ELECTRIC CHAIN HOIST OPERATION MANUAL & PARTS LIST SERIES: □ YSS(D)-200 □ YST(D)-200 □ YSS(D)-250 □ YST(D)-250 □ YSS(D)-300 □ YST(D)-300 □ YSS(D)-500 YST(D)-500 □ YSS(D)-750 □ □ □ YSS(D)-1000 □ CHENG DAY MACHINERY WORKS CO., LTD.
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.
CONTENTS Safety – Important … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 1 1.Foreword… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . 3 2.Main Specification… .… … … … … … … … … … … … … … … … … … … … … … … … … … … … 4 2.1 Specification… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 4 2.2 Mechanical Classification (Grade) and Life… … … … … … … … … … … … … … … … … 5 2.3 Safety Device… … … … … … … … … … … … … … … … … … … … … … … … … … … … … 6 2.
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 putting the 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.
2. 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(℃) -20 to +40 Working humidity range (%) 85 or less Hoist IP 42 Push button IP 20 Protection(Option) Electric power supply Three Phase, 200~600V, 50/60 Hz Single speed hoist 81 Dual Speed hoist 81 WLL (working load limit) (t) Nominal diameter (mm) Pitch (mm) 2T(YSS), 3T 10.0 30 2.5T,5T, 7.5T, 10T 11.
2.2 Mechanical Classification (Grade) and Life Safety and life for electric chain hoists are guaranteed only when the said equipment is operated in accordance with the prescribed grade. Black Bear electric chain hoists have been designed for grade 1Am in the FEM regulations (FEM 9.511). Details are provided in Table 2-2. Average daily operating time and total operating time are determined by load distribution.
2.3 Safety Devices (1) Motor brake "Electro-Magnetic Brake" is of a unique design in its field. It features simultaneous motor braking upon switching off power even under full load condition. (2) Mechanical load brake The mechanical load brake can hold a full capacity load independent of motor brake. This brake assures that load does not accelerate while being lowered. (3) Hook and hook latch The hook is drop - forged from high tensile steel and heat treated for strength and toughness.
2.4 Main Specification and Dimensions of Hook Suspension Type Hoist: Capacity (ton) Lift Height Load Chain (mm) Single 50HZ YSS Speed 60HZ YSS (m/min) Dual 50HZ YSS Speed 60HZ YSS (m/min) N.W./G.W. (kg) MOTOR POWER (kw) 2 2.5 3 5 3 (6) etc. φ10 7.5 10 φ10 φ11.2 6.6 5.2 4.3 2.6 1.8 2.6 7.9 6.4 5.2 3.2 2.1 3.2 6.6/2.2 5.2/1.7 4.3/1.4 2.6/0.9 1.8/0.6 2.6/0.9 7.9/2.6 6.4/2.0 5.2/1.7 3.2/1.0 2.1/0.7 3.2/1.0 φ11.2 125/155 130/160 140/170 153/183 195/230 410/470 3.7 3.
2.4.2 Standard Lifting Height and Tools ◎ Standard Lifting Height: 3 Meters With Chain Container ◎ One Tool Sets 2.5 Optional Trolley Accessory ● Plain Trolley A F B Dimensions (mm)PT C G Capacity L I H K D1 2 3 5 7.
2.5.1: ●Specification of hoist with motorized trolley. Dimensions/Specifications (mm) Capacity Model (ton) H A B C Adjustable Span(mm) D 2 MT-200 995 323 567 358 209 100-150 3 MT-300 1120 359 662 417 245 125-175 5 MT-500 1200 389 673 422 251 125-175 7.5 MT-750 1300 400 736 465 271 150-200 10 MT-1000 1415 536 821 550 271 150-200 2.5.2: ● Specification of hoist with GT/PT type trolley. Dimensions/Specifications (mm) Capacity (ton) 2 3 5 9 Model H A B C D1 D2 214 277.
3. SAFETY RULES DANGER 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 a qualified professional engineer. (1) Only the trained personnel are allowed to operate the hoist. DANGER (2) Do not use the hoist in explosive atmosphere.
(4)Firm and steady button operation is required, never push the button switch intermittently. (5) Always avoid excessive inching operation. (6) Always make sure the hoist motor completely stops before reversing. (7) Always leave the pendant button switch 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.
DANGER (12) Never stand under a raised load (Illus. 5) Illus. 5 (13) Lifting must always be personally attended, never leave a raised load unattended. (14) Over-capacity-load lifting is hazardous and should not be undertaken. (15) Never lift a 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 external condition of the electrical cables, contactor, gearbox and motor casing for damage. Check and ensure that these items are present. Each hoist is supplied as standard with the following accessories: 1. Chain bucket 1 set 2.Power cable 3 meters 3.Push button control switch 1 piece Table 4-1 4.
(1) Prior to installation check and ensure that the top hook assembly is securely attached to the hoist by means of the connecting pin (page 35, item 13) NOTE: If the hoist is to be suspended from an electric trolley, assembly may be eased by firstly removing the top hook, just attaching hoist top hook to the trolley load plate. (2) Assemble chain bucket. Illus. 6 (3) Connect power supply to hoist and operate the push button switch. This operation must be carried out by a trained person . Illus.
(4) Operation Test (A) Firmly push switch button to lower load chain until the limit 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. (C) Check the emergency stop device function (if fitted): While holding down either or button on the push button switch, push the emergency stop button. Check that the hook stops when the emergency stop button is pushed.
5. OPERATION After running test and checks have been completed, the hoist will be ready for normal operation. WARNING Since dealing with heavy loads may involve unexpected danger, all of the "SAFETY RULES" (Ref 3.) must be followed and the operator must be aware of the following points while using the hoist. (1) The operator must have a clear and unobstructed view of the entire working area before operating the hoist.
(3) When it is necessary to keep the unit outdoors, a protective covering should be fitted. 6.2 Inspection (1) Daily inspection: Before starting daily operation, check the following (a) Correct power supply. (b) "Up", "Down" and "Emergency stop" (where fitted) test runs under no load. (c) Correct motor performance. (d) No abnormal or excessive noise. (e) No malfunction of the bottom hook safety latch. (f) Proper function of moving/turning parts, limit switches and brake. (g) Well lubricated load chain.
WARNING 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 damage to the hoist unit. To ensure safe and efficient operation, the chain links must be checked for their pitch (inside length), inside width and outside width monthly according to following table.
(c) Limit Switches: A qualified electrician should perform this inspection. Check correct operation of the limit switches. Clean thoroughly and apply a thin lubrication to ensure correct operation. (3) Annual inspection Your dealer should be asked to perform this inspection. (a) Check gearing for any excessive wear or damage. (b) Replace gearbox lubricant completely. (c) Check brake lining and ratchet pawl for any wear or damage. (d) Check operation of pawl spring.
Chain Gauge – Wear and Stretch Measuring (1) The chain gauge is useful and convenience for measuring. (2) Please use a chain gauge to measure the chain pitch and diameter, such as illustrations (1) and (2). (3) Every chain ring must be measured , and the chain must be replaced when one of chain rings is wear or stretch. (4) It will be a cutting-out possibility if you use a chain fall either wear or stretch during operation.
7. TROUBLESHOOTING 7.1 Wiring Diagrams (1) C10011: dual voltage 220V/380V +220V/440V +230V/460V motor lead wiring diagram.----------------------------------------------------------------------------------22 (2) A50143: single speed wiring diagram 230V/110V(with Emergency Stop).
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8. Drawings and parts list (1). VIII- 1 Motor Assembly & Housing Drawing --------------------------------------------- 30 (2). VIII- 1 Motor Assembly & Housing B.O.M ----------------------------------------------- 31 (3). VIII- 2A Hook Assembly 2,2.5,3,5 Tons Drawing ------------------------------------------ 34 (4). VIII- 2A Hook Assembly 2,2.5,3,5 Tons B.O.M ------------------------------------------ 35 (5). VIII- 2B Hook Assembly 7.5 Tons Drawing -------------------------------------------------37 (6).
VIII-1 MOTOR ASS'Y & HOUSING 1 2 3 4 5 16 6 13 17 7 14 18 19 8 9 11 10 15 20 21 10 11 14 12 3 4 5 7 22 23 DU AL SP EE D 8 25 19 26 24 27 12 28 29 38 21 30 21 31 39 32 33 34 35 36 40 37 2 41 42 43 44 39 45 46 39 52 47 48 53 49 54 2 50 55 51 14 15 30 EX190E1
VIII – 1 MOTOR ASSEMBLY & HOUSING S : SINGLE SPEED D : DUAL SPEED Q’TY REQ’D EACH UNIT KEY NO. 1 2 3 4 5 6 7 8 9 10 11 12 PARTS CODE 400014 400095 100424 100425 100490 100495 100395 100409 100406 400237 400239 100414 100498 400193 400141 400200 100325 100324 2T DESCRIPTION Hex. Recess Bolt Spring Washer Motor End Cover 3T S D S 11 4 15 11 1 1 D 1 Spacer Ring Brake Gap Adjuster Brake Drum 1 1 4 15 16 17 18 400006 400264 400220 400221 Hex. Recess Bolt
VIII – 1 MOTOR ASSEMBLY & HOUSING S : SINGLE SPEED D : DUAL SPEED Q’TY REQ’D EACH UNIT KEY NO. PARTS CODE DESCRIPTION 2T S 3T D S 2.5, 5T D S D 7.5T S D 10T S D 28 29 30 31 402507 400084 100339 200308 Gasket 7# Nut
VIII – 1 MOTOR ASSEMBLY & HOUSING S : SINGLE SPEED D : DUAL SPEED KEY NO.
HOOK ASSEMBLY (2, 2.5, 3, 5T) 1 5 1 2 6 2 7 3 4 2T&2.5T 8 9 10 3T&5T 5 11 12 13 14 14 17 15 23 16 24 17 25 18 26 27 19 28 20 29 21 19 22 21 2 20 2T&2.
VIII – 2A HOOK ASSEMBLY(2, 2.5, 3, 5T) S : SINGLE SPEED D : DUAL SPEED Q’TY REQ’D EACH UNIT KEY NO. PARTS CODE 2T DESCRIPTION S 1 2 3 4 200012 200013 1 S 2 2 S D 1 2 2 1 1 200177 Chain Connecting Pin <ø19×70L> 1 200178 Chain Connecting Pin <ø19×72L> 7 5T D 200095 Top Hook Pin <ø34×134L> 6 10 D 200094 Top Hook Pin <ø25×107L> 400603 Cotter Pin <3/32”×1”L> 9 S 3T 1 400301 Safety Latch Ass’y 5 8 D 1 Top Hook 2.5T 1 1 1 2 2 400091 Lock Nut
VIII – 2A HOOK ASSEMBLY(2, 2.5, 3, 5T) S : SINGLE SPEED D : DUAL SPEED Q’TY REQ’D EACH UNIT KEY NO. PARTS CODE DESCRIPTION 2T S 400015 Hex. Recess Bolt 2.5T D S D 3T S 5T D S D 4 18 400018 Hex. Recess Bolt
HOOK ASSEMBLY (7.
VIII – 2B HOOK ASSEMBLY (7.5 T) S : SINGLE SPEED D : DUAL SPEED Q’TY REQ’D EACH UNIT KEY NO. PARTS CODE DESCRIPTION 7.5T S D 1 200162 Side Plate 2 2 200754 Suspended Frame Ass’y 1 3 200119 Idle Wheel’s Axle <ø40×83L> 1 4 400212 Spring Pin <ø5×16L> 2 5 200148 Stay Bolt <ø25×124L> 3 6 200125 Idle Wheel’s Inner Sleeve <ø49.5×ø40.5×5.
VIII – 2B HOOK ASSEMBLY (7.5 T) S : SINGLE SPEED D : DUAL SPEED Q’TY REQ’D EACH UNIT KEY NO. PARTS CODE DESCRIPTION 7.5T S D 25 200762 Bottom Hook Ass’y 1 26 200145 Stay Bolt Sleeve <ø32×ø27×13L> 2 27 200316 Chain Guide(C) 1 28 400091 Lock Nut
HOOK ASSEMBLY (10T) 1 2 3 4 5 6 7 8 9 12 10 11 13 14 20 21 15 22 16 23 17 24 25 18 26 19 4 27 6 28 29 12 30 13 31 10 32 33 34 35 39 36 37 38 40 40
VIII – 2C HOOK ASSEMBLY(10T) S : SINGLE SPEED D : DUAL SPEED Q’TY REQ’D EACH UNIT KEY NO. PARTS CODE DESCRIPTION 10T S D 1 200755 Top Hook Ass’y 1 2 200312 Side Plate Connector 2 3 200174 Side Plate Connector Spacer<ø26.5 P44 t6×50×92L> 4 4 400212 Spring Pin <ø5×16L> 3 5 200149 Side Plate Stay Bolt <ø25×139L> 4 6 400287 Rubber Chain Guide Wheel 8 7 200163 Side Plate 2 8 200120 Idle Wheel Axle <ø40×92L> 1 9 200125 Idle Wheel Inner Sleeve <ø49.5×ø40.5×5.
VIII – 2C HOOK ASSEMBLY(10T) S : SINGLE SPEED D : DUAL SPEED Q’TY REQ’D EACH UNIT KEY NO. PARTS CODE DESCRIPTION 10T S D 24 200763 Bottom Hook Ass’y 1 25 200106 Bottom Hook Side Plate 2 26 200316 Chain Guide(C) 2 27 200144 Bottom Hook Stay Bolt <ø25×169L> 6 28 200145 Stay Bolt Spacer Sleeve <ø32×ø27×13L> 4 29 200314 Chain Guide(A) 2 30 200118 Bottom Hook Idle Wheel Axle <ø40×123L> 2 31 200122 Idle Wheel Inner Sleeve <ø49.5×40.
VIII-3 REDUCING GEAR BOX 1 2 3 4 5 6 7 8 9 13 10 11 12 14 15 16 17 21 18 19 22 20 23 EX190E5 43
VIII – 3 REDUCING GEAR BOX ASSEMBLY S : SINGLE SPEED D : DUAL SPEED Q’TY REQ’D EACH UNIT KEY NO. PARTS CODE DESCRIPTION 2T S 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 400140 400201 400797 200695 400183 200198 200199 400185 407754 200286 Load Sheave D S 2.5, 5T D 1 1 1 1 1 1 1 1 1 1 1 1 S D 7.
LOAD CHAIN SECTION 1 3 4 5 6 2 7 8 9 10 11 12 20 13 14 15 16 17 18 8 19 45
III – 4 LOAD CHAIN SECTION ASSEMBLY S : SINGLE SPEED D : DUAL SPEED Q’TY REQ’D EACH UNIT KEY PARTS NO. CODE DESCRIPTION 2T S 3T D S 2.5T D S 5T D S D 7.5T S 10T D S D 1 400089 Lock Nut 2 2 2 2 2 4 2 400029 Hex. Bolt 2 2 2 2 2 4 3 200203 Chain Regulating Plate 1 1 1 1 1 2 4 400005 Hex. Recess Bolt
VIII-5 ELECTRIC PARTS (Stansard Parts) 12 13 27 25 24 12 5 26 31 23 11 12 4 13 3 2 28 1 20 32 DUAL SPEED 6 3 14 7 8 9 15 10 11 16 12 13 3 19 2 12 13 21 20 17 22 12 26 13 27 25 24 12 23 11 29 12 12 23 13 28 20 Optional 18 30 Optional EX190E7 47
VIII – 5 ELECTRIC ASSEMBLY(Standard Parts) S : SINGLE SPEED D : DUAL SPEED Q’TY REQ’D EACH UNIT KEY NO. PARTS CODE DESCRIPTION 2T S 3T D S 1 2.5, 5T D S 1 D 7.5T S 1 D 10T S 1 D 400222 Cable Gland(M20) 1 400941 Cable Gland(M25) 2 400053 Cross Headed Screw
VIII – 5 ELECTRIC ASSEMBLY(Standard Parts) S : SINGLE SPEED D : DUAL SPEED Q’TY REQ’D EACH UNIT KEY NO. PARTS CODE DESCRIPTION 2T 3T 2.5, 5T 7.5T 10T S D S D S D S D S D 2 3 2 3 2 3 2 3 2 3 20 300363 P.E.R/E.O Box 21 300078 Contactor Rail<1PC> 1 1 1 1 2 22 300079 Contactor Rail<2PC> 1 1 1 1 1 23 400052 Cross Headed Screw
VIII-5-1 ELECTRIC PARTS 12 13 28 27 25 12 5 26 32 24 4 11 3 12 2 13 1 29 33 21 DUAL SPEED 6 3 7 8 9 10 11 14 12 13 17 15 20 12 13 22 18 21 16 23 3 2 28 12 27 13 26 25 12 24 11 30 12 24 12 13 29 21 OPTION 19 31 Optional EX190E7-1 50
VIII – 5 – 1 ELECTRIC ASSEMBLY S : SINGLE SPEED D : DUAL SPEED Q’TY REQ’D EACH UNIT KEY NO. PARTS CODE DESCRIPTION 2T S 3T D S 1 2.5, 5T D S 1 D 7.5T S 1 D 10T S 1 D 400222 Cable Gland(M20) 1 400941 Cable Gland(M25) 2 400053 Cross Headed Screw
VIII – 5 – 1 ELECTRIC ASSEMBLY S : SINGLE SPEED D : DUAL SPEED Q’TY REQ’D EACH UNIT KEY NO. PARTS CODE DESCRIPTION 2T S 3T D S 1 2.5, 5T D S S S Phase Error Relay(P.E.R) 21 300363 P.E.R/E.O Box 22 300078 Contactor Rail <1PC> 1 1 1 1 2 23 300079 Contactor Rail<2PC> 1 1 1 1 2 24 400052 Cross Headed Screw
53 23 24 25 22 26 21 27 25 17 24 13 15 22 20 14 17 16 19 8 24 17 9 25 18 10 27 33 8 25 17 9 39 12 24 11 1 48 47 2 49 38 32 50 51 37 44 25 39 41 38 40 24 7 28 25 42 36 3, 5T 43 6 29 27 35 30 5 31 34 9 4 24 8 45 52 46 3 37 8 LOW HEADROOM MODEL'S TROLLEY EXPLOSION 9 34 42 36 2, 2.
VIII – 6 LOW HEADROOM MODEL’S TROLLEY Q’TY REQ’D EACH UNIT NO PART NO PART NAME 2T 2.5T 3T 1 400399 Stay Bolt <7/8”×9UNC×220L > 2 2 400070 Hex. Nut <7/8”×9UNC > 4 3 203221 Spacer Washer <ø40×ø24×1/8”> 4 4 202804 Counter Weight Block 2 400046 Hex. Bolt 400047 Hex. Bolt 6 400096 Spring Washer 4 7 101295 Motor 1 8 400006 Hex. Recess Bolt
400495 Hex. Bolt <1 1/2”×13”L> 2 VIII – 6 LOW HEADROOM MODEL’S TROLLEY. Q’TY REQ’D EACH UNIT NO PART NO PART NAME 2T 24 25 26 27 28 29 30 31 400176 400169 408051 400174 Needle Bearing Needle Bearing Needle Bearing Needle Bearing 4 202814 202815 200110 200111 400072 Sprocket Axle <ø25×88L> Sprocket Axle <ø40×99L> Sprocket <ø38×42L> Sprocket <ø50×51L> Hex. Nut <1 1/4”× 7UNC> 1 400073 400105 400106 Hex.
202822 2 VIII – 6 LOW HEADROOM MODEL’S TROLLEY Q’TY REQ’D EACH UNIT NO PART NO PART NAME 2T 2.5T 3T 38 400617 Cross Head Screw 2 39 300534 Limit Switch 1 202816 Load Sprocket Axle <ø26×80L> 202817 Load Sprocket Axle <ø40×91L> 41 200636 Key Plate <ø8.5 P28 t6.0×25×50L> 1 42 400011 Hex. Recess Bolt 2 43 400340 Compressing Spring 4 40 1 1 1 202841 202781 1 1 202840 44 5T 1 Limit Plate 1 202782 45 46 47 48 49 50 1 400085 Nut
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CONFORMITY DECLARATION DECLARATION OF CONFORMITY CHENG DAY MACHINERY WORKS CO., LTD. 173 WEN CHIU ROAD, TA CHIA CHEN, TAICHUNG HSIEN, TAIWAN R.O.C.
