EXE RISE D8 Troubleshooting guide

USER AND SERVICE MANUAL

FOR EXE-RISE CHAIN HOIST

250/500/1000/2000 kg

D8 (DC/LVC)

150/300/600/800/1200 kg

D8+ (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]

2 / 64

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.

Should you have any questions or have problems with this product, please call RWM S.r.l..

Check the EXE website for the latest version of the manual or the manual related to the year of purchase

of your hoist.

Before using the hoist, please fill in the following information (referred to the hoist identification plate).

Such information must be communicated every time that the RWM S.r.l service department or your local

distributor is contacted. If you are in doubt or need any further information, please contact us.

Customer Name

and address (1)

Customer Name

and address (2)

Model number

Instructions for use

Serial number

Purchase date

Voltage

Nominal capacity

Revision

Modifications

Description

Issue Date

All manual

First issue in according to Machine Directive 2006/42/CE

29/11/2017

All manual

Update information

28/02/2018

Do not use a chain hoist before all operators have carefully read this manual.

Failure to operate the equipment as here described may cause injury or even death.

3 / 64

CONTENT

CONTENT OF FIGURES................................................................................................................................................ 5

CONTENT OF TABLE..................................................................................................................................................... 6

1. GENERAL INFORMATION ................................................................................................................................... 7

1.1 MANUAL SCOPE........................................................................................................................................... 7

1.2 CHAIN HOIST IDENTIFICATION ................................................................................................................ 8

1.3 SAFETY SIGNAL ........................................................................................................................................... 9

1.4 TERMS AND DEFINITIONS......................................................................................................................... 9

1.5 REPAIRING –REPLACEMENT –WARRANTEE POLICY.................................................................. 10

1.6 DOCUMENTATION...................................................................................................................................... 12

2. SAFETY INFORMATION..................................................................................................................................... 13

2.1 GENERAL SAFETY WARNING................................................................................................................. 13

2.2 SAFETY WARNING FOR USE AND MAINTENANCE.......................................................................... 13

2.3 SAFETY WARNING FOR INSTALLATION, ASSEMBLY AND DISASSEMBLY................................ 15

2.4 SAFETY WARNING FOR INCORRECT USE ......................................................................................... 16

2.5 SAFETY WARNING FOR RESIDUAL RISKS ......................................................................................... 17

2.6 SAFETY WARNING FOR ELETRICAL CONNECTION.......................................................................... 18

3. EXE-Rise CHAIN HOIST INFORMATION......................................................................................................... 19

3.1 GENERAL DESCRIPTION ......................................................................................................................... 19

3.2 IDENTIFICATION......................................................................................................................................... 20

3.2.1 Type of Control..................................................................................................................................... 21

3.3 COMPONENTS DESCRIPTION................................................................................................................ 23

3.3.1 Chain ..................................................................................................................................................... 24

3.3.2 Hook....................................................................................................................................................... 25

3.3.3 Chain Bag Bracket............................................................................................................................... 27

3.3.4 Chain Stop............................................................................................................................................ 27

3.3.5 Quick Link –Quick link........................................................................................................................ 27

3.3.6 Chain Guide Plate................................................................................................................................ 28

3.3.7 Plugs and Socket................................................................................................................................. 29

3.3.8 Brake ..................................................................................................................................................... 29

3.3.9 Limit switch................................................................................................................................................. 30

3.3.10 Chain Bag ................................................................................................................................................ 30

3.3.11 Bolts and nuts............................................................................................................................................ 31

3.3.12 EXE-Rise Chain Hoist Controllers..................................................................................................... 32

3.4 SAFETY DEVICE......................................................................................................................................... 33

3.4.1 Primary Safety Component................................................................................................................ 33

4 / 64

3.4.2 Secondary Safety Component........................................................................................................... 34

3.4.3 Safety Conditions................................................................................................................................. 35

3.5 TECHNICAL DATA ...................................................................................................................................... 36

3.6 EXE-Rise DRAWING................................................................................................................................... 39

4. HANDLING AND INSTALLATION...................................................................................................................... 41

4.1 HANDING & TRANSPORTATION............................................................................................................. 41

4.2 TRANSPORT AND STORAGE .................................................................................................................. 42

4.2.1 Packaging storage............................................................................................................................... 42

4.2.2 Unpacking and ground handling of the hoist ................................................................................... 42

4.3 SUSPENDING THE HOIST........................................................................................................................ 43

4.3.1 Mounting the hoist “motor-down” (self-climbing mode).................................................................. 43

4.3.2 Mounting the hoist in “motor-up“ position......................................................................................... 43

4.4 ELECTRICAL CONNECTIONS................................................................................................................. 44

5. USE......................................................................................................................................................................... 45

5.1 ATTACHING AND MOVING THE LOAD.................................................................................................. 46

5.2 LOWERING AND DISCONNECTING THE LOAD.................................................................................. 46

5.3 LIMIT SWITCH SETTING AND REPLACEMENT................................................................................... 47

5.4 TURN 1000kg SINGLE REEVE IN 2000kg DOUBLE REEVE............................................................. 47

6. INSPECTIONS ...................................................................................................................................................... 49

6.1 INITIAL AND EACH ASSEMBLY INSPECTION AND CONTROLS..................................................... 49

6.2 FREQUENT AND PERIODICAL INSPECTION....................................................................................... 50

6.2.1 Chain Inspection .................................................................................................................................. 51

6.2.2 Hook Inspection ................................................................................................................................... 53

6.2.3 Chain Bag Inspection.......................................................................................................................... 53

6.3 PERIODICAL CONTROLS ......................................................................................................................... 53

6.4 EXTRAORDINARY INSPECTION............................................................................................................. 54

7. MAINTENANCE AND REPAIR........................................................................................................................... 55

7.1 CHAIN MAINTENANCE .............................................................................................................................. 55

7.1.1 Cleaning Chain..................................................................................................................................... 55

7.1.2 Lubrication of Chain............................................................................................................................. 55

7.2 BRAKE AND LIMIT SWITCH MAINTENANCE / ADJUSTMENT.......................................................... 56

7.3 CLUTCH AND GREAR BOX MAINTENANCE / ADJUSTMENT .......................................................... 57

7.4 TROUBLESHOOTING................................................................................................................................. 57

8. SPARE PART........................................................................................................................................................ 59

9. DEMOLITION AND DISPOSAL.......................................................................................................................... 62

10. DECLARATION MODELS............................................................................................................................... 63

5 / 64

CONTENT OF FIGURES

Figure 1

Example of EXE-Rise chain hoist plate

Figure 2

EXE-Rise chain hoist parts

Figure 3

EXE-Rise chain hoist serial number

Figure 4

EXE-Rise chain hoist 2000 kg DC principal components

Figure 5

Chain dimensions

Figure 6

Chain identification

Figure 7

Lift chain hook with safety latch” D8 250 kg and D8+ 150 kg - D8 500 kg and D8+ 300kg

Figure 8

“Lift chain hook with safety latch” D8 1000 kg and D8+ 600 kg

Figure 9

“Lift chain hook with safety latch” D8 2000 kg and D8+ 1200 kg

Figure 10

Example of Body Swivel Hook

Figure 11

Chain stop

Figure 12

Chain bag –bracket Quick Link dimensions

Figure 13

End chain –bracket Quick Link dimensions

Figure 14

External Chain Guide Plate

Figure 15

Plugs and Socket

Figure 16

Double brake version

Figure 17

Brake Features

Figure 18

Limit Switch large medium and body

Figure 19

Chain bag

Figure 20

Example of securing a load suspended from a tower by means of a locking bar

Figure 21

Example of secondary safety component attached directly to the load that is being lifted

(front view)

Figure 22

Example of secondary safety component attached directly to the load that is being lifted

Figure 23

Example of secondary safety component attached below the hoist, bypassing the hoist

lifting mechanism (front view)

Figure 24

Example of secondary safety component attached below the hoist, bypassing the hoist

lifting mechanism (perspective view)

Figure 25

EXE-Rise DRAWING: 250kg D8 DC/LVC and 150kg D8+ DC/LVC

Figure 26

EXE-Rise DRAWING: 500kg D8 DC/LVC and 300kg D8+ DC/LVC

Figure 27

EXE-Rise DRAWING: 1000kg D8 DC/LVC and 600kg D8+ DC/LVC

Figure 28

EXE-Rise DRAWING: 2000kg D8 DC/LVC and 1200kg D8+ DC/LVC

Figure 29

EXE-Technology package label

Figure 30

EXE-Rise motor up e down

Figure 31

Reversing of barycentre

Figure 32

Required Components

Figure 33

Removing the Frame Block

Figure 34

Replacement of the Chain hook

Figure 35

Re-applying of the frame block

Figure 36

External chain guide plate

Figure 37

Brake components

Figure 38

Spare Part of D8 250kg DC/LVC and, D8+ 150kg DC/LVC

Figure 39

Spare Part of D8 500kg DC/LVC and, D8+ 300kg DC/LVC

Figure 40

Spare Part of D8 1000kg DC/LVC, D8 2000kg DC/LVC and D8+ 600kg DC/LVC, D8+

1200kg DC/LVC

6 / 64

CONTENT OF TABLE

Table 1

Residual risks

Table 2

Relation between power and lengths of cable

Table 3

EXE-Rise chain hoist parts

Table 4

EXE-Rise chain hoist identification

Table 5

Selection criteria for electric chain hoists for moving and holding loads above people

Table 6

FEM Classification

Table 7

Average operating time per day in hours

Table 8

Chain measures

Table 9

Chain technical data

Table 10

Chain stop code

Table 11

Chain bag –bracket Quick Link technical data

Table 12

End chain –bracket Quick Link technical data

Table 13

Brake technical data

Table 14

Chain bag characteristic

Table 15

Chain bag dimensions

Table 16

Chain bag size

Table 17

Bolts

Table 18

Plug wiring

Table 19

Socket wiring

Table 20

Minimum frequent inspections

Table 21

Minimum periodic inspections

Table 22

Troubleshooting based on hoist behavior

Table 23

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

7 / 64

1. GENERAL INFORMATION

Thank you for choosing an EXE-Rise chain hoist.

1.1 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.

Follow all instructions and signs for inspecting, maintaining and operating this chain hoist. The use of any

chain hoist presents risk of personal injury or property damage. That risk is greatly increased if proper

instructions and warnings are not followed.

Before using this chain hoist, each operator should become thoroughly familiar with all warnings,

instructions, and recommendations in this manual. To carry out these operations, all safety rules specified

therein must be followed. Should some passages not be clear, please contact RWM S.r.l.

The manual should be adhered to and followed to ensure safe, reliable and correct function of the product, in

order to eliminate the possibility of any damage to persons or equipment.

For health and safety reasons people operating, assembling, disassembling, transporting and maintaining

the chain hoist should wear adequate Personal Protection Equipment like, but not limited to, gloves, noise

protection, hard hats and safety shoes.

This manual and the other documents contained in the packing are an integral part of the supply, and must

be carefully kept for the lifecycle of the hoist. You should keep this manual clean, complete and in a legible

condition for future references. They must follow the hoist in case of transfer to any other user or new owner.

The information reported in this document refers solely to care and maintenance of a single chain hoist; that

is to say, the “rigging” process and they way to control the hoist is not covered by this manual.

It is the sole responsibility of the client to check with local authorities if the legislation used by EXE-Rise

chain hoist is acceptable in the country of use.

Please make sure manuals are available at all times for all users and employees. The operator is

responsible for supervising all personnel involved and ensuring they are aware of the hazards and safety

implications of working with the electric chain hoist.

8 / 64

1.2 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. The body of plate contains:

-Model: commercial name, model and type of machinery;

-Working Load Limit (WLL): the maximum working load designed by the manufacturer;

-Working speed: units of measure “m/min” and “ft/min”;

-Motor power: units of measure “kW”;

-Power supply: operating voltage;

-Brake: number of brakes;

-Years of construction;

-IP Rating code: International Protection Rating (first digit is the solid protection and second digit is the

liquids protection);

-FEM class: European Federation of Materials handling and safety Factor;

-Chain size: units of measure “mm” in according to EN DIN 818-7

-Serial number;

-Safety Factor (SF) and Double Brake: this information is included in a square;

-Warning: Before opening or maintaining a hoist, turn the power supply off. Keep the chain

properly lubricated. Do not lift people. Do not lift over people. Do not lift more than WLL

(Working Load Limit). Failure to comply may lead to serious injury or death.

The plate is in English language. In others languages, the translation is present only in this manual.

9 / 64

1.3 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.

WARNING: indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION: indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE: address practices not related to personal injury.

SAFETY INSTRUCTIONS: is used to list steps, procedures or instructions that might otherwise constitute a

DANGER, WARNING or CAUTION notification. Note that equivalent phrases, such as SAFE OPERATION

PROCEDURES or SAFE SHUT DOWN PROCEDURE, can be used in place of the words “SAFETY

INSTRUCTIONS.“

1.4 TERMS AND DEFINITIONS

Operator: it is intended a person who, by virtue of training and professional experience, has a specific

competence in the field of safety and mechanical equipment and is familiar with the related national rules on

health protection and safety at work and with the rules of good technical practice (technical regulations

issued by the Country in which the hoist is used). The expert must be able to verify the safety and

mechanical equipment and give the related evaluation.

Maintenance: a combination of all technical and administrative actions, including supervision actions,

intended to maintain or restore an entity in a state where they can perform the required function.

Maintainer: personnel authorized to perform maintenance

Lifting Machinery: also known as lifting gear, is a general term for any equipment that can be used to lift

loads. This includes jacks, block and tackle, hoists, rotating screws, gantries, A frames, gin poles, shear legs,

sheerleg, windlasses, lifting harnesses, fork lifts, hydraulic lifting pads, air lift bags, and cranes.

10 / 64

1.5 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. or authorised agent, repairing or replacement of the unit will be

made free of charge in favour of the original purchaser.

This repairing/replacement policy only applies to installed, under maintenance and operating Hoists, as

highlighted in this manual and does not include the parts subject to normal wear and tear, misuse, improper

installation, inadequate and incorrect maintenance, the effects of hostile environments and unauthorised

repairing/modifications.

The manufacturer and dealers cannot accept responsibility for any damage or lack of functionality due to the

following situations:

-carrying out inappropriate operations for an electric chain hoist;

-product modification without the express authorization of the manufacturer;

-inappropriate operation of the hoist;

-operational errors;

-failure to use the product as stated in the manual.

RWM S.R.L. DECLINES LIABILITY FOR ANY DAMAGES ARISING FROM A NON-COMPLIANT

INSTALLATION AND MAINTENANCE INDICATED IN THIS DOCUMENT.

WARRANTY POLICY

1. For a period of 12 month we undertake to repair, free of charge any damage attributable to faulty

materials or workmanship, provided that the appliance is forwarded, freight paid, to our works or one of

the EXE contract service organisations.

2. The guarantee-period begins with the day of the delivery, proven by a purchase receipt like an invoice

or delivery note or their copies.

3. The guarantee only is applicable for new equipment.

4. The guarantee does not cover damage due to transport damage, negligent handling, overload or parts

subject to normal wear and tear. Nor damages that originate from a case of misuse because of non-

observance the instructions in this manual.

5. Warrantee also does not include the cost to be made to get access to a hoist in case it is built in. It is

the users sole responsibility that hoist can be inspected and service in a normal manner and in places

accessible for persons and their equipment.

6. 6The fitting of replacement parts not supplied by us or modifications of our design by third parties also

invalidates the guarantee.

7. Guarantee repairs do not renew nor extend the guarantee-period.

8. In case of a claim under the guarantee, a malfunction or spare part requirements please contact your

point of sale or EXE

The complete chain hoist comes with a 12 month manufacturer’s limited warranty from the date of purchase.

A 24-month warranty covers the mechanicals parts excluding electrical and wear parts (brake disc, pendant

with cable, safety catch, plastic box, chain bag ).

This manual suits for next models

Table of contents

Other EXE RISE Chain Hoist manuals

EXE RISE

EXE RISE SF-8 Troubleshooting guide

Popular Chain Hoist manuals by other brands

EINHELL

EINHELL Herkules H-F 1000 operating instructions

RED ROOSTER

RED ROOSTER TCR-250 user manual

POWERTEX

POWERTEX PCB-S1 Instructions for use

Parkside

Parkside PSZ 250 A1 Operation and safety notes

Ingersoll-Rand

Ingersoll-Rand QCH Series Product information

Creative Conners

Creative Conners CM Varistar Smart Chain Hoist Reference manual

Stagemaker

Stagemaker SR05 user manual

KITO

KITO TCL Series owner's manual

CRYSTEEL

CRYSTEEL LO-BOY manual

Performance Tool

Performance Tool W4005DB owner's manual

Parkside

Parkside PSZ 250 A1 Original operating instructions

Stahl

Stahl ST Series Product information

Coffing Hoists

Coffing Hoists EC Series Operating, Maintenance & Parts Manual

CM 622A Series Operating, Maintenance & Parts Manual

KITO

KITO RY Series Disassembly and Reassembly

Haklift

Haklift LOABT800 Original instructions

Tractel

Tractel bravo Operating and maintenance instruction

Villager

Villager VEH 250 Original operating instructions