottom hook installation. A 7.5 Chain Installation: 0.
8.0 Overload Protection All models of the AL100 Aluminium Hand Chain Hoist have overload protection in the form of a slip clutch. For 0.25 and 0.5 ton models, the slip clutch is effective at 180-200% ±20% of the rated hoist capacity. For all other models, 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 load, if the load is too heavy for the hoist.
10.0 Load Limits 10.1 Load Chain Capacity 0.25 ton 0.5 ton 1 ton 1.5 ton 2 ton 3 ton 5 ton 5 Links Normal 1.772" 2.362" 3.110" 3.937" 4.724" 3.937" 5.315" 5 Links Limit 1.823" 2.433" 3.201" 4.051" 4.866" 4.051" 5.476" Table 1 Figure 14 Carefully inspect the entire load chain. As illustrated in Figure 14, measure five consecutive links with callipers to measure the length. Check every three feet and especially where excessive wear is indicated.
11.0 Troubleshooting JET® Aluminum Hand Chain Hoists Symptom Possible Cause Correction1 Hoist will not move in either direction. Hand chain wheel is jammed, worn, or damaged. Hand chain slips over wheel. Inspect and clean hand chain and hand chain wheel. Replace if worn or damaged. Check hand chain wheel for damage or worn cogs. Replace if needed. Inspect and clean. Check for chain link deformation. Replace elements if needed. Oil load chain for optimal performance. Inspect, clean, and re-grease gears.
12.0 Timing Marks for Gear Replacement If the gears on the AL100 hoist need replacement or removal for any reason, make sure they are reinstalled correctly. Figure 16 shows the proper orientation of the timing marks when meshing the gears. Figure 16 13.0 Replacement Parts Replacement parts are listed on the following pages. To order parts or reach our service department, call 1-800-274-6848, Monday through Friday (see our website for business hours, www.jettools.com).
13.1.1 AL100 Aluminum Chain Hoist Parts Breakdown (0.
13.1.2 Parts List: AL100-050 Aluminium Chain Hoist (0.5 Ton) Parts listed under each assembly are parts that make up that assembly (sold as an assembly only). Index No. Part No. Description Size Qty 1...................AL100-50-01 ..................Warning Tag ................................................................................................................1 2...................AL100-25-02 ..................Screw & Washer ...............................................................
13.1.3 Parts List: AL100-100 Aluminium Chain Hoist (1 Ton) Parts listed under each assembly are parts that make up that assembly (sold as an assembly only). Index No. Part No. Description Size Qty 1...................AL100-100-01 ................Warning Tag ................................................................................................................1 2...................AL100-100-02 ................Screw & Washer ...............................................................
13.1.4 Parts List: AL100-150 Aluminium Chain Hoist (1.5 Ton) Parts listed under each assembly are parts that make up that assembly (sold as an assembly only). Index No. Part No. Description Size Qty 1...................AL100-150-01 ................Warning Tag ................................................................................................................1 2...................AL100-100-02 ................Screw & Washer ...............................................................
13.1.5 Parts List: AL100-200 Aluminium Chain Hoist (2 Ton) Parts listed under each assembly are parts that make up that assembly (sold as an assembly only). Index No. Part No. Description Size Qty 1...................AL100-200-01 ................Warning Tag ................................................................................................................1 2...................AL100-100-02 ................Screw & Washer .......................................................................
13.1.6 Parts List: AL100-300 Aluminium Chain Hoist (3 Ton) Parts listed under each assembly are parts that make up that assembly (sold as an assembly only). Index No. Part No. Description Size Qty 1...................AL100-300-01 ................Warning Tag ................................................................................................................1 2...................AL100-100-02 ................Screw & Washer ...............................................................
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13.1.8 Parts List: AL100-500 Aluminium Chain Hoist (5 Ton) Parts listed under each assembly are parts that make up that assembly (sold as an assembly only). Index No. Part No. Description Size Qty 1...................AL100-500-01 ................Warning Tag ................................................................................................................1 2...................AL100-500-02 ................Screw & Washer ...............................................................
14.0 Warranty and Service JET warrants every product it sells against manufacturers’ defects. If one of our tools needs service or repair, please contact Technical Service by calling 1-800-274-6846, 8AM to 5PM CST, Monday through Friday. Warranty Period The general warranty lasts for the time period specified in the literature included with your product or on the official JET branded website. • JET products carry a limited warranty which varies in duration based upon the product.
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427 New Sanford Road LaVergne, Tennessee 37086 Phone: 800-274-6848 www.jettools.
