Duke DU903, Operation Manual

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Page 2: ...acteristics 9 3 1 1 Usages 9 3 1 2 Features 9 3 2 Specifications 10 3 3 Overall dimensions 11 3 4Working space required and operating position 12 3 5 Main units and name 13 4 Pre use Preparation 14 4...

Page 3: ...Observing these instructions helps to avoid danger to reduce repair costs and downtimes and to increase the reliability and life of the winch The instruction manual is to be supplemented by the respec...

Page 4: ...s are tightened securely without loosening 10 Before operating the electric hoist check to see if the chain runs to the correct direction and the brake works normally 11 Do not allow any person approa...

Page 5: ...ace a new one immediately and please note its original rated specification 7 After connecting power check the direction of motor rotation and the direction of hoist is correct or not 8 Please check wh...

Page 6: ...examine and repair it 5 If abnormal temperature phenomenon happens during operation operator should stop the hoist immediately and then examine and repair it 6 Don t modify the original design of mec...

Page 7: ...Page 7 2 2 All safety related elements ITEM DESCRIPTION 1 EMERGENCY STOP 2 FUSE 3 Chain Guide Spring 1 2 3...

Page 8: ...requency and phase marked correctly YES 10 Is the machine earthed YES 11 Is there an independent earth copper plate equipped inside electric box YES 12 Is every function of control device regular YES...

Page 9: ...reated for strength and durability the ball or needle bearings at all rotating points run in oil bath lubrication for a quieter smoother and cooler operation Loading sheave Provide smooth lifting redu...

Page 10: ...idth mm 212 214 Height mm 535 675 Capacity kg 1000 2000 Standard Lift m Control Cable m 3 3 Lifting Speed m min 50HZ 4 60HZ 5 50HZ 2 60HZ 2 5 Chain mm 7 1x20 7 1x20 Safety Factor WLL x 1 25 Insulation...

Page 11: ...Page 11 3 3 Overall dimensions MODEL Length Width Height DU 903 456mm 212mm 535mm DU 904 456mm 214mm 675mm...

Page 12: ...Page 12 3 4Working space required and operating position FRONT OPERATOR TopView 1500mm 1500mm 1500mm 1500mm FRONT OPERATOR...

Page 13: ...Page 13 3 5 Main units and name Item Part s name 1 Electric Department 2 Motor 3 Chain 7 1mm x 20mm 4 Lower Hook 5 Chain bag 6 Gear Box 7 Upper Hook 1 2 3 4 7 6 5...

Page 14: ...nimpaired tools wire yarns waste etc 4 1 2 Electrical Check 1 Are all ground conductors connected 2 Are all cables connected 3 Is there any mechanical damage of electrical control operating and indica...

Page 15: ...well lighting well ventilation clean environment dry and maintains a normal temperature The winch needs the following supplies Electric power single phase 220 240V 50Hz and 60Hz or base on previous de...

Page 16: ...and Dismantle 5 1 Transport Always carry the winch with two hands to prevent a strike Below table shows net weight and gross weight for each model of winch MODEL NET WEIGHT GROSSWEIGHT DU 903 23 KGS...

Page 17: ...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 cable...

Page 18: ...b 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...

Page 19: ...or using one or more slings 10 Run the chain up until the load chain just taut 11 Check all lifting and slinging connections and lift the load until it is freely floating of the ground 12 Visually ch...

Page 20: ...e 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 lo...

Page 21: ...ns of the load and working frequency During long operating periods make sure to use the hoist within its continuous rating Continuous Rating means the amount of allowable usage within one hour which i...

Page 22: ...e is prohibited from operating machine Preparation before Working3 Working Me Check all safety and environmental conditions Connect the main power source and ensure grounding Do not lift loads exceedi...

Page 23: ...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 t...

Page 24: ...erating 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 Record...

Page 25: ...of wear or damaged links e Load chain for proper reeving and twists Minimum Periodic Inspections TYPE OF SERVICE ITEM Normal Heavy Severe a All items in minimum frequent inspections b External eviden...

Page 26: ...e 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 Re...

Page 27: ...and let the chain hang dripping for 24 hours before putting in the hoist Note In the entertainment industry chain wear in general is only very limited and often even impossible to measure after 10 yea...

Page 28: ...r up position run the hook to its up limit 2 Remove the load block assembly from the old chain 3 Make a C link attach the new chain to the load end of the old chain 4 Carefully jog the UP button and r...

Page 29: ...end 8 Attached the chain stop and load block assembly Be sure there are no twists in the chain CHAIN END STOP The end stop on the dead end chain should be mounted on the 11th link No less than 11 lin...

Page 30: ...engineered for low maintenance and also serve as an overload protection Hook a load of 1 25 times the nominal load into the hoist SIGNS OF INADEQUATE ELECTRICAL POWER The hoist must be supplied with...

Page 31: ...wiring for relay rectifier 2 Hook does not stop promptly A Chain hoist overloaded A Reduce load within rated capacity of chain hoist B Brake not holding B Check brake and it may be necessary to repla...

Page 32: ...o 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...

Page 33: ...e 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 pow...

Page 34: ...Page 34 8 Drawings and Parts List 8 1 Assembly drawings and part list MODEL DU 903 Assembly Drawing...

Page 35: ...N 65 SNAP RING 112 CHAINBAG 19 CARBON BRUSH SET PROTECTION 66 BEARING 112 1 BOLT 20 SCREW 67 CHAIN SHEAVE 112 2 NUT 21 BINDER OF CABLE 68 LOAD CHAIN 113 SWITCH CONTACTOR 22 LANYARD CLIP 69 NUT 114 SWI...

Page 36: ...Page 36 MODEL DU 904 Assembly Drawing...

Page 37: ...N 57 GEAR COVR 98 BRAKE PAWL SET 19 CARBON BRUSH SET PROTECTION 58 SCREW 99 BEARING 20 SCREW 59 NUT 100 OIL SEAL 21 BINDER OF CABLE 60 SCREW 101 GEAR 22 LANYARD CLIP 61 LEFT MAIN BODY SHEET 102 SNAP R...

Page 38: ...Page 38 8 2 Electrical system drawings and part list MODEL DU 903 DU 904 Electrical System Drawings...