Using an explosion-proof lever hoist safely requires strict adherence to operational guidelines and environmental considerations to prevent accidents in hazardous settings. Below are key precautions organized by category:

1. Pre-Use Inspection

Check Certification & Labels:

Verify the hoist is marked with explosion-proof certification (e.g., ATEX, IECEx, or national standards like GB 3836 in China) and matches the environmental hazard classification (e.g., Zone 1/2, Gas Group IIA/IIB/IIC, Temperature Class T1-T6).

Ensure the hoist’s temperature rating is below the ignition temperature of the surrounding gases/vapors.

Visual Inspection:

Examine the hoist for damage, corrosion, or wear, especially on critical components like the load chain, hooks, and braking system.

Check for loose fasteners, cracks in the housing, or signs of overheating (discoloration, melting).

Confirm that seals and gaskets (e.g., on gearboxes or bearings) are intact to prevent ingress of explosive substances.

Functional Test:

Perform a no-load test to ensure smooth operation of the lever mechanism, pawl system, and brake. Listen for unusual noises (grinding, clicking) that may indicate internal issues.

Test the upper/lower limit switches (if equipped) to prevent overtravel.

2. Environmental Considerations

Hazardous Zone Compliance:

Use the hoist only in environments classified for its explosion-proof rating (e.g., Zone 1 for intermittent gas presence, Zone 2 for rare anomalies).

Avoid using non-explosion-proof tools or equipment nearby that could generate sparks (e.g., non-intrinsically safe electrical devices).

Temperature & Humidity:

Operate within the hoist’s specified temperature range (typically -20°C to +40°C). Extreme cold may stiffen components, while high heat can reduce braking efficiency or damage seals.

In humid or corrosive environments (e.g., chemical plants), select hoists with stainless steel or coated parts to resist rust.

Ventilation & Gas Dispersion:

Ensure adequate ventilation to prevent gas accumulation. Avoid using the hoist in poorly ventilated pits or confined spaces unless risk-assessed and approved.

If lifting containers with flammable liquids, ensure they are properly sealed to prevent vapor release.

3. Load Handling Precautions

Capacity Limits:

Never exceed the hoist’s rated capacity (e.g., 1 ton, 2 tons). Overloading can cause chain failure, brake slippage, or structural deformation.

Account for dynamic loads (e.g., swinging, sudden stops) by reducing the working load limit (WLL) by 25-50% if applicable.

Load Attachment:

Use certified shackles, slings, or hooks compatible with the hoist’s safety latch. Ensure the load is balanced and centered to prevent tipping.

Avoid side-loading or shock loading, which can damage the chain or gears.

Lifting Path:

Clear the lifting area of obstacles, personnel, and flammable materials. Maintain a safe distance from ignition sources (e.g., open flames, electrical sparks).

Use guide ropes to control load swing if lifting at height.

4. Operational Safety

Manual Operation Only:

Explosion-proof lever hoists are manually operated to eliminate electrical spark risks. Do not modify the hoist to add electric or pneumatic power.

Use slow, steady lever strokes. Avoid rapid or jerky movements that could generate heat or stress components.

Brake Testing:

Before lifting, test the brake by applying upward pressure on the load. The hoist should hold the load firmly without slipping.

If the brake feels weak or fails, lower the load immediately and inspect/repair the hoist.

Avoid Prolonged Use:

Continuous operation can cause overheating. Take breaks to allow the hoist to cool down, especially in high-temperature environments.

5. Maintenance & Storage

Regular Inspections:

Schedule monthly visual inspections and annual professional servicing. Replace worn chains, hooks, or brakes as needed.

Lubricate moving parts (e.g., lever pivot, gear teeth) with non-flammable grease to reduce friction and heat.

Cleaning:

After use in dirty or chemical environments, clean the hoist with a non-flammable solvent and dry thoroughly to prevent corrosion.

Avoid using water or steam cleaners, which could damage seals or electrical components (if applicable).

Storage:

Store the hoist in a dry, ventilated area away from direct sunlight, chemicals, and extreme temperatures.

Hang the hoist by its top hook to prevent chain kinking or deformation.

6. Emergency Procedures

Spill Response:

If flammable liquids leak during lifting, stop operations immediately, evacuate the area, and follow site-specific spill protocols.

Do not use the hoist until the area is declared safe and decontaminated.

Equipment Failure:

If the hoist malfunctions (e.g., chain breaks, brake fails), lower the load slowly using manual control (if possible) or secure it with secondary supports.

Tag the hoist as “out of service” and report the incident for investigation and repair.

7. Training & Compliance

Operator Training:

Ensure all users are trained in explosion-proof hoist operation, hazard recognition, and emergency procedures.

Provide refresher courses annually or after incidents.

Regulatory Adherence:

Follow local safety regulations (e.g., OSHA, ATEX directives) and manufacturer guidelines. Keep records of inspections, maintenance, and training.

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