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USER AND SERVICE MANUAL
FOR EXE-RISE CHAIN HOIST
[ORIGINAL INSTRUCTION]
250/500/1000/2000 kg
150/300/600/800/1200 kg
EXCLUSIVELY DISTRIBUTED BY
LITEC ITALIA S.R.L.
Via Martin Luther King 70, I-31032 Casale sul Sile (TV), Italy
Tel: +390422997300 Fax: +390422997399
D8
(DC/LVC)
D8+
(DC/LVC)
www.exetechnology.com
www.litectruss.com
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Summary of Contents for EXE RISE D8
- Page 1 USER AND SERVICE MANUAL FOR EXE-RISE CHAIN HOIST 250/500/1000/2000 kg (DC/LVC) 150/300/600/800/1200 kg (DC/LVC) EXCLUSIVELY DISTRIBUTED BY LITEC ITALIA S.R.L. Via Martin Luther King 70, I-31032 Casale sul Sile (TV), Italy Tel: +390422997300 Fax: +390422997399 www.exetechnology.com www.litectruss.com [ORIGINAL INSTRUCTION]...
- Page 2 MANUFACTURER IDENTIFICATION RWM S.R.L. Sede Legale: Via Bartolomeo Colleoni 80/7, 36034 Malo (VI), Italia Sede Operativa: Via della Tecnica 15, 36034 Molina di Malo (VI), Italia Tel: +39 0445 637 002 – Fax: +39 0445 637 019 www.rwmitalia.com Retain this manual for future reference and use. Forward this manual to the chain hoist operator and maintainer.
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Page 3: Table Of Contents
CONTENT CONTENT OF FIGURES..............................5 CONTENT OF TABLE ..............................6 GENERAL INFORMATION ........................... 7 MANUAL SCOPE ............................7 CHAIN HOIST IDENTIFICATION ........................ 8 SAFETY SIGNAL ............................9 TERMS AND DEFINITIONS ......................... 9 REPAIRING – REPLACEMENT – WARRANTEE POLICY ..............10 DOCUMENTATION............................ - Page 4 Secondary Safety Component ......................34 3.4.2 3.4.3 Safety Conditions ..........................35 TECHNICAL DATA ............................36 EXE-Rise DRAWING ........................... 39 HANDLING AND INSTALLATION ........................41 HANDING & TRANSPORTATION ......................41 TRANSPORT AND STORAGE ........................42 Packaging storage ..........................42 4.2.1 4.2.2 Unpacking and ground handling of the hoist ...................
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Page 5: Content Of Figures
Chain dimensions Figure 6 Chain identification Lift chain hook with safety latch” D8 250 kg and D8+ 150 kg - D8 500 kg and D8+ 300kg Figure 7 “Lift chain hook with safety latch” D8 1000 kg and D8+ 600 kg Figure 8 “Lift chain hook with safety latch”... -
Page 6: Content Of Table
Spare Part of D8 250kg DC/LVC and, D8+ 150kg DC/LVC Table 24 Spare Part of D8 500kg DC/LVC and, D8+ 300kg DC/LVC Table 25 Spare Part of D8 1000kg DC/LVC, D8 2000kg DC/LVC and D8+ 600kg DC/LVC, D8+ 1200kg DC/LVC 6 / 64... -
Page 7: General Information
1. GENERAL INFORMATION Thank you for choosing an EXE-Rise chain hoist. MANUAL SCOPE Scope of manual is to inform operator about properly install, operate of chain hoist to prevent and minimize risks during the man-machine interaction. In addition, the manual contains also information confidential to the maintainer to perform maintenance work. -
Page 8: Chain Hoist Identification
CHAIN HOIST IDENTIFICATION EXE-Rise chain hoists are marked on the body by an aluminium plate visibly, legibly and indelibly with dimensions 90x90 mm and thickness 0.8 mm. Figure 1 “Example of EXE-Rise chain hoist plate” The title of plate contains the business name and full address of the manufacturer, designation of the machinery and website. -
Page 9: Safety Signal
SAFETY SIGNAL The present manual contains different safety signal to individuate and to point out precautionary statements. The safety signals are sentences providing information on potential hazards, and proper procedures, as is provided below: DANGER: indicates a hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. -
Page 10: Repairing - Replacement - Warrantee Policy
REPAIRING – REPLACEMENT – WARRANTEE POLICY REPAIRING AND REPLACEMENTE POLICY The hoist has been checked and performance verified by RWM S.r.l. or one of its authorised service agents before shipping. If the correctly maintained hoist should present a performance problem due to faulty material or workmanship, after inspection by RWM S.r.l. - Page 11 WARRANTY LIMITATIONS, REMEDIES AND DAMAGES This warranty does not apply where normal wear, abuse, improper or inadequate maintenance, eccentric or side loading, overloading, chemical or abrasive actions, excessive heat, outdoor use without appropriate measures or unauthorised modifications or repairs cause deterioration of the hoists. This warranty does not apply to products which RWM S.r.l.
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Page 12: Documentation
DOCUMENTATION The manual is integral part of EXE-Rise chain hoist and it contains the following documents attached: Declaration of conformity of EXE-Rise chain hoist; Declaration of conformity of chain; Declaration of conformity of hook; Wiring Diagrams; Data sheet of EXE-Rise chain hoist. These documents are an integral part of the manual and they are an integral part of the hoist. -
Page 13: Safety Information
2. SAFETY INFORMATION GENERAL SAFETY WARNING Indicated below are the structural and environmental requirements that must be checked by the user for guaranteeing safe use of the hoist: The user is responsible for the construction method used for the set-up structure, the related load capacity and the conditions of the suspension points arranged in the place of use. - Page 14 The hoist must be used with a control system that meets local electrical safety regulations. The operational parameters do not allow, but are not limited to: exceeding the defined load capacity any lateral load to be applied the hoist body any side pull to be applied the lift chain heaving, pulling or dragging the load standing beneath suspended and/or lifted loads...
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Page 15: Safety Warning For Installation, Assembly And Disassembly
Secure the load with a secondary device before entering the area beneath the suspended load . or use D8+ hoist with EXE-Load cells. Depending on local legislation and the outcome of a risk assessment the hoist may be left without these precautions. -
Page 16: Safety Warning For Incorrect Use
This manual gives the necessary information for safe installation, use, and maintenance in a generic working environment. Since it is not possible to foresee all the risk conditions of the working environments in which the hoist will be used, the person responsible for the management and supervision of the installation, assembly and disassembly must produce their own specific risk assessment each time the hoists are used. -
Page 17: Safety Warning For Residual Risks
Do not remove or tamper with the protective and safety devices Use of the hoist is prohibited to unauthorised operators who are not adequately trained in use of the hoist and the associated dangers. Do not use of the hoist outside the limits indicated in this document. Make sure the chain is running straight into the hoist body. -
Page 18: Safety Warning For Eletrical Connection
Residual risk, dangerous zone Course of action to eliminate or reduce risk and person exposed Do not insert the hoist power plug directly into a CEE socket. The hoist may only be powered using suitable control devices, such as Sudden start owing to the insertion EXE-DRIVE controllers. -
Page 19: Exe-Rise Chain Hoist Information
3. EXE-Rise CHAIN HOIST INFORMATION The intended use of EXE-Rise chain hoist is to vertically lift loads or hold loads once lifted within the rated capacity of the model selected. They can be installed either as a fixed device or can be mobile. GENERAL DESCRIPTION ... -
Page 20: Identification
= 100 m / 220 lbs (XL) chain bag size Table 4 “EXE-Rise chain hoist identification” For example LT XRH1D100DB-20M is EXE-Rise chain hoist D8 bouble brake direct control with WLL 1000kg, chain bag size M and with 20m of chain. 20 / 64... -
Page 21: Type Of Control
EXE-Rise Chain hoist models are based on a German standard that differentiates between three types of electric chain hoists: D8 Hoist Electric chain hoist according to DGUV 115 (formerly known as BGV D8) "Winches, lifting and pulling devices") for use as a chain hoist for lifting loads in construction. D8 Plus Hoist Electric chain hoist based on DGUV 115 "Winches, lifting and pulling devices"... -
Page 22: Table 7 Average Operating Time Per Day In Hours
Load spectrum Average operating time per day in hours ≤0.25 ≤0.5 ≤1 ≤2 ≤4 ≤8 ≤16 Light Moderate Heavy Very Heavy Table 7 “Average operating time per day in hours” Direct control hoists The terms direct control (DC) and low-voltage controlled (LVC) refer to the system used to manage hoist movement, not to the power supply voltage. -
Page 23: Components Description
chain will continue to travel through the hoist in the chosen direction until it reaches a mechanical stop on the chain, or until the electrical limit switch reaches its pre-set end point. Once the limit switch is activated the hoist can only be run by reversing the direction of travel. Any control unit used to power EXE-Rise LVC hoists must provide an "un-inverted"... -
Page 24: Chain
The chain used for EXE-Rise chain hoist is in Zinc Galvanized Steel EN DIN 818-7 (grade of steel: 80). There are five measures in order to hoist chain of destination: CHAIN SF-8 4x12 mm D8 250 kg D8+ 150 kg 6x18 mm D8 500 kg D8+ 300 kg... -
Page 25: Hook
D8 250 kg and D8+ 150 kg - D8 500 kg and D8+ 300 kg DIMENSIONS [ mm ] Figure 7. “Lift chain hook with safety latch” D8 250 kg and D8+ 150 kg - D8 500 kg and D8+ 300 kg D8 1000 kg and D8+ 600 kg DIMENSIONS [ mm ] Figure 8. -
Page 26: Figure 9 "Lift Chain Hook With Safety Latch" D8 2000 Kg And D8+ 1200 Kg
D8 2000 kg and D8+ 1200 kg DIMENSIONS [ mm ] Figure 9. “Lift chain hook with safety latch” D8 2000 kg and D8+ 1200 kg The standard ingress protection Level of IP55 means that when the hoist is used in wet environments, adequate protection of the hoist body is required. -
Page 27: Chain Bag Bracket
3.3.3 Chain Bag Bracket The chain-bag bracket allows the hoist to be used motor up or down. The design ensures the bag is positioned correctly to accept chain without the need for any adjustment, reducing the chance of chain spills. 3.3.4 Chain Stop Fits below dead end link on lifting chain for added measure of safety. -
Page 28: Chain Guide Plate
Manufactured according to BGV C-1. It has a compact shape, is galvanized and stamped with the DIN standard, manufacturer´s name and the carrying capacity. Figure 13 “End chain – bracket Quick Link dimension” weight Litec Code Chain size [mm] [kg] [mm] [mm] [mm]... -
Page 29: Plugs And Socket
3.3.7 Plugs and Socket Plugs and sockets are produced from POLYAMIDE 6 as well as PC/ABS. The main characteristics of these materials are: excellent impact resistance combined with high rigidity and solidity, high thermal stability (self-extinguishing), very good insulating qualities, high disruptive strength, high abrasion resistance, high weathering resistance,... -
Page 30: Limit Switch
D8 250 kg D8 500 kg D8 1000 kg D8 2000 kg hoist D8+ 150 kg D8+ 300 kg D8+ 600kg D8+ 800 kg - 1200 kg DC Brake Size DC Brake Power DC Brake 105VDC 105VDC 105VDC Operating Voltage... -
Page 31: Bolts And Nuts
Figure 19 “Chain bag” SPECIFICATIONS CHAIN BAG XS CHAIN BAG S CHAIN BAG M CHAIN BAG L CHAIN BAG XL Litec Code CHB029 CHB024 CHB025 CHB026 CHB027 External 14x9 20x17 20x17 20x17 27x21 Dimensions [cm] Height [cm] ≈ 0.75 ≈ 1.00 ≈... -
Page 32: Exe-Rise Chain Hoist Controllers
3.3.12 EXE-Rise Chain Hoist Controllers More EXE-Rise Chain hoists shall be operated by controllers designed and specified for this purpose. We advise to use the EXE-DRIVE range controllers for proper use of your EXE-Rise chain hoist. The use of other brands, in alternative to EXE-DRIVE controllers is not recommended unless they comply with the applicable directives and standards. -
Page 33: Safety Device
Removal of these guards and safety devices should only be allowed during maintenance by competent and authorised persons and in controlled conditions. Chain guide plate EXE Rise chain hoists are fitted with a special plastic chain guide plate that provides various safety functions. Prevents accidental contact with the internal moving parts. -
Page 34: Secondary Safety Component
3.4.2 Secondary Safety Component A secondary safety component is a second independent suspension element of equivalent capacity to the primary suspension point, which is intended to prevent the fall of the load should the primary point fail. Some application examples are illustrated here below. When operating a system according to the German DGUV V54 standard, or if maintenance is required on a hoist that is still suspended, a secondary safety device should be used. -
Page 35: Safety Conditions
Figure 23: Example of a secondary safety component attached below the hoist, bypassing the hoist lifting mechanism (front view) Figure 24: Example of a secondary safety component attached below the hoist, bypassing the hoist lifting mechanism (perspective view) Never use a chain clutch to connect the hoists lifting chain to a safety device. A lateral load to the lifting chain can easily lead to failure. -
Page 36: Technical Data
TECHNICAL DATA power cable fitted with CEE 16A 6h 400VAC – 3PH +G black plug. 4 x 1.5 mm control cable fitted with CEE 16A 4h 24VAC – 3PH +G black plug (LVC only). 4 x 1.5 mm Internal 25VA transformer: 400VAC on the primary windings, and 24VAC on the secondary windings. - Page 37 MODEL D8 DC / LVC D8 250kg D8 500kg D8 1000kg D8 2000kg Hoist Specifications Hoist Specifications Hoist Specifications Hoist Specifications Hoist Specifications Working Load Limit (WLL) 250kg 500kg 1000kg 2000kg Lifting Speed @50Hz 4m/min 4 m/min 4m/min 4 m/min Motor Power 0.5 kW...
- Page 38 MODEL D8+ DC / LVC D8+ 150kg D8+ 300kg D8+ 600kg D8+ 800kg - 1200kg Hoist Specifications Hoist Specifications Hoist Specifications Hoist Specifications Hoist Specifications Working Load Limit (WLL) 150kg 300kg 600kg 800kg 1200kg Lifting Speed @50Hz 4m/min 4m/min 4m/min...
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Page 39: Exe-Rise Drawing
EXE-Rise DRAWING 250kg D8 DC/LVC and 150kg D8+ DC/LVC Figure 25: “EXE-Rise DRAWING: 250kg D8 DC/LVC and 150kg D8+ DC/LVC” 500kg D8 DC/LVC and 300kg D8+ DC/LVC Figure 26: “EXE-Rise DRAWING: 500kg D8 DC/LVC and 300kg D8+ DC/LVC” 39 / 64... -
Page 40: Figure 28 Exe-Rise Drawing: 2000Kg D8 Dc/Lvc And 1200Kg D8+ Dc/Lvc
1000kg D8 DC/LVC and 600kg – 800kg D8+ DC/LVC Figure 27: “EXE-Rise DRAWING: 1000kg D8 DC/LVC and 600kg – 800kg D8+ DC/LVC” 2000kg D8 DC/LVC and 1200kg D8+ DC/LVC Figure 28: “EXE-Rise DRAWING: 2000kg D8 DC/LVC and 1200kg D8+ DC/LVC”... -
Page 41: Handling And Installation
4. HANDLING AND INSTALLATION When handling and unpacking the hoist you should use safe handling techniques. Electric chain hoists must be assembled by qualified personnel. Always refer to your local areas manual lifting directives, as well those mentioned in this manual. Should the electric chain hoist be destined for operation outdoors then it is necessary to use a protection cover to shield it from the effects of the weather. -
Page 42: Transport And Storage
It is advised to transport the electric chain hoist in its original packaging or a dedicated flight case. Before putting your EXE Rise hoist in storage make sure all components are dry Use flight cases with ventilation openings for all compartments... -
Page 43: Suspending The Hoist
SUSPENDING THE HOIST It is the user’s responsibility to ensure all hanging points, lifting hardware and control systems are inspected and tested prior before use. Cables must be placed in such a way that they do not come into contact with sharp edges and do not run the risk to be cut off or damaged. -
Page 44: Electrical Connections
EXE Rise hoists are factory set to be run with a voltage of 400 V AC. The DC hoist is fitted with a CEE 16A 6h 400VAC – 3PH +G black plug. plug as standard. The LVC hoist comes with a CEE 16A 4h 110VAC - 3PH +G black socket. -
Page 45: Use
Do stay clear of moving chains. Do ensure chain is lubricated at all times. Call your EXE Rise supplier if the hoist does not work properly. If damaged or worn parts are detected do not use the hoist. Seek assistance for service of the unit. -
Page 46: Attaching And Moving The Load
ATTACHING AND MOVING THE LOAD Insert the lifting hook into the load pick-up point. Make sure chain travel is in the same direction as shown on the controls. Check to be sure that the attachments to the load hook are firmly seated. Make sure the hook latches are closed and not supporting any part of the load. -
Page 47: Limit Switch Setting And Replacement
24.5 metres. TURN 1000kg SINGLE REEVE IN 2000kg DOUBLE REEVE EXE-Rise chain hoist D8 1000kg single reeve (DC and LVC) can be turned in D8 2000kg double reeve (DC and LVC). The procedure to be performed is reported below: 1) Make sure the lifting chain is just 100cm long before modifying the hoist. -
Page 48: Figure 33 Removing The Frame Block
4) Remove the lifting hook. 5) Remove Aluminum Frame Block (see figure 34). Figure 33: “Removing the Frame Block” 6) Feed the lifting chain through the new lift hooks pulley. Make sure the chain is not twisted (see figure 35). Figure 34: “Replacement of the Chain hook”... -
Page 49: Inspections
6. INSPECTIONS For a correct and safe use of EXE-Rise chain hoist it’s important to carry out appropriate inspections and control. RWM recommended to comply with the frequency of inspections and follow the check reported in this chapter. INITIAL AND EACH ASSEMBLY INSPECTION AND CONTROLS The purpose of the following test and inspection is to ensure the hoist has been correctly assembled, installed, is not damaged and is safe to use. -
Page 50: Frequent And Periodical Inspection
FREQUENT AND PERIODICAL INSPECTION Here the term inspection refers to the visual examination of the hoist and its accessories. In order to keep a continuous and satisfactory operation inspection intervals must be determined by the individual application and are based on the type of service to which the hoist will be subjected and the degree of exposure to wear, deterioration or malfunction of the critical components. -
Page 51: Chain Inspection
TYPE OF SERVICE ITEM Severe a) All items listed in Table 8 for frequent inspections. Normal Heavy b) External evidence of loose screws, bolts, nuts. c) External evidence of worn, corroded, cracked or distorted hook block, suspension screw, bearings and dead end block and chain pin. d) External evidence of damage to hook retaining nut and pin. -
Page 52: Figure 36 External Chain Guide Plate
Particular attention should be paid to the condition of all bolts and safety components. If defects are discovered the hoist must be taken out of service and repaired immediately. TIP! To detect surface damage and deformations on the external surfaces of the links, use a piece of cotton fabric and pull the chain through. -
Page 53: Hook Inspection
The clutch settings of the EXE RISE hoist are set at 120% of the nominal load to meet the German standards for the use of hoists above people. Due to the nature of the clutches and the above conditions, these settings can vary easily by +/- 10%... -
Page 54: Extraordinary Inspection
EXTRAORDINARY INSPECTION In case of extraordinary events which can jeopardise the safety of the working equipment, extraordinary testing must be carried out. In particular, extraordinary events include accidents, modifications to the hoist, prolonged downtime periods and natural phenomena. Testing must be carried out only by authorised personnel, duly authorised for the purpose. In addition to the above inspection and testing procedure, a preventive maintenance program should be established to prolong the useful life of the hoist and maintain its reliability and continued safe use. -
Page 55: Maintenance And Repair
7. MAINTENANCE AND REPAIR Visual inspection and testing of the hoist and lubricating the chain are the only interventions that should be undertaken by the user of the hoist. All other maintenance, replacement, adjustment interventions that involve the opening of the hoist housing should only be carried out by RWM authorised service engineers. -
Page 56: Brake And Limit Switch Maintenance / Adjustment
links are those links which stop on, resp. immediately at the inlet of the drive and reversing wheels at constant stroke when switching from lifting to lowering. These chain links are charged especially heavy by dynamic vibrations and have therefore to be lubricated carefully in shorter intervals. The choice of a suitable lubricant is dependent from the operating place and the existent environment conditions. -
Page 57: Clutch And Grear Box Maintenance / Adjustment
CLUTCH AND GREAR BOX MAINTENANCE / ADJUSTMENT Any intervention on the clutch is prohibited. Only RWM authorised service engineers are allowed to carry out maintenance work on clutches. Do not use any kind of fluid or spray which causes a lubrication effect on the clutch friction disk. For cleaning use a resolving agent suitable for the application. - Page 58 6) Hook does a) Brake slipping. a) Check brake. not stop b) Excessive load. b) See item 1H promptly a) Excessive load a) See item 1H b) Low voltage b) Correct low voltage condition. 7) Hoist operates c) Phase failure or unbalanced current in the c) See item 1b.
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Page 59: Spare Part
8. SPARE PART 250kg D8 DC/LVC and 150kg D8+ DC/LVC Figure 39: “Spare Part of D8 250kg DC/LVC and D8+ 150kg DC/LVC” CODE DESCRIPTION CODE DESCRIPTION COVER GEAR BOX COVER ROTOR BRAKE FLANGE STATOR GEAR BOX HOUSING BRACKET GEAR BOX FLANGE... -
Page 60: Table 24 Spare Part Of D8 500Kg Dc/Lvc And, D8+ 300Kg Dc/Lvc
500kg D8 DC/LVC and 300kg D8+ DC/LVC Figure 40: “Spare Part of D8 500kg DC/LVC and D8+ 300kg DC/LVC” CODE DESCRIPTION CODE DESCRIPTION COVER GEAR BOX COVER ROTOR BRAKE FLANGE STATOR GEAR BOX HOUSING BRACKET GEAR BOX FLANGE FRAME BLOCK... -
Page 61: Table 25 Spare Part Of D8 1000Kg Dc/Lvc, D8 2000Kg Dc/Lvc And D8+ 600Kg Dc/Lvc, D8
1000kg D8 DC/LVC and 600kg D8+ DC/LVC 2000kg D8 DC/LVC and 1200kg D8+ DC/LVC Figure 22: “Spare Part of D8 1000kg DC/LVC, D8 2000kg DC/LVC and D8+ 600kg DC/LVC, D8+ 1200kg DC/LVC” CODE DESCRIPTION CODE DESCRIPTION COVER GEAR BOX COVER... -
Page 62: Demolition And Disposal
9. DEMOLITION AND DISPOSAL Before carrying out demolition and disposal of the hoist, complete the working cycle and disconnect power. Upon demolition, plastic parts must be separated from electric components and must be sent to selective collections according to regulations in force. With regard to metal housing, aluminium parts should be separated from all other metals before sending for recycling. -
Page 63: Declaration Models
10. DECLARATION MODELS The declaration of conformity completed, dated and signed is attached to this manual. This document is integral part of the manual. 63 / 64... - Page 64 EXE-RISE CHAIN HOIST IS EXCLUSIVELY DISTRIBUTED BY LITEC ITALIA S.R.L. Via Martin Luther King 70, I-31032 Casale sul Sile (TV), Italy Tel: +390422997300 Fax: +390422997399 www.exetechnology.com www.litectruss.com 64 / 64...
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