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Yale Series Y80 User's Manual

1. 6 Lubricate cable per paragraph 4 3 f Reeving 6 part single See Figure 5 15 for diagram See Figure 9 13 for block parts With new rope installed on the drum as described in paragraph 5 9c single reeved above proceed with rereeving following steps below Page 16 1 Grasp cable at a point one third approx 14 0 the distance hanging below the rope drum and form a loop Place one upper sheave in this loop Slide upper sheave with cable into sheave pocket partially insert sheave pin to hold sheave in place 2 Repeat 1 above and install second upper sheave with rope Insert sheave pin and install key plates and bolts to secure sheave pin UPPER SHEEVES ROPE ANCHOR ROPE REEVING AS VIEWED FROM MOTOR SIDE 12205A Figure 5 15 Hoist Reeving Six Part Single 3 Pass free end of rope thru bottom opening of hoist between floating limit rod and motor and insert in rope anchor fitting at hoist frame Be certain power is off before attempting to place rope in anchor fitting With end fitting properly seated in anchor replace bolt and lockwasher in end of socket Three loops have now been formed for bottom block sheaves 4 Place sheave in each loop Install one sheave with cable in bottom block partially insert sheave pin to hold sheave in place NOTE Be certain that washers are installed between sheaves as shown on parts illustration 5 Repeat step 4 for remaining bottom block sheaves
2. Qty Reqd 1 Dp ee ee ee ee Ce Figure 9 6 Upper Limit Switch Parts Part Qty Number Description Reqd 800 501 Pin Pivot Arm Lever 800 502 Short Frame 800 503 Long Frame 800 526 First Extension 800 527 Second Extension Lever Floating 800 504 Short Frame 800 505 Long Frame 800 528 First Extension 800 529 Second Extension 800 506 Washer 800 507 Pin Cotter 800 525 Coupling 800 509 Pin Roll 800 510 Switch Assembly Limit Reversing Includes Wire Leads 800 511 Connector Wire 800 512 Switch Assembly Limit Stop Includes Wire Leads 800 513 Screw Round Head 800 514 Screw Socket Head Shoulder 800 515 Shaft amp Cam Assembly 800 516 Insulator Limit Switch 800 517 Bearing Nylon 800 518 Screw Socket Head Cap 800 519 Lockwasher 800 520 Nut Lock 800 521 Bracket Assembly Mounting 800 522 Nut Hex Recommended Spares NH ANMNNNH HHP HWHNHAND Page 33 12748A Figure 9 7 Electrical Control Equipment Part Number Description 800 670 Cord Grip Conductor 800 654 Screw Self Tapping 800 655 Contactor Two Speed 800 656 Contactor 800 657 Screw Self Tapping 800 671 Transformer 800 663 Screw Self Tapping 800 672 Terminal Board Reconnectable Hoist Only 800 673 Fuse Fuse Holder and Wire Assembly 800 674 Fuse Only 2A 300V 800 675 Brake Module 800 676 Screw Self Tapping t Recommended Spares NO
3. 800 1504 Lockwasher 800 1505 Key Plate 800 1506 Fitting Grease 800 1507 Pin Upper Sheave 800 1508 Spacer Washer Upper Sheave 800 1509 Bearing Upper Sheave Includes Outer Race 800 1510 Sheave Upper 800 1535 Pin Rope Guide 800 1513 Spacer Washer Lower Sheave 800 1514 Bearing Lower Sheave Includes Outer Race 800 1515 Sheave Lower 800 1516 Pin Roll Hook Nut 800 1517 Nut Hook 800 1518 Bearing Thrust Hook 800 1530 Shield Bearing Not Shown 800 1531 Washer Thrust Not Shown 800 1519 Fitting Grease 800 1520 Hook Assembly includes Hook Latch amp Nut 800 1521 Plate Capacity 800 1522 Screw Round Head Self Tapping Capacity Plate 800 1523 Guard Sheave 800 1524 Body Lower Block 800 1525 Pin Lower Sheave 800 1526 Screw Button Head Cap Self Locking Sheave Guard 800 1527 Ring Retaining External 800 1528 Lockwasher Capacity Plate 800 1529 Spacer Upper Block 9 16 t Recommended Spares Hook Nuts with roll pins are not interchangeable Available only as an assembly yHrToPNonnRon nt SO Spa wwOnNnnNAH NVbD gt AMAA AAD AG MANMAAAAANMAANMAAAANNMANAANM AAADND Page 42 MOUNTING HOLES 12757A Figure 9 14 Screw Type Limit Switch Parts Part Number Description 800 1655 Limit Switch Assembly Includes Ref Nos 2 3 and 4 800 1651 Cap Screw Hex Socket Head
4. 800 1652 Sealing Washer 800 1657 Drum Shaft Insert For switch element replacement order 800 1654 NOTES Page 43 Recommended Spare Parts for Your Yale Hoist Certain parts of your hoist will in time require replacement under normal wear conditions It is suggested that the following parts be purchased for your hoist as spares for future use One Friction Disc Kit One Motor Brake Solenoid Coil One Set Of Contactors One Transformer One Wire Rope Assembly One Gearcase Gasket Note When ordering parts always furnish Hoist Serial Number Catalog Number Motor Horsepower Voltage Phase Frequency and Rated Load of Hoist on which the parts are to be used Parts for your hoist are available from your local authorized SHAW BOX repair station For the location of your nearest repair station write IN USA YaleeLift Tech P O Box 769 Muskegon MI 49443 0769 Phone 800 742 9269 Fax 800 742 9270 WARRANTY WARRANTY AND LIMITATION OF REMEDY AND LIABILITY A Seller warrants that its products and parts when shipped and its work including installation construction and start up when performed will meet applicable specifications will be of good quality and will be free from defects in material and workmanship All claims for defective products or parts under this warranty must be made in writing immediately upon discovery and in any event within one 1
5. Enclosure Rear Gasket Screw Slotted Head Screw Slotted Head NN ARBAB oa A Din D 2 for Figure 9 9 Push Button Station and Conductor Cable Assembly Cont d Ref Part Qty No Number Description Req d i Clamp Conductor Contact Block Assembly 800 1815 Contact Block ZB2 BE101 800 1816 Contact Block ZB2 BE201 i Interlock Mechanical 800 1817 Up Push Button Assembly Includes 1 Each of Ref Nos 23 and 25 thru 29 800 1818 Down Push Button Assembly Includes 1 Each of Ref Nos 23 25 thru 28 and 30 Ring Retaining Enclosure Front Seat Spring Spring Seal on Plate Push Button Push Button Up 5 Push Button Down kk kk kk kk PONNN_DND Not available separately Order Push Button Station Not available separately Order Push Button Assembly NOTES Page 37 2 3 4 5 6 7 8 9 a l a4 N Page 38 Part Number 800 1801 800 1802 800 1803 800 1804 800 1805 800 1806 800 1807 800 1808 800 1809 800 1810 800 1811 800 1812 800 1813 800 1814 Figure 9 10 Push Button Station and Conductor Cable Assembly Two Speed Hoists Only Early Version Description Push Button Station and Conductor Cable Assembly Includes Ref Nos 1 thru 30 Anchor Bracket Strain Cable Grip Assembly Conductor Connector Strain C
6. or if Seller s products have been dismantled prior to submission to Seller for warranty inspection D The foregoing is Seller s only obligation and Buyer s exclusive remedy for breach of warranty and is Buyer s exclusive remedy hereunder by way of breach of contract tort strict liability or otherwise In no event shall Buyer be entitled to or Seller liable for incidental or consequential damages Any action for breach of this agreement must be commenced within one 1 year after the cause of action has accrued Yale HOISTS
7. year from shipment of the applicable item unless Seller specifically assumes installation construction or start up responsibility All claims for defective products or parts when Seller specifically assumes installation construction or start up responsibility and all claims for defective work must be made in writing immediately upon discovery and in any event within one 1 year from completion of the applicable work by Seller provided however all claims for defective products and parts made in writing no later than eighteen 18 months after shipment Defective items must be held for Seller s inspection and returned to the original f o b point upon request THE FOREGOING IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER EXPRESS IMPLIED AND STATUTORY INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS B Upon Buyer s submission of a claim as provided above and its substantiation Seller shall at its option either i repair or replace its product part or work at either the original f o b point of delivery or at Sellers authorized service station nearest Buyer or ii refund an equitable portion of the purchase price C This warranty is contingent upon Buyer s proper maintenance and care of Seller s products and does not extend to normal wear and tear Seller reserves the right to void warranty in event of Buyer s use of inappropriate materials in the course of repair or maintenance
8. Limit Switch Parts Electrical Control Equipment Lower Block Assembly 2 part double reeved Upper and Lower Block Parts 3 amp 5 Ton Screw Type Limit Switch Parts Page 22 INDEX OF EXPLODED VIEW PARTS ILLUSTRATIONS Push Button Station Assembly and Conductor Cable Single Speed Push Button Station Assembly and Conductor Cable Two Speed Later Version Push Button Station Assembly and Conductor Cable Two Speed Early Version Lower Block Assembly 2 parts rope single reeved 11455C 1 Figure 9 1 Frame Gearcase and External Parts Part Qty Number Description Req d 800 197 800 192 800 105 800 106 800 107 800 109 800 111 800 2100 800 108 800 110 800 2101 800 113 800 115 800 112 800 114 800 2102 800 2103 800 2104 800 2105 Plug Oil Level Cover amp Bearing Assembly Gearcase Dowel Gasket Gearcase Gearcase amp Bearing Assembly Drum amp Hub Assembly Double Reeved Models 1 2 amp 1 Ton 3 6 Dia Rope 18 Lift 34 Lift 47 Lift 2 Ton 1 4 Dia Rope 14 Lift 25 Lift 36 Lift Drum amp Hub Assembly Single Reeved Models 1 2 amp 1 Ton 1 4 Dia Rope 25 Lift 50 Lift 2 Ton 5 16 Dia Rope 20 Lift 40 Lift 3 Ton 5 16 Dia Rope 30 Lift 45 Lift 5 Ton 5 16 Dia Rope 20 Lift 30 Lift Page 23 Figure 9 1 Frame Gearcase amp External Parts Cont d Part Number Description Page 24 800 116 800 117 800 118 80
9. Set Screw Oval Point 1 4 28 x 1 Hex Socket Shoulder Screw 10 24 x 1 Hex Head Self Locking Nut Plated 10 24 Brake Spring Use Red Spring Only Brake Lever Assembly Pressure Pad Brake Disc Non asbestos Brake Support Stud Separating Spring Brake Mounting Plate Hex Socket Head Self Locking Set Screw Cup Point 1 4 20 x 3 8 Brake Hub Hex Socket Head Screw 3 8 16 x 3 4 Lock Washer 3 8 Wire Nuts Not Shown No 22 thru 14 AWG Not available as individual parts See replacement kits listed below Later models have a hex socket head screw 1 4 20 x 1 1 2 with a hex head self locking nut plated 1 4 20 Kits include quantities shown above Page 28 KRPOPYP NM DNN HN HH HK HK MH CL MHC AHR NUD AHN OO HK KH KH BAH ND AH YD Figure 9 3 Hoist Motor Brake Cont d Kit Description Part Number Reference Numbers Included Brake Disc 800 2405t 23 24 26 Brake Lever 800 2406 6 15 17 18 19 20 21 Red Color 22 Adjusting Screw Label Brake Adjust Label Discard Zinc Colored Spring Rectifier 800 2407 12 13 4 Wire Nuts Hardware 800 2408 1 3 4 5 7 9 10 12 16 18 20 25 28 30 31 Instruction Label Power Warning Label Brake Hub 800 2409 28 29 Hub Drive Key Shown Elsewhere t Recommended spares NOTES Page 29 12756A Figure 9 4 Hoist Motor Brake Early Version Part Q
10. WA IN FOR FLANGE WIDTH CURVED TRACK PLUS 1 4 IN FLANGE i QUANTITY OF GUTSIDE WASHERS SHOULD BE EQUAL BOTH SIDES f QUANTITY OF INSIDE re WIDTH WASHERS SHOULD BE EQUAL BOTH SIDES Figure 2 1 Sectional View of Trolley showing proper wheel and washer spacing 2 3 CONNECTING HOIST TO ELECTRICAL SERVICE Electrical service to the hoist may be power cable or a guarded system having sliding shoe collectors Page 4 AWARNING Be certain that electrical power supply is off and locked in the open position before attempting any electrical connections to the hoist This equipment must be effectively grounded according to the National Electric Code or other applicable codes If the grounding method used is through the trolley wheels then each section of track must be grounded by metal to metal connection to the building ground Certain environments may prevent proper grounding by this means In this case a separate grounding conductor should be provided a Follow National State and Local Electrical Codes when providing electrical service to the hoist ACAUTION 208 230 460V single speed motors are reconnectable at the motor See motor nameplate Transformer may be reconnected for 200 230 460 575V See transformer Check with wiring diagram to make certain that motor transformer and brake leads are properly connected b Make electrical connections using the appropriate wiring diagrams furnished with the
11. and then the reversing switch is actuated Figure 2 3 Stop switch stops hoist Reversing switch lowers hook block in case of floating rod over travel If limit switch does not function in this manner refer to trouble shooting chart Section VI for possible remedy Figure 2 3 Electrical Compartment Cover Removed Showing Limit Switch and Reversing Switch Arrangement AWARNING Do not attempt to make above test with hook in a high position near hoist 2 A screw type upper and lower limit switch is provided optionally when both upper and lower limit stops are required Figure 7 2 This switch is adjustable and must be adjusted at time hoist is installed to desired high and low limits of lower block travel Refer to Section VII d Check Lower Block and Hoisting Cable Depress WY push button and run lower block to its lowest position No less than two wraps shall remain on the drum with the loaded hook in its lowest position unless hoist is equipped with a lower limit switch in which case no less than one and one half wraps shall remain on the drum Also check to see that lower block and rope does not twist excessively If it does twist to the extent that two ropes rub against each other disengage rope from the frame anchor and twist rope four or five turns in a direction opposite to that which the block turns Reconnect rope to anchor Figure 2 4 holding firmly to eliminate rope twisting back to its original position Operate
12. block sheaves when hoist is so equipped for wear damage and freedom of rotation If sheaves do not rotate freely disassemble block and inspect bearings Replace worn or damaged bearings washers pins or sheaves b Make certain that all sheaves bearings and hanger pins are free of foreign material and properly lubricated Bearings without grease fittings are lubricated for the life of the bearing and require no further lubrication After inspection lubricate all upper block lubrication fittings c Make certain that rope guide pins are not bent loose or otherwise distorted guide pins must have close clearance to sheave flange to keep rope in sheave grooves d Check hoist suspension bolts on lug suspended hoists make certain that bolts are secure properly tightened and free from damage e Inspect suspension lug at top of hoist frame for damage cracks hole elongation or other signs of wear On all hoists the suspension lug is integral with hoist frame and the entire frame must be replaced when suspension lug is damaged and requires replacement AWARNING Do not operate a hoist having worn or damages suspension bolts f Reinstall all parts following procedure in reverse of disassembly 5 4 INSPECT ELECTRICAL CONTROLS Arrangement of electrical control equipment varies with the type of control physical space and the optional control features ordered with the hoist a Disconnect electrical power to hoist remove
13. electrical compartment cover Figure 9 1 Ref No 29 and inspect wiring and terminals Terminals should be securely crimped to wires and electrical insulation should be sound Terminal screws should be tight b Check condition of contactor assembly transformer and limit stop and reverse switches Page 9 INSPECTION SCHEDULE AND MAINTENANCE REPORT HOIST SERIAL NO MFGRS CUSTOMER CRANE IDENTITY NO RATED LOAD LOCATION IN PLANT TYPE THIS INSPECTION IS MONTHLY O ANNUAL O VOLTAGE SEMI ANNUAL O INSPECTED BY DATE Recom CONDITION COMPONENT UNIT OR PART mended Check column best indicating condition when CORRECTIVE ACTION and location Inspection part or unit is inspected Use note column to NOTES Interval the right if condition is not listed below Indicate corrective action taken during inspection and note date For corrective action to be done after inspection a designated person must determine that the existing deficiency does not constitute a safety hazard before allowing unit to operate When corrective action is completed describe and note date in this column COMPONENT UNIT OR PART LOCATION MONTHLY SEMI ANNUAL ADJUSTMENT REQUIRED REPAIR REQUIRED Loose Parts or Wires REPLACEMENT REQUIRED Worn or Damaged LUBRICATION REQUIRED Low Oil or Grease Rust or Corrosion CLEANING OR PAINTING REQUIRED Motor Motor Brake Mechanical Load Brake Overload Clutch Couplings Gears Shafts amp Bearin
14. end and enclosed by a steel cover control operation and rotating direction of a driving motor A hoisting rope and an enclosed lower block assembly are used for lifting loads An upper limit stop is used to limit travel of the lower block in the raising direction to protect hoist from damage A push button control station for operating the hoist is suspended from the electrical compartment 1 3 DIFFERENCES BETWEEN MODELS The main differences between models are in rope reeving and frame size as described below a Rope Reeving There are four types of rope reeving used Two parts of rope single reeved four parts of rope single reeved six parts of rope single reeved and two parts of rope double reeved Single reeved hoists have one end of the rope anchored to the drum whereas double reeved hoists have both ends anchored to the drum On single reeved models the lower block travels sideways as rope winds on drum double reeved models offer true vertical lift For illustrations refer to Section V paragraph 5 9 Rope Reeving instructions b Frame Size Length of frame furnished is dependent on hoist capacity and lift Four frame lengths are used short frame long frame first and second extensions Short frame hoists have a rope drum flange to flange distance of approximately 9 3 4 whereas this distance on a long frame hoist is approximately 16 3 4 First extension frame hoists have a flange to flange distance of 22 15 16
15. functioning properly visually inspect clutch adjusting nut and spring washer for signs of damage or looseness With a small hex allen wrench make certain two set screws in adjusting nut are tight DO NOT TURN ADJUSTING NUT OR DISASSEMBLE CLUTCH If spring washer adjusting nut or gear is loose or damaged or the clutch did not function properly before disassembly of hoist for inspection consult the nearest YALE Authorized Repair Station for repair or adjustment 5 7 INSPECT ROPE DRUM AND SHAFT a To remove drum remove wire rope electrical compartment cover and electrical panel assembly Figure 9 1 and gearing and load brake assembly paragraph 5 6 b Remove four hex socket head bolts securing gearcase to cover Three bolts are accessible from inside frame Figure 2 2 Section II and the fourth is accessible from electrical end of frame thru special access hole using a socket hex key wrench with an extension Figure 5 11 With bolts removed pry assembled gearcase and motor from frame Exercise caution so that gearcase and motor assembly does not fall as it comes free of frame This disassembly operation is not recommended with hoist suspended Drum will remain in frame and can be lifted from drum shaft To remove shaft remove internal retaining ring from bearing bore in frame Page 13 Figure 5 11 Removing Bolt Securing Gearcase to Frame c Check parts for wear and damage Replace drum if there are any signs of cracks
16. hoist up and down a few times If lower block still rotates repeat process until twisting is corrected e Lubricate Hoisting Cable For longer cable life it is recommended that the cable be lubricated at time of installation by applying a Chain and Cable Fluid as outlined in Section IV paragraph 4 3 RETAINING SCREW Figure 2 4 Rope End Anchor Page 5 SECTION Ill OPERATION 3 1 GENERAL Operation of Series 800 YALE electric hoists is controlled by a convenient pendant push button station With it the hoist can be controlled to give fast lifting and lowering or controlled to lift or lower load in small increments providing accurate spotting The push button station has a built in interlock to prevent depressing opposing buttons simultaneously When first using hoist break in by operating under lighter loads to full travel before applying maximum load 3 2 PUSH BUTTON OPERATION a Depress push button marked to raise load b Depress push button marked W to lower load c Jogging the push button will give hairline load movement The quickness of the depressing motion will determine the amount of movement Excessive use of this Jogging feature will cause premature burning of contact tips and motor overheating d On two speed hoists partial depression of button operates the hoist at slow speed depressing button completely operates the hoist at fast speed 3 3 OVERLOAD CLUTCH
17. of hoist as shown on nameplate Check for loose connections See that necessary jumper wires are properly installed on contactor Check limit switch mounting and connections See that necessary jumper wires are properly installed Verify that the contactor armatures are free to move If binding occurs replace contactor Check for burned out contactor coils Check push button contacts and wires Page 19 SECTION VI TROUBLE SHOOTING Continued Probable Cause 6 5 Hoist Will Not Lift Rated a Low voltage See that power supply current is same voltage Load 6 6 Hoist Motor Overheats 6 7 Load Drifts Excessively When Hoist Is Stopped 6 8 Hoist Operates Intermittently Page 20 Overload Clutch not properly adjusted Excessive load Excessive duty cycle Wrong voltage or frequency Defective motor or worn bear ings in hoist frame Overload Clutch slipping without lifting load Excessive load Motor brake not holding Load brake not holding a Collectors make poor contact b Loose connections listed on motor data plate Check hoist motor connections Check size of power supply lines See Section VII paragraph 7 5 Reduce loading to rated load of hoist shown on nameplate Reduce frequency of lifts or amount of jogging Check current rating on motor data plate against power supply Check hoist motor connections Disass
18. of reel so rope can be pulled straight out with the reel rotating ACAUTION It is imperative that the rope reel or coil rotates as rope unwinds If coil or reel does not rotate the wire will be twisted as it is uncoiled and kinking will result A kinked rope may be damaged and unsafe Before removing the old rope refer to reeving diagrams Figures 5 12 5 14 5 15 and 5 17 Face the rope drum on your hoist from the side which the rope comes off drum To assist with rereeving your hoist select the reeving diagram for your hoist Note the description such as 2 part double reeved Figure 5 17 and refer to the paragraph below with the same description which describes rereeving procedure b Removing old rope for all reevings 1 Lower the bottom block to a scaffold located 6 to 7 feet below hoist to relieve tension on wire rope Bottom block may be lowered to floor if desired however to handle less weight and for ease of rereeving adequate scaffold below the hoist is recommended 2 Remove bottom block sheave guard 3 Remove key plates from both sides of sheave pin and slide sheave pin from bottom block 4 Lift out sheaves from the top of the bottom block and remove wire rope 5 Remove key plates or snap rings from upper block sheave s and slide out upper block sheave pins releasing upper block sheaves Remove wire rope from sheaves 6 Make certain all personnel are clear of hoist and operate hoi
19. shall be performed only by qualified persons Steel angles or plates used to suspend hoist should be spaced as close to the hoist suspension lug as possible Mounting bolts or threaded studs attaching hoist to mounting structure shall have a diameter not less than recommended by manufacturer and material equivalent to ASTM A 325 Make certain that mounting bolts or studs are long enough so that the threads do not engage the mounting support and that mounting bolts or studs are secured with nuts and lockwashers self locking nuts or cross bolting if unthreaded b Trolley Mounted hoists are attached to moveable trolleys If the hoist is mounted on an existing trolley a qualified person shall determine that the trolley and its supporting structure are adequate to support the rated load and weight of the hoist Hoist trolley units may be shipped from the factory with trolley packaged separately If the trolley can be installed directly over the end of the supporting beam assemble trolley to hoist Be certain that the spacing between wheel flanges after assembly is 1 4 greater than exact width of beam flange See Figure 2 1 below and instruction sheet furnished with trolley Using proper equipment carefully lift trolley and hoist and install on end of beam Page 3 For trolleys which are to be mounted along the span of a beam not having open ends measure exact width of beam flange and assemble trolley to hoist so that spacing betwe
20. sizes 1 2 1 2 3 and 5 tons with various lifts lifting speeds and electrical service Equipped with an integrally welded mounting lug they are designed to be rigidly attached to an overhead structure or mounted on YALE rigid mount trolleys for operation on runway beams On certain models optional base mounting or other supporting methods may be obtained For full information apply to factory at Muskegon Michigan 49443 NOTICE YALE hoists are available with an optional built in mechanical overload clutch Hoists having this device are identified with words WEIGHT WATCHER on the hoist The WEIGHT WATCHER overload clutch permits operation of your hoist within its rated load and helps prevent lifting of excessive loads which could cause permanent deformation of a properly maintained hoist or trolley 1 2 BASIC CONSTRUCTION All models are of the same basic construction and consist of a rugged welded steel frame which houses a lifting drum and serves as the suspension for carrying the entire hoist load A mounting lug for attaching the hoist to a trolley or overhead support is located on top of the frame An aluminum alloy gearcase and cover attached to one end of frame houses a three reduction gear train and a mechanical load brake An electric driving motor with disc type motor brake is located beside the frame face mounted on the back of the gearcase Electrical system components located on the end of the frame opposite gearcase
21. 0 2106 800 2107 800 2108 800 2109 800 2110 800 2111 800 2112 800 121 800 124 800 125 800 130 800 131 800 2113 800 2114 800 132 800 133 800 134 800 135 800 136 800 137a 800 138 800 139 800 194c 800 2121 800 146a 800 2122 800 149 See Fig 9 3 amp Fig 9 4 800 155 800 156 800 158 800 161 800 157 800 160 800 2115 800 2116 800 2117 800 2118 800 164 800 165 Screw Hex Socket Button Head Self Locking Frame Assembly Single Reeved Models 1 2 1 amp 2 Ton Short Frame Long Frame 3 Ton First Extension Second Extension 5 Ton First Extension Second Extension Frame Assembly Double Reeved Models 1 2 1 amp 2 Ton Short Frame Long Frame First Extension Closure 1 2 Plug Nut Hex Double Reeved Models Lockwasher Double Reeved Models Shaft Extension Drum Short Frame Long Frame First Extension Second Extension Key Woodruff Hi Pro Type Ring Retaining Hub Internal Bearing Drum Shaft Ring Retaining External Ring Retaining Beveled Hub Internal Plate Assembly Base Lockwasher Screw Hex Socket Head Cap Cover Assembly Electrical Screw Self Tapping Plate Assembly Base Short Frame Shell Brake Short Frame Screw Self Tapping Motor amp Brake Screw Hex Socket Head Lockwasher Rope amp Thimble Assembly Single Reeved Models 1 2 amp 1 Ton 1 4 Dia Rope 25 Lift 50 Lift 2 Ton 5 16 Dia Rope 20 Li
22. 12759C INDICATING TANG Figure 7 1 Motor Brake Early Version a Examine position of indicating tang located below the solenoid coil Figure 7 1 or 7 1A b On the later version of the brake Figure 7 1A if the tang is below the line by more than 1 8 the brake should be adjusted to bring the top of the tang back up alongside the line on the adjust label c On the early version of the brake Figure 7 1 if the tang is below the midway position of the two adjustment points shown on the brake the brake should be adjusted to bring the tang back up alongside the NORMAL position on the brake d Remove the hex key 1 8 size from the holster on the cover mounting stud and carefully turn the ADJUSTING SCREW located above the solenoid coil clockwise The indicating tang will move a large distance for a small turn of the adjusting screw therefore turn the screw no more than one quarter turn before checking adjustment e After adjustment operate the brake by hand to assure brake disc running clearance The outboard brake pad should separate from the brake disc by approximately 010 f Replace hex key in holster g Replace brake cover 7 3 BLOCK OPERATED LIMIT SWITCH The block operated upper limit stop furnished as standard equipment is nonadjustable and designed to stop lower block at its high point of travel to guard against over travel with possible damage to hoist When high point is reached limit stop switch auto
23. 407 5 6 8 11 17 Brake Lever 800 1408 18 20 21 22 23 Brake Hub 800 1409 28 29 Hub Drive Key Shown Elsewhere Special Hardware 800 1410 3 4 9 26 Instruction Label inside cover Adjust Label Adjusting Screw Label on brake lever assembly Power Warning Label on cover Hardware 800 1411 1 5 7 10 12 14 16 18 20 21 28 30 NOTES Page 31 800 1301 800 1302 800 1303 800 1304 800 1305 800 1306 800 1307 800 1308 800 1309 800 1310 800 1311 800 1312 800 1313 800 1314 800 1315 800 1316 800 1317 800 1318 800 1319 800 1320 800 1321 800 1322 800 1323 800 1324 800 1325 Figure 9 5 Three Phase Motor Assembly Part Number Description Motor Assembly Includes Ref Nos 1 thru 8 1 Horsepower 1 Speed 200 Volt 230 460 Volt 575 Volt 2 Horsepower 1 Speed 200 Volt 230 460 Volt 575 Volt 4 Horsepower 1 Speed 200 Volt 230 460 Volt 575 Volt 1 1 3 Horsepower 2 Speed 200 Volt 230 Volt 460 Volt 575 Volt 2 2 3 Horsepower 2 Speed 200 Volt 230 Volt 460 Volt 575 Volt 3 1 Horsepower 2 Speed 200 Volt 230 Volt 460 Volt 575 Volt 4 2 Horsepower 2 Speed 200 Volt 230 Volt 460 Volt 575 Volt Bell End Ring Retaining Bearing Ball Ring Retaining Key Brake Rotor and Shaft Assembly Stator Assembly Bolt Motor Furnished only as part of motor assembly Page 32
24. 5 14 for diagram See Figure 9 13 for block parts With new rope installed on the drum as described in paragraph 5 9c single reeved above proceed with rereeving following steps below 1 Grasp the cable near the middle about 14 0 of the unwound end and form a loop Place upper sheave in this loop Slide upper sheave with cable into sheave pocket 2 Insert sheave pin into sheave Replace key plates and bolts to hold sheave pin in place Page 15 Figure 5 13 Upper Sheave Installed Typical 3 and 5 Ton 3 Pass free end of rope thru bottom opening of hoist between floating limit rod and motor and insert rope in anchor fitting at hoist frame Be certain power is off before attempting to place rope in anchor fitting With end fitting properly seated in anchor replace bolt and lockwasher in end of socket Two loops have now been formed for bottom block sheaves UPPER SHEEVE ROPE ANCHOR ROPE REEVING AS VIEWED FROM MOTOR SIDE 12204A Figure 5 14 Hoist Reeving Four Part Single 4 Place one sheave in each loop Install one sheave with cable in bottom block partially insert sheave pin to hold sheave in place NOTE Some blocks have spacer washers between sheaves Be certain that washers are installed between sheaves when shown on parts illustration Install second sheave with cable into bottom block Slide sheave pin through sheave Replace key plates and bolts securing sheave pin 5 Replace sheave guard
25. 800 827 800 828 800 829 800 857 800 858 800 832 800 833 t Recommended Spares Figure 9 12 Lower Block Assembly Two Parts Double Reeved Block Assembly Lower Complete 2 Ton Block Assembly Lower Complete 1 Ton Block Assembly Lower Complete 1 2 Ton Screw Flat Heads Self Threading Cover Lower Block 2 Ton Cover Lower Block 1 Ton Cover Lower Block 1 2 Ton Ring Retaining Fitting Lube Pin Sheave Spacer Sheave Assembly Consists of Items 7 and 8 Bearing Sheave Cover Intermediate Screw Flat Head Self Threading Hook Assembly Consists of Hook Nut amp Grooved Pin 2 Ton Hook Assembly Consists of Hook Nut amp Grooved Pin 1 2 amp 1 Ton Shroud Thrust Bearing 2 Ton Shroud Thrust Bearing 1 2 amp 1 Ton Bearing Thrust 2 Ton Bearing Thrust 1 2 amp 1 Ton Body Lower Block 2 Ton Body Lower Block 1 2 amp 1 Ton Safety Hook Latch Assembly 2 Ton Safety Hook Latch Assembly 1 2 amp 1 Ton Furnished as Standard with hook Qty Reqd s eS Ss Ss eS Ss sss os Rs PPO MO NYO RH NNONMOND A A H Page 41 12197LA Figure 9 13 Upper and Lower Block Parts 3 amp 5 Ton Typical Quantity Required Part Number Description 3 Ton 4 PS 5 Ton 6 PS 800 1501 Block Assembly Lower 4 Part Single Complete 800 1502 Block Assembly Lower 6 Part Single Complete 800 1503 Screw Hex Head Cap
26. Assembly Lower Complete 1 2 Ton 800 804 Screw Flat Head Self Threading 800 805 Cover 2 Ton 800 806 Cover 1 Ton 800 807 Cover 1 2 Ton 800 808 Ring Retaining 2 Ton 800 809 Ring Retaining 1 2 amp 1 Ton 800 810 Lube Fitting 800 811 Pin Sheave 2 Ton 800 812 Pin Sheave 1 2 amp 1 Ton 800 813 Spacers 2 Ton 800 814 Spacers 1 2 Ton amp 1 Ton 800 815 Sheave Assembly 2 Ton Consists of Items 7 and 8 800 816 Bearing 800 817 Sheave 800 818 Sheave Assembly 1 2 amp 1 Ton Consists of Items 7 and 8 800 819 Bearing 800 820 Sheave 800 821 Cover Lower Block 2 Ton 800 822 Cover Lower Block 1 Ton 800 823 Cover Lower Block 1 2 Ton Hook Assembly Consists of Hook Nut amp Grooved Pin 2 Ton Hook Assembly Consists of Hook Nut amp Grooved Pin 1 2 amp 1 Ton Shroud Thrust Bearing 2 Ton Shroud Thrust Bearing 1 2 amp 1 Ton Bearing Washer Thrust 2 Ton Bearing Washer Thrust 1 2 amp 1 Ton Body Lower Block 2 Ton Body Lower Block 1 2 amp 1 Ton Safety Hook Latch Kit 2 Ton Safety Hook Latch Kit 1 2 amp 1 Ton Screw Flat Head Self Threading N a ee ee ee ee Oe DO i ee Oe Oe te a ee ad Recommended Spares Page 40 Part Number Description 800 851 800 852 800 853 800 804 800 854 800 806 800 807 800 809 800 810 800 855 800 814 800 818 800 819 800 820 800 856 800 834 800 824 800 825 800 826
27. Change Gear Case Oil Lubricate Hoist Cable Paragraph 4 1 Paragraph 4 2 Paragraph 4 3 Paragraph 4 4 Paragraph 4 5 Paragraph 4 6 Lubricate Limit Stop Lever Lubricate Limit Switch SECTION V Paragraph 5 1 Paragraph 5 2 Paragraph 5 3 Paragraph 5 4 Paragraph 5 5 Paragraph 5 6 Paragraph 5 7 Paragraph 5 8 Paragraph 5 9 Paragraph SECTION VI TROUBLE SHOOTING CHART SECTION VII ADJUSTMENTS Paragraph 7 1 Mechanical Load Brake Paragraph 7 2 Motor Brake Paragraph 7 3 Block Operated Limit Switch Paragraph 7 4 Screw Type Limit Switch Paragraph 7 5 Overload Clutch Adjustment SECTION VIII WIRING DIAGRAMS SECTION IX PARTS LIST Paragraph 9 1 General Paragraph 9 2 List of Parts Illustrations General Inspect Lower Block Inspect Upper Block and Hoist Suspension Inspect Electrical Controls Inspect Motor Brake Inspect Rope Drum and Shaft Rope Reeving INSPECTION AND PREVENTIVE MAINTENANCE 5 10 Testing Hoist and Overload Clutch Optional Lubricate Upper Sheave and Lower Block Assembly Inspect Mechanical Load Brake Gearing and Overload Clutch Optional Rope Inspection Maintenance and Replacement No part of this document may be reproduced in any form in an electronic retrieval system or otherwise without prior written permission of the publisher Page 2 SECTION GENERAL DESCRIPTION 1 1 GENERAL YALE electric hoists are precision built wire rope and drum type hoists which are made in five rated load
28. Install sheave pin through sheaves Replace key plates and bolts securing sheave pin 6 Replace sheave guard 7 Lubricate cable per paragraph 4 3 g Reeving 2 part double See Figure 5 17 for diagram See Figure 9 12 for block parts With new rope installed on the drum as described in paragraph 5 9c double reeved above proceed with rereeving following steps below 1 Form loops in the two ropes coming from rope drum Place these loops into bottom block pockets and slide pipe or rod through sheave pin holes Note position of ropes passing limit stop bar 2 Partially insert upper block sheave pin in opening and install one spacer washer Raise remaining rope up to hoist form a loop and place upper sheave in this loop F w i oD ie REY PLATE a j i ESHEAVE Pii SHEAVE Figure 5 16 Upper Sheave Installed Typical 3 Place sheave with rope into upper sheave pocket and slide pin partially thru sheave Install remaining washer and push pin thru side plates Install snap ring on each end of pin to secure pin in place UPPER EQUALIZER SHEEVE REEVING AS VIEWED FROM MOTOR SIDE 12206A Figure 5 17 Hoist Reeving Two Part Double 4 Insert lower sheave pin into bottom block removing pipe as sheave pin is inserted Be certain washers are replaced as shown on parts illustration With sheave pin installed replace key plates and bolts to secure sheave pin 5 Replace sheave gua
29. LE Inspect and lubricate per paragraph 5 8 1 3 Months ELECTRICAL CONTROLS Inspect per paragraph 5 4 Check hoist gearcase oil level add oil as required per paragraph 4 2 6 Months LOWER BLOCK Inspect per paragraph 5 2 UPPER BLOCK Inspect per paragraph 5 3 Motor brake and actuating mechanisms Inspect and adjust per paragraph 5 5 Annually Inspect hooks with suitable crack detecting procedures per paragraph 5 2 Drain and refill hoist gearcase per paragraph 4 2 Inspect electrical controls per paragraph 5 4 Change hoist gearcase oil Fill 6 Months or with oil per paragraph 4 2 Lubricate hoist cable per paragraph 4 3 Lubricate 500 750 hours upper and lower hook block per paragraph 4 4 Lubricate limit stop lever per on time paragraph 4 5 If a screw type limit switch is furnished add a light film of NLGI No 2 grease to bevel gear 5 Years elapsed Complete inspection disassembly and maintenance required It is recommended time or 5000 that your YALE Repair Station be contacted for this service hours on time Perform services described by paragraph indicated Figure 5 2 Inspection and Maintenance Schedule 5 5 INSPECT MOTOR BRAKE See Figure 9 4 a Remove acorn nuts holding brake cover and remove brake cover b Remove brake mounting plate screws and lift brake assembly off c Check braking surfaces for wear and scoring Replace badly worn or scored parts d Reinstall
30. NG DO NOT operaie hoist with the hoisting rope out of the drum groves Such operation may result in the rope breaking and dropping the load which can cause damage to equipment and injury to operator and other personnel Hoist rope will remain in the drum groves during operation under normal operating conditions however slack or kinked rope excessive side pulls swinging or jerking of load or similar abuse may cause the rope to leave the groves aq DO operate hoist within recommended duty cycle and do not jog unnecessarily ar DO conduct regular visual inspections for signs of damage or wear as DO NOT operate hoist with hooks that have opened up See Figure 5 1 at DO provide supporting structure or anchoring means that has a load rating at least equal to that of the hoist au DO NOT use hoists in locations that will not allow operator movement to be free of the load av DO when starting to lift or pull move the load a few inches at which time the hoist should be checked for proper load holding action The operation shall be continued only after the operator is assured that the hoist is operating properly aw DO NOT leave a loaded hoist unattended at the end of a work shift or for extended periods during the work shift Where operations are such that this condition cannot be avoided the operator must be assured that the condition does not create a hazard to personnel or property ax DO NOT use the hoist load l
31. OPERATION Optional The overload clutch when furnished with the hoist is factory preset and tested so that the hoist will lift its full rated load but will refuse to lift overloads which could cause deformation or weakening of your hoist If the load to be lifted exceeds the clutch setting the hoist motor will continue to run when the button is depressed and rotate the load brake gear without lifting the load Whenever this slipping occurs immediately release the push button to prevent overheating of the clutch friction surfaces and the hoist motor NOTICE Always know load to be lifted Lift Tech does not recommend lifting loads greater than the rated load of your hoist 3 4 OPERATING PRECAUTIONS AWARNING Equipment covered herein is not designed or suitable as a power source for lifting or lowering persons Safe operation of an overhead hoist is the operator s responsibility Listed below are some basic rules that can make an operator aware of dangerous practices to avoid and precautions to take for his own safety and the safety of others Observance of these rules in addition to frequent examinations and periodic inspection of the equipment may save injury to personnel and damage to equipment a DO read ANSI B30 16 Safety Standard for Overhead Hoists and the Operation Service and Parts Manual b DO be familiar with hoist operating controls procedures and warnings c DO make sure hook travel is in the
32. OPERATION SERVICE amp PARTS MANUAL TON Before installing hoist fill in the information below Refer to the Hoist and Motor data plates Model No Serial No SERIES Y80 ay d aS Voltage YAL J Rated Load WIRE ROPE ELECTRIC HOISTS INCLUDING WEIGHT WATCHER OVERLOAD CLUTCH MODELS RATED LOADS 1 2 THRU 5 TONS Yale HOISTS Printed in U S A May 2003 Copyright 2003 Yale Lift Tech division of Columbus McKinnon Corporation Part No 117404 10 FOREWORD This manual contains important information to help you install operate maintain and service your new YALE electric hoist We recommend that you study its contents thoroughly before putting the hoist into use Read ANSI B30 16 safety code for hoists Then thru proper installation application of correct operating procedures and by practicing the recommended maintenance suggestions you can expect maximum lifting service from the hoist It will likely be a long time before parts information found in Section IX is needed therefore after the hoist is installed and you have completely familiarized yourself with operation and preventive maintenance procedures we suggest that this book be carefully filed for future reference When ordering replacement parts from this book it will be necessary that you include with your order the Hoist Serial Number Model Number and Catalog Number which is found on the nameplate attached to the hoist electri
33. TES Page 34 Figure 9 8 Push Button Station and Conductor Cable Assembly Single Speed Hoists Part Qty Number Description Req d 800 2701 Push Button Station and Conductor Cable Assembly Includes Ref Nos 1 thru 17 800 2702 Push Button Station Includes Ref Nos 1 thru 15 j Type 1 Pan Head Machine Screw M 3 5 x 0 6 x 12 Pltd Lockwasher M 3 5 Pltd i Rear Cover 800 2703 Gasket i Type 1 Pan Head Thread Cutting Screw M 4 x 15 Pltd 800 2704 Contact Assembly 800 2705 Button Assembly 7 Type 1 Pan Head Machine Screw M 6 x 1 x 12 Pltd Lockwasher M 6 PItd Plain Washer M 6 PIitd Type 1 Pan Head Machine Screw M 3 5 x 1 x 14 Pltd Lockwasher M 3 5 Pltd Housing Cap 800 2706 Grommet Housing 800 2707 Conductor Cable Assembly 800 2708 Plastic Warning Tag OONDOAARWND ee Ss Ss PP HH H KH HB HAH dS AH A NSS GM Not available separately Order Push Button Station Page 35 Ref No Page 36 Part Number 800 1821 800 1822 800 1823 800 1812 800 1813 800 1814 Figure 9 9 Push Button Station and Conductor Cable Assembly Two Speed Hoists Only Later Version Description Push Button Station and Conductor Cable Assembly Includes Ref Nos 1 thru 30 Grommet Conductor Cable Operator Warning Label Push Button Station Includes Ref Nos 12 thru 30 Sleeve Conductor Support Strain Cable Screw Slotted Head Lockwasher
34. able Thimble Strain Cable Connector Conductor to Strain Cable Clamp Conductor Conductor Cable Strain Cable Sleeve Pressure Tie Conductor Operator Warning Label Push Button Station Includes Ref Nos 12 thru 30 Sleeve Conductor Figure 9 10 Push Button Station and Conductor Cable Assembly Cont d Part Qty Number Description Req d Support Strain Cable Screw Slotted Head Lockwasher Enclosure Rear Gasket Screw Slotted Head Screw Slotted Head Clamp Conductor Contact Block Assembly 800 1815 Contact Block ZB2 BE101 800 1816 Contact Block ZB2 BE201 i Interlock Mechanical 800 1817 Up Push Button Assembly Includes 1 Each of Ref Nos 23 and 25 thru 29 800 1818 Down Push Button Assembly Includes 1 Each of Ref Nos 23 25 thru 28 and 30 ae Ring Retaining Enclosure Front i Seat Spring i Spring Seal a Plate Push Button nae Push Button Up vn Push Button Down PpoNhM NMN HH AP HP AH _ kk PMPNNNHDND Not available separately Order Push Button Station Not available separately Order Push Button Assembly NOTES Page 39 Figure 9 11 Lower Block Assembly Two Parts Rope Single Reeved Part Qty Number Description Req d 800 801 Block Assembly Lower Complete 2 Ton 800 802 Block Assembly Lower Complete 1 Ton 800 803 Block
35. and second extensions have 35 3 8 c Motor Brake Hoists are equipped with a disc brake mounted on the motor end bell and operated by a short stroke solenoid This brake requires periodic adjustment SECTION II INSTALLATION 2 1 GENERAL YALE electric hoists are lubricated and tested before being shipped from the factory To place hoist in service attach to a suitable suspension paragraph 2 2 connect to electrical service paragraph 2 3 and perform pre operation tests and checks paragraph 2 4 AWARNING Before attempting installation of hoist or trolley the main power switch must be locked in the open position off 2 2 SUSPENDING HOIST The hoist may be suspended in a fixed location servicing only the area directly below the hoist Lug Mounted or the hoist may be attached to a moveable trolley or trolleys which in turn may be mounted on an I beam attached to a building or crane servicing a larger area Trolley Mounted AWARNING DO NOT use small holes for attaching this hoist unless rated load on lower block is 1 one ton 2000 Ibs or less a Lug Mounted hoists attach to adequate supports welded or bolted to a building or other structure The supporting structure must have sufficient strength with appropriate safety factor to support the weight of the hoist and rated load as well as other loads to which the supporting structure may be subjected AWARNING Design and installation of hoist support
36. bly Includes Items 26 thru 30 34 36 thru 38 and 43 thru 45 a po a A SH AH NMa Available only as part of 800 250 or 800 251 above 800 253 Brake Gear Center 800 252 Clutch Assembly 800 260 Ring Retaining 800 263 Oil Seal Drum Shaft 800 261 Bearing Assembly Ball Drum Shaft 800 262 Shaft Drum 800 254 Spring Retainer t Recommended spares Recommended Replacement Kit for Load Brake Clutch Complete Replacement Complete Less Bearings and Thrust Washers For hoists built prior to March 1997 gearing part numbers with four digits rather than three after 800 must be replaced in sets For hoists built between March 1 1997 and July 1 1997 contact the factory for gearing requirements Page 27 800 2401 800 2402 800 2410T OONDOARWN 800 2411 800 2403 800 2404 Figure 9 3 Hoist Motor Brake Later Version Description Motor Brake Assembly Includes Ref Nos 1 thru 31 Acorn Nut Plated 10 32 Brake Cover Assembly Includes Brake Cover and Label Inside Cover Cover Stud Gasket Phillips Pan Head Self Tapping Screw Plated 10 32 x 1 3 4 Solenoid Frame Cover Assembly Hex Key 1 8 3 4 x 2 Solenoid Coil Assembly Tubing Hex Nut Plated 10 32 Solenoid Frame Hex Head Self Locking Nut Plated 10 32 Solenoid Support Hex Washer Head Thread Forming Screw Plated 10 32 x 1 4 Solenoid Plunger Hex Socket Head
37. cal cover For your convenience a space has been provided on the front cover of this Manual for entering this information We recommend that you fill it out immediately so it is readily at hand when needed The contents of this manual are of necessity general in nature and may cover features not incorporated on your hoist therefore the user must exercise care in applying instructions given in this manual If specific information not in this manual is required contact the factory at Muskegon Michigan 49443 THE INFORMATION CONTAINED IN THIS MANUAL IS FOR INFORMATIONAL PURPOSES ONLY AND YALE LIFT TECH DOES NOT WARRANT OR OTHERWISE GUARANTEE IMPLIEDLY OR EXPRESSLY ANYTHING OTHER THAN THE COMPONENTS THAT YALE LIFT TECH MANUFACTURES AND ASSUMES NO LEGAL RESPONSIBILITY INCLUDING BUT NOT LIMITED TO CONSEQUENTIAL DAMAGES FOR INFORMATION CONTAINED IN THIS MANUAL NOTICE Information contained in this book is subject to change without notice SECTION GENERAL DESCRIPTION Paragraph 1 1 General Paragraph 1 2 Basic Construction Paragraph 1 3 Differences Between Models SECTION II INSTALLATION Paragraph 2 1 General Paragraph 2 2 Suspending Hoist Paragraph 2 3 Connecting Hoist to Electrical Service Paragraph 2 4 Pre Operation Checks SECTION III OPERATION Paragraph 3 1 General Paragraph 3 2 Push Button Operation Paragraph 3 3 Overload Clutch Operation Optional Paragraph 3 4 Operating Precautions SECTION IV LUBRICATION General
38. ciencies DO NOT constitute a safety hazard Written dated and signed inspection reports for many items are mandatory under OSHA regulations and many state safety codes It is strongly recommended that the Inspection Schedule and Maintenance Report shown herein be completed by a qualified person designated with the responsibility for hoist operation and safety or an inspector appointed by this person Inspection records can point out the service life of hoist components and help forecast the need for adjustments repairs and ordering of replacement parts File and review these reports after each inspection AWARNING Do not operate a hoist having unusual vibrations sounds or other conditions Danger may be present that the hoist operator cannot see Determine and correct cause of unusual conditions and make certain the hoist can be operated safely Be certain to disconnect power to the hoist whenever electrical cover is removed 5 2 INSPECT LOWER BLOCK a Check lubrication of all parts If the thrust bearing is not equipped with a grease fitting lubricate with SAE No 50 oil Also lubricate the shank of the hook which passes through the lower block body b Check each sheave to ensure rope groove is smooth and free from burrs or other surface defects c Check each sheave for freedom of rotation bearings if defective replace d Make certain that dowel pin holding the hook nut to the hook is securely in pos
39. d SEVERE DAMAGE AND OR A DROPPED LOAD COULD RESULT Allow 6 for hook drift in both directions Never allow less than 1 1 2 complete wraps of rope on drum with hook in lowest position Provide a light film of NLGI No 2 grease on bevel gear of limit switch 7 5 OVERLOAD CLUTCH ADJUSTMENT When properly adjusted the overload device is designed so that the hoist will lift its full rated load but will refuse to lift an excessive overload The overload clutch is not externally adjustable It is necessary to remove the overload clutch assembly from the hoist for proper adjustment Therefore it is strongly recommended that when adjustment and or replacement parts are required a SHAWBOX Authorized Repair Station be contacted Consult your SHAWBOX Distributor for nearest Repair Station SECTION VIII WIRING DIAGRAMS Wiring diagrams for SHAWBOX electric hoists have been omitted from this book because of many possible variations This is due to different currents and types of electrical components used in their construction A print of the correct wiring diagram for each hoist is furnished as a separate insert and shipped with hoist We suggest you carefully file the wiring diagram with this book for future reference WHEN ORDERING PARTS OR INFORMATION ON THIS EQUIPMENT ALWAYS INCLUDE MODEL AND SERIAL NUMBER ON ORDER SECTION IX PARTS LIST 9 1 GENERAL The parts lists and illustrations in this section of the manual cov
40. ditional units or provide a similar form to suit particular conditions which may exist However written dated and signed inspection reports should be maintained particularly on critical items such as hoist hooks hoisting ropes sheaves drums and brakes Periodic review of old inspection reports can point out service life of hoist components forecasting need for adjustment repair or replacement of these components As a matter of expedience appointed maintenance personnel inspecting the hoist can also take care of minor adjustments repairs and cleaning where required Note the column on Inspection Schedule and Maintenance Report form headed Corrective Action and Notes When corrective action is made during inspection note condition of part or unit as inspected in appropriate Condition column with a check mark v Note during inspection corrective action taken and date in space provided In this manner items requiring further attention will be checked v without showing corrective action This will advise the designated person responsible for hoist operation and safety who reviews the reports that deficiencies exist The designated person will check all deficiencies as listed and reexamine or otherwise determine whether they constitute a safety AWARNING Deficiencies may be hazardous to personnel and equipment Do not operate a hoist having deficiencies unless a designated qualified person has determined that these defi
41. emble hoist and inspect for defective worn or damaged parts See Section VII paragraph 7 5 Reduce loading to rated load as shown on nameplate With No Load check hoist for drift If drifting is excessive inspect motor brake Section V paragraph 5 5 and adjust as outlined in Section VII paragraph 7 2 1 After determining that the motor brake is working properly attach rated load to hook and operate hoist If the load accelerates during lowering the load brake is not functioning properly See Section V paragraph 5 6 for replacing worn or damaged parts 2 If load brake checks O K magnetic motor brake needs adjustment see b above Check collectors for free movement of spring arm weak spring or electrical connections Check all wiring for loose connections SECTION VII ADJUSTMENTS 7 1 MECHANICAL LOAD BRAKE The mechanical load brake on Series 800 YALE hoists is a pawl and ratchet Weston type automatic brake The brake is not adjustable and requires only periodic inspection and occasional replacement of the friction washers 7 2 MOTOR BRAKE Instructions for adjusting the brake are inside the brake cover and are repeated below Check brake adjustment after the first 30 days of service and regularly thereafter during the six month inspection procedure Two versions of the motor brake occur in this manual ADJUSTING a A aj INDICATING f TANG
42. en wheel flanges is 1 4 see Figure 2 1 greater than beam width 3 8 if beam has curves This is accomplished by rearranging the spacer washers on the bolts connecting trolley side plates to hoist mounting lug If trolley is shipped separate from hoist see instruction sheets furnished with trolley for orientation and installation When proper spacing has been determined loosen mounting nuts item 1 Figure 2 1 to allow trolley wheels to spread far enough to pass over edges of beam flange Some installations may require complete removal of one trolley side plate Using adequate equipment carefully lift the hoist and trolley so the wheel treads will rest on the lower beam flange Replace side plate and washers if removed for installation Replace suspension stud nuts ACAUTION Recheck spacer washers to make certain that the number of washers between the side plate and hoist suspension lug are equal and also the number on the outside of each side plate are equal The suspension stud nuts should only be snugged up on the lockwashers until a load has been applied on the hook A partial load approx 25 rated hoist load placed on the hook will properly seat hoist in the trolley Tighten suspension stud nuts only after hoist has been properly seated in the trolley AWARNING Mounting of the hoist trolley unit on the monorail and final pre operation inspection shall be performed only by qualified persons properly supervised
43. er parts for all standard 800 SHAWBOX Electric Hoists A typical hoist is shown as the basis for the exploded parts illustrations therefore certain variations may occur from the information given For this reason always give the Hoist Serial Number Catalog Number Motor Horsepower Voltage Phase Frequency and Rated Load of Hoist when ordering parts Certain parts of your hoist will in time require replacement under normal wear conditions It is suggested that these parts be purchased for your hoist as spares for future use These parts are indicated by a t symbol at the right side of the parts reference numbers AWARNING NON FACTORY AUTHORIZATIONS OR MODIFICATION OF EQUIPMENT AND USE OF NON FACTORY REPAIR PARTS CAN LEAD TO DANGEROUS OPERATION AND INJURY TO AVOID INJURY Do not alter or modify equipment without factory authorization Do use only factory provided replacement parts The numbers assigned to the parts of our various assemblies in our parts lists are not the part numbers used in manufacturing the part They are identification numbers that when given with the model number permit us to identify select or manufacture and ship the correct part needed Figure No 9 1 9 2 9 3 9 4 9 5 9 6 9 7 9 8 9 9 9 10 9 11 9 12 9 13 9 14 Frame Gearcase and External Parts Gearing and Load Brake Parts Hoist Motor Brake Later Version Hoist Motor Brake Early Version Three Phase Motor Assembly Upper
44. ft 40 Lift 3 Ton 5 16 Dia Rope 30 Lift 45 Lift 5 Ton 5 16 Dia Rope 20 Lift 30 Lift Screw Hex Socket Head Roll Pin Qty Req d ee i a a EN oO pO YH N Figure 9 1 Frame Gearcase amp External Parts Cont d Part Qty Number Description Req d 800 166 Lockwasher 800 167 Screw Hex Head Cap Key Plate Shaft Sheave Double Reeved Models Bracket Sheave Double Reeved Models Bearing Sheave Double Reeved Models 800 172 Sheave Assembly Upper Double Reeved Models Includes Bearing Rope amp Thimble Assembly Double Reeved Models 1 2 amp 1 Ton 3 16 Dia Rope 800 174 18 Lift 800 176 34 Lift 800 2119 47 Lift 2 Ton 1 4 Dia Rope 800 173 14 Lift 800 175 25 Lift 800 2120 36 Lift 800 177 Plug Pin 800 178 Bolt Hex Head 800 196 Label Rated Load Specify Rated Load tRecommended spares NOTES Page 25 Figure 9 2 Gearing and Load Brake Parts Part Qty Number Description Req d Page 26 800 201 800 202 800 203 800 204 800 205 800 266 800 206 800 2205A 800 207 800 209 800 210 800 2209 800 211 800 212 800 2211 Bearing Assembly Needle Intermediate amp Drum Gear Shaft Race Thrust Bearing Bearing Assembly Needle Thrust Gear Intermediate 104 Teeth 109 Teeth 103 Teeth 90 Teeth 107 Teeth Key Woodruff Gear Drum 71 Teeth 61 Teet
45. gs Upper Block Lower Block Hook amp Throat Opening Hoist Rope Rope Drum Guards Limit Switch Record Hook Throat Opening OOOOOO0O O Pushbutton CONTROL STATION OR PUSH BUTTON Wiring Motor Brake when so equipped Couplings Gears Shafts amp Bearings Frame Wheels Bumpers Guards Conductors Collectors Hoist Trolley TROLLEY RESISTORS Monorail Joints Monorail Main Conductors Main Collectors General Condition Load Attachment Chains Rope Slings amp Connections Change Gearcase Lub Grounding Faults RUNWAYS See text for DAILY amp WEEKLY REQUIREMENTS SIGNED amp DATED REPORT REQUIRED OSHA O INSPECTION INTERVAL X MAGNETIC PARTICLE OR EQUIVALENT EXAMINATION REQUIRED Typical Inspection Schedule and Maintenance Report form User must adjust inspection interval and components to suit his individual conditions and usage 12375B Page 10 TIME INTERVAL INSPECTION OR MAINTENANCE Daily or start Check operation of all functional mechanisms including limit switch operation bf each shift brakes and control Check hoist cable for kinks abrasions corrosion or broken Visual wires or evidence of improper spooling on drum Inspect hooks upper and lower blocks and all load bearing components for damage 1 Month HOIST CAB
46. h 71 Teeth Shaft Intermediate Gear 14 Teeth 24 Teeth 14 Teeth Figure 9 2 Gearing and Load Brake Parts Cont d Description 800 219 Ring Retaining Drum Shaft Bearing 800 221 Ring Retaining 800 222 Bearing Assembly Roller Intermediate Shaft 800 269 Cover Oil Hole 800 224 Pipe Plug Hex Socket 800 225 Oil Seal Motor Shaft 800 226 Bearing Assembly Ball Motor Shaft 800 227 Bearing Assembly Needle Load Brake Shaft 800 228 Ring Retaining Motor Shaft Bearing 800 229 Washer Thrust Steel Brake Assembly Load Complete Includes Items 26 thru 37 800 230 23 Teeth 800 231 36 Teeth 800 267 24 Teeth 800 232 18 Teeth 800 2232A 20 Teeth 800 233 Ring Retaining Brake Flange 800 234 Flange Load Brake 800 235 Washer Friction 800 236 Pawl amp Ratchet Assembly Load Brake Available Only As An Assembly 800 237 Bushing Ratchet 800 238 Gear amp Center Assembly 800 239 Pin Groove 800 240 Cam Load Brake 800 241 Spring Load Brake 800 242 Retainer Spring Load Brake 800 243 Key Woodruff Shaft amp Integral Pinion Load Brake 800 244 23 Teeth 800 245 36 Teeth 800 268 24 Teeth 800 246 18 Teeth 800 2246A 20 Teeth 800 247 Washer Thrust Used With 800 246 Only 800 248 Washer Thrust Bronze 800 249 Bearing Assembly Needle Load Brake Shaft 800 250 Load Brake Clutch Assembly With Bearings Complete 800 251 Load Brake Clutch Assem
47. hipped from the factory without an exterior coating on hoisting cable It is recommended where conditions permit that the cable be thoroughly coated at installation and kept well lubricated with LUBRIPLATE Chain and Cable Fluid or equal suitable for all temperature ranges 4 4 LUBRICATE UPPER SHEAVE AND LOWER BLOCK ASSEMBLY a All hoists have grease fittings located in ends of sheave pins Apply NLGI No 2 grease for operating temperatures from 50 F to 125 F For colder temperatures 20 F to 50 F use NLGI No 1 grease b Apply a few drops of S A E No 50 oil to hook thrust bearings National Lubricating Grease Institute 4 5 LUBRICATE LIMIT STOP LEVER a Apply a few drops of S A E No 50 oil to pivot points of limit rod b Apply a few drops of S A E No 50 oil to shaft bearing at rear of electrical compartment Page 7 4 6 LUBRICATE LIMIT SWITCH Provide a light film of NLGI No 2 grease on bevel gear of limit switch SECTION V INSPECTION AND PREVENTIVE MAINTENANCE 5 1 GENERAL YALE Series 800 hoists are inspected and tested at the factory Regular in service inspection and preventive maintenance programs not only help reduce overall maintenance costs but may also prevent serious shutdowns by forewarning of problems that could cause these shutdowns Regular inspections periodic minor adjustments regular cleaning and lubrication and replacement of worn parts can help preserve good performa
48. hoist All electrical connections including connections to collectors or power cord shall be made only by qualified journeymen electricians AWARNING The green wire provided in the power supply cable when furnished is a grounding wire and must be connected to a proper ground c When trolley is shipped separate from hoist see special instructions furnished with trolley for orientation and installation 2 4 PRE OPERATION CHECKS a Check Oil Level and Grease Fittings The gearcase has been filled with oil to the proper level and grease points for lower and upper sheaves have been lubricated at the factory However this should be checked before operating hoist Check oil level by removing oil level plug with hoist in a level position Oil level should be at the bottom edge of the plug hole If not add oil as specified in Section IV Grease fittings in lower and upper sheave pins should show evidence of grease ACAUTION Overfilling of the gearcase may result in the excess fluid being expelled through the breather b Check Push Button Operation and Phasing AWARNING On three phase hoists it is possible to have Reverse Phasing causing the lower block to lower when the 4 button is depressed When this condition exists the automatic limit stop switch is inoperative and hoist operation will be dangerous To properly check the phase of the hoist follow the steps below 1 With POWER OFF
49. iewing brake from flange end with strap wrench and press down on flange until snap ring groove in shaft is exposed allowing snap ring to be installed Use extreme care not to over wind spring as yield will result and final spring torque will be reduced Do not wind gear beyond point necessary to install snap ring in groove h Install gearing and load brake assembly in gearcase in reverse order of disassembly Be certain roller thrust bearings are installed at both ends of intermediate gear shaft as shown in Figure 5 4 and that thrust washers are properly installed at both ends of load brake shaft as noted below 1 A steel thrust washer with 5 8 I D must be installed on the brake flange end end opposite pinion of load brake as shown in Figure 5 5 2 A bronze thrust washer with a lug on one side goes on pinion end of load brake shaft and it must be installed so that its lug engages the special slot located on the spot face surrounding the load brake bearing bore inside gearcase cover Use heavy grease to hold it in place on cover as cover is installed On hoists with 18 or 20 tooth load brake pinion an 11 16 I D steel thrust washer is installed between pinion and bronze thrust washer j At completion of reassembly of gearing and load brake in gearcase refill gearcase to proper level using correct grade of oil as outlined in Section IV LUBRICATION k For hoists equipped with an overload clutch optional which has been
50. imiting device to measure the load ay DO NOT operate hoist unless hook moves in the same direction as indicated on the pushbutton If opposite direction occurs see pre operation checks Paragraph 2 4 b az Observe recommended inspection and maintenance procedures ba DO use common sense and best judgement whenever operating a hoist Observe American National Standard Safety standard ANSI B30 16 latest issue SECTION IV LUBRICATION 4 1 GENERAL The lubrication services outlined in paragraphs 4 2 thru 4 6 should be performed at regular intervals to maintain top hoist performance and ensure long life Intervals of at least six 6 months coinciding with spring and fall seasons are recommended The reason for this is on hoists installed out of doors and in unheated areas a cold test lubricant is required in cold below freezing climates making seasonal changes necessary 4 2 CHANGE GEARCASE OIL Figure 4 1 a Remove oil drain plug from bottom of gearcase and drain out oil Two drain plugs one on front and one on back of gearcase b Flush out housing using petroleum solvent Reinstall drain plug c Refill thru oil hole cover to proper level bottom of oil level plug hole using 10 pints of Automatic Transmission Fluid DEXRON III Type suitable for all temperature ranges DRAIN PLUG E 11413A Figure 4 1 View Showing Location of One Oil Drain Plug 4 3 LUBRICATE HOISTING CABLE Hoists are s
51. ironmental conditions Various codes also regulate inspection and maintenance programs Attention must be given to applicable Federal Standards OSHA regulations National Standards state and local codes which may include mandatory rules relating to hoist inspection and maintenance The user should become familiar with all applicable codes for his area and be guided accordingly Listed on the Recommended Inspection and Maintenance Schedule are inspection frequencies and requirements Perform these inspections regularly as scheduled and additional inspections as may be required for activity service and environment of your hoist The hoist operator must be responsible for determining the operating conditions and severity of service Inspection Schedule and Maintenance Report Form Shown on page 10 of this manual is a recommended Inspection Schedule and Maintenance Report form which lists various components of the hoist The form also includes trolley components runway components and miscellaneous items This form is suggested as a guide for written inspection Page 8 reports Inspections are recommended each month and should be performed thoroughly enough to inform the hoist user of deficiencies for any item listed This form does not supersede the Inspection and Maintenance Schedule listed below but may be used to record scheduled inspection and maintenance services required The user should revise the inspection interval add ad
52. ition e If hook is equipped with a safety latch or rotational lock check to determine that they are in good operating condition f Check throat opening of hook Refer to Figure 5 1 It is recommended that upon receipt of the hoist a measurement be made and recorded of the hook throat opening OSHA Standards require that the hook be replaced if the throat opening exceeds 15 percent of the original opening or if the hook is twisted more than 10 degrees from the unbent plane A gage block properly identified to the hoist similar to the one shown in Figure 5 1 is suggested to be made for each hook for use in these measurements NOTE Hooks and hook openings shown are based on hooks normally furnished with standard hoists For dimensions of hooks having a special size shape or material consult the Muskegon Michigan factory For hooks with certain kinds of safety latches it may be necessary to remove latch to measure hook opening g Hooks showing signs of cracks must be replaced Hooks should be inspected at least once per year using dye penetrants magnetic particle or other suitable crack detecting methods RATED HOOK JCORRECT L SIZE DIMENSION NEW HOOK GAGE BLOCK LOWER BLOCK HOOK 11202A Figure 5 1 Proper Hook Opening Shown with latch removed for clarity h Check wear of the hook especially at the saddle and replace if badly worn 5 3 INSPECT UPPER BLOCK AND HOIST SUSPENSION a Check upper
53. matically stops hook travel If hook drifts upward slightly after stop switch is actuated a reversing switch will close and automatically reverse direction of hook travel 7 4 SCREW TYPE LIMIT SWITCH This limit switch has a rotary screw driven by a gear reduction which is coupled to the end of the drum shaft Adjustment discs operate the contacts of separate switches one for the hoisting circuit and one for the lowering circuit The switch assembly must be wired in accordance with the appropriate wiring diagram which is packaged with hoist Adjustment of this screw type limit switch is accomplished as follows Refer to Figure 7 2 AWARNING Before attempting actual adjustments be certain main power switch is OFF and locked in the open position ADJUSTMENT DISCS SWITCH SWITCH LOCKING 12758B PLATE Figure 7 2 Screw Type Limit Switch Adjustment Wires not Shown for Clarity a Remove four screws and lift off switch cover b Loosen locking plate screws Slide locking plate away from adjustment discs Page 21 c Turn proper adjustment disc right for up left for down toward stitch to reduce hook travel or away from switch to increase hook travel d Slide locking plate back into position ensuring slots on adjustment discs are fully engaged tighten locking plate screws to 4 in lbs e Replace cover AWARNING Check limit switch operation carefully without load before placing hoist in service If misadjuste
54. nce and operation of your hoist Many factors influence the inspection and preventive maintenance program required for your hoist Frequency and severity of service and material handled local environmental conditions and various applicable codes are some of the factors that the user must consider to adjust inspection and maintenance program outlined in this section to meet his specific conditions The inspection and maintenance services outlined in this section are considered minimum Recommended in the schedule are minimum inspection and maintenance intervals based on average daily use in a normal environment Average daily use is based on 1000 operational hours per year maximum and intermittent operation of the hoist eight hours per day five days per week with a maximum 40 on time and the average loading not exceeding 65 of rated load Environmental conditions in which the hoist operates are also important considerations for the user when adjusting hoist inspection and maintenance programs to local conditions Frequency of inspection and maintenance must be increased if hoist is subjected to severe atmospheric environmental conditions such as corrosive vapors extreme heat or cold cement or dust and other airborne contaminants The user should carefully consider all environmental conditions and adjust frequency and degree of maintenance for his local conditions Consult Lift Tech Field Service Department for advice for unusual env
55. nd refuse to lift load before 200 of the rated load is reached Should hoist lift 200 of the rated load STOP TEST A CLUTCH ADJUSTMENT IS REQUIRED See paragraph 7 5 OVERLOAD CLUTCH ADJUSTMENT 3 Run hoist with load causing clutch to slip hoist refusing load five cycles of approximately 1 second each ACAUTION To prevent overheating release the hoist control button at once when the hoist refuses to lift the load 4 Remove weights added in step 2 and return to hoist rated load Lift rated load one final time Clutch should not slip AWARNING Do not lift more than rated load except for test purposes NOTICE ALWAYS KNOW LOAD TO BE LIFTED LIFT TECH DOES NOT RECOMMEND LIFTING LOADS GREATER THAN THE RATED LOAD OF YOUR HOIST Page 18 6 1 Hoist Will Not Operate 6 2 Hook Moves in Wrong Direction 6 3 Hook Will Raise But Not Lower 6 4 Hook Will Lower But Not Raise Loose or Contactor Contactor Contactor SECTION VI TROUBLE SHOOTING Probable Cause a No power to hoist Wrong voltage broken wire connections in hoist electrical system assembly not functioning No control voltage f Motor burned out Reverse phasing on three phase hoists Hoist wired wrong Lower electrical circuit open assembly not functioning Down push button inoperative Excessive load Hoist electrical circuit open assembly n
56. ng e If block still tends to twist repeat the above procedure until block rotation is corrected 5 10 TESTING HOIST AND OVERLOAD CLUTCH Optional a General Before placing hoist in service or after disas sembly and reassembly hoist should be tested To test sus pend hoist from an overhead supporting member of sufficient strength to support the weight of the hoist and the rated load Hoists having overload clutches require an overhead sup porting structure capable of supporting with appropriate safety factor a load equal to 200 percent rated load and the weight of the hoist Connect hoist to power supply as shown on hoist nameplate and perform the checks listed in b and c below b Check hoist as outlined in PRE OPERATION CHECKS Section Il paragraph 2 4 c Check hoist with capacity load 1 Attach rated load to lower hook 2 Depress push button and raise load When push button is released hoist should immediately stop and hold load at that level 3 Depress WV push button lower load a short distance and release button Hoist should stop immediately and hold load at that level NOTE If load drifts downward slowly in step 2 or 3 above motor brake requires adjustment see MOTOR BRAKE ADJUSTMENT Section VII paragraph 7 2 d Overload Clutch The overload clutch optional must be tested for proper operation before placing hoist in service or after disassembly and reassembly of hoist F
57. nnel clear of hoist TURN ON POWER 3 Operate hoist 48 guiding rope into grooves at both ends of drum until the distance from the drum to the loop is about 28 for 2 part double reeved 4 Proceed with reeving as described in appropriate paragraph below and the reeving diagram for your hoist d Reeving 2 part single See Figure 5 12 for diagram See Figure 9 11 for block parts With new rope installed on the drum as described in paragraph 5 9c single reeved above proceed with rereeving following steps below 1 Pass other end of rope thru bottom opening of hoist between floating limit rod and motor and attach rope to cast dead end anchor fitting A slot is located at top of fitting to accept cable Reinstall bolt and lockwasher in end of anchor fitting to lock rope compression fitting in place 2 Grasp loop formed after installing end anchor and place bottom block sheave in loop Lower sheave into bottom block and insert sheave pin Replace key plates and bolts holding sheave pin in place 3 Replace sheave guard Make certain rope is not twisted Should the two parts of rope tend to wind around each other remove cable from anchor slot and untwist cable Reattach the cable anchor 4 Lubricate cable per paragraph 4 3 ROPE ANCHOR ROPE RETAINING REEVING AS VIEWED FROM MOTOR SIDE 12203A Figure 5 12 Hoist Reeving Two Part Single e Reeving 4 part single See Figure
58. operate all the push buttons and determine that they do not bind or stick in any position AWARNING If any push button binds or sticks in any position DO NOT TURN POWER ON determine the cause and correct the malfunction before operating 2 Temporarily connect hoist to power source 3 Operate a button briefly to determine direction of hook travel 4 If hook raises phase is correct Turn power off and make temporary connections permanent 5 If hook lowers hoist is Reverse Phased TURN POWER OFF and correct by interchanging any two leads at power source connection Do not change internal wiring of hoist c Check Limit Switch Operation 1 A block operated upper limit stop Figure 2 2 is furnished as standard equipment This limit stop is factory set to stop lower block in its high position and guard against over travel and possible damage to hoist Note mounting position of floating lever for 3 and 5 ton hoists No adjustment can be made Limit switch operation should be tested when hoist is installed Move hook to a low position by depressing push button marked Now depress button marked to raise hook While hook is traveling upward manually or with an extension pole raise limit stop mechanism Figure 2 2 LECETA FHA D TOH WIQELG LOT a P ETH BOCES Mios Figure 2 2 Limit Stop Mechanism Being Tripped By Lower Block When floating rod is raised stop switch is actuated first
59. or other damage 5 8 ROPE INSPECTION MAINTENANCE AND REPLACEMENT AWARNING Wire rope improperly handled or abused can create a SAFETY HAZARD Read and comply with inspection maintenance and replacement information given herein a Inspection Wire rope on your hoist is one of the most important components requiring frequent inspection and maintenance All wire ropes will eventually deteriorate to a point where they are not safe and will require replacement WIRE ROPE SHOULD BE THOROUGHLY INSPECTED AT REGULAR MONTHLY INTERVALS BY AN AUTHORIZED PERSON AND A DETERMINATION MADE WHEN FURTHER USE OF THE ROPE WOULD CONSTITUTE A SAFETY HAZARD Each inspection should include a written dated and signed report of rope condition Reports should be filed and reviewed each month and any rope deterioration carefully noted Inspections revealing but not limited to the following conditions should cause the inspector to question remaining strength of rope and consider replacement 1 Twelve randomly distributed broken wires in one rope lay or four broken wires in one strand 2 Wear of one third of the original diameter of outside individual wires 3 Kinking crushing or bird caging 4 Heat damage from any cause 5 Reductions from nominal diameter of more than 1 64 for 3 16 1 4 and 5 16 diameter rope 6 Rope corrosion internal or external 7 Effects from improper lubrication 8 Rope idle for month or more due to shu
60. or test procedure follow instructions listed below Page 17 AWARNING BEFORE ATTEMPTING TO TEST THE OVERLOAD CLUTCH MAKE CERTAIN THE FOLLOWING PREREQUISITES ARE STRICTLY OBSERVED a An appointed person must determine before starting that all structures supporting the hoist are adequately strong to withstand the test load of 200 of the rated load plus the weight of the hoist whether hoist is tested in installed position or moved to a designated test facility b Loads used for testing must be accurately known c Test must be made ONLY by a qualified operator thoroughly familiar with the hoist and the purpose of the test d Adequate and proper rigging must be provided to ensure that test loads are securely attached properly balanced and lifted level Failure to provide adequate support could cause injury to personnel and or damage to equipment 1 Using a known load equal to the hoist rated load energize hoist to lift the load Raise this load just high enough to be certain hoist is lifting the entire load Clutch should not slip with the rated load Lower load to rest position If clutch slips with rated load adjustment is required See paragraph 7 5 OVERLOAD CLUTCH ADJUSTMENT If hoist will lift rated load proceed to step 2 2 Increase load in steps from rated load TO A MAXIMUM OF 200 of the rated load attempting to lift load with each increase in weight Hoist Overload Clutch should slip a
61. ot functioning Up push button inoperative a Check switches circuit breakers or fuses and connections in power supply lines Check power collectors Check voltage required on motor data plate against power supply Shut off power supply remove electrical cover on hoist and check wiring connections Also check connections in push button station and limit switches See that necessary jumper wires are properly installed Verify that the contactor armatures are free to move If binding occurs replace contactor Check for burned out contactor coils Check transformer fuse If blown check for grounding and or shorts in the push button station Check the transformer coil for signs of overheating Replace transformer if burned out Verify the transformer secondary is the same voltage as the coils to which it is connected Replace motor Check input power supply Check hoist motor connections Interchange any two power supply line leads Refer to Section II paragraph 2 4 b Check wiring connections with appropriate wiring diagram Check for loose connections See that necessary jumper wires are properly installed on contactor See that necessary jumper wires are properly installed Verify that the contactor armatures are free to move If binding occurs replace contactor Check for burned out contactor coils Check push button contacts and wires Reduce loading to rated load
62. parts in reverse of disassembly 11404A e Adjust brake as explained in Section VII Figure 5 3 View of Gearcase Cover Removed 5 6 INSPECT MECHANICAL LOAD BRAKE GEARING AND OVERLOAD CLUTCH Optional b To inspect gearing pull out intermediate gear and pinion assembly and roller thrust bearings Figure 5 4 and load brake assembly Figure 5 5 Do not remove drum gear unless visual inspection indicates replacement is necessary a The mechanical load brake and gearing may be inspected and serviced with hoist suspended To do so remove lower block and wire rope drain oil from gearcase remove 12 hex head bolts and lockwashers holding gearcase cover and pull c Inspect gears and pinions for signs of tooth wear and cover from gearcase Figure 5 3 damage If replacement of any parts appears necessary disassemble drum gear intermediate gear and pinion assembly and load brake assembly as directed on following page Page 11 Figure 5 4 Removing Intermediate Gear and Pinion Assembly LOAD BRAKE Da ASSEMBLY Figure 5 5 Removed Load Brake Assembly d To disassemble drum gear remove external snap ring from splined shaft using heavy duty snap ring pliers and pull off gear e To disassemble intermediate gear and pinion press pinion shaft from gear using an arbor press f Itis recommended that load brake assembly be returned to an Authorized Repair Station for inspection and repair If it is neces
63. rd 6 Lubricate rope per paragraph 4 3 h Checking for and removal of rope twisting Although rereeving of hoist may have been done carefully sometimes after new rope has been installed twisting may occur With new rope installed the hoist block should be raised and lowered several times with gradually increasing loads through full lift If the block still rotates excessively at no load the rope may have twists which should be removed 1 To remove rope twist in single reeved hoists a Observe direction block tends to rotate b Lower the block to a low position and turn off power c Rotate rope near the anchor end several turns in a direction tending to correct block rotation This rotates rope end fitting in the anchor d Turn on power raise and lower the block several times to feed the correcting twist in the rope through the reeving e If block still tends to twist repeat the above procedure until block rotation is corrected 2 To remove rope twist in double reeved hoists a Observe direction block tends to rotate b Lower the bottom block unspooling rope from rope drum until only one quarter 1 4 turn remains to rope end anchors in drum c Rotate rope near ends entering drum in a direction tending to correct block rotation This rotates rope end fittings in the drum d Turn on power raise and lower the block several times to feed the correcting twist in the rope through the reevi
64. rope around the load x DO NOT lift a load if any binding prevents equal loading on all supporting ropes y DO NOT apply the load to the tip of the hook z DO NOT operate unless load is centered under hoist aa DO NOT allow your attention to be diverted from operating the hoist ab DO NOT operate the hoist beyond limits of wire rope travel ac DO NOT use limit switches as routine operating stops unless recommended They are emergency devices only ad DO NOT use hoist to lift support or transport people ae DO NOT lift loads over people af DO NOT leave a suspended load unattended unless specific precautions have been taken ag DO NOT allow sharp contact between two hoists or between hoist and obstructions ah DO NOT allow the rope or hook to be used as a ground for welding ai DO NOT allow the rope or hook to be touched by a live welding electrode aj DO NOT remove or obscure the warnings on the hoist ak DO NOT adjust or repair a hoist unless qualified to perform hoist maintenance al DO NOT attempt to lengthen the wire rope or repair damaged wire rope am DO NOT allow personnel not physically fit or properly qualified to operate hoist an DO NOT operate hoist unless limit switch is operating properly ao DO be sure there is no twist in wire rope ap DO avoid operating hoist when hook is not centered under hoist Avoid side pulls and swinging of load or load hook when traveling hoist AWARNI
65. same direction as shown on controls Page 6 d DO make sure hoist limit switches function properly e DO maintain firm footing when operating a hoist f DO make sure that load slings or other approved single attachments are properly sized and seated in the hook saddle g DO make sure that the hook latch is closed and not supporting any part of the load h DO make sure that load is free to move and will clear all obstructions i DO take up slack carefully check load balance lift a few inches and check load holding action before continuing j DO avoid swinging of load or load hook k DO make sure that all persons stay clear of the suspended load DO warn personnel of an approaching load m DO protect wire rope from weld splatter or other damaging contaminants n DO promptly report any malfunction unusual performance or damage of the hoist o DO inspect hoist regularly replace damaged or worn parts and keep appropriate records of maintenance p DOuse the hoist manufacturer s recommended parts when repairing a hoist q DO use hook latches r DO apply lubricant to wire rope as recommended s DO NOT lift more than rated load t DO NOT use a damaged hoist or a hoist that is not working correctly u DO NOT use the hoist with twisted kinked damaged or worn wire rope v D NOT lift a load unless wire rope is properly seated in its drum groove s w DO NOT use wire rope as a sling or wrap
66. sary that you make your own inspection and repair instructions below must be followed 1 Place load brake assembly flange up in a vise equipped with brass or copper jaw plates to protect pinion gear teeth Remove snap ring from end of load brake shaft Figure 5 6 SNAP RING Figure 5 6 Remove Snap Ring From Load Brake Shaft Page 12 2 Using a puller tool remove brake flange from shaft A groove is provided around outer diameter for this purpose See Figure 5 7 Remove key from shaft and lift off 2 friction discs and the pawl and ratchet assembly Figure 5 8 PULLER GROOVE FRICTION Disc Figure 5 7 View Showing Load Brake Flange Removed 3 Remove load brake gear If replacement of spring spring retainer or cam is necessary press off shaft Figure 5 9 4 The load brake pawl and ratchet is a riveted assembly and is not to be disassembled 5 Clean all parts thoroughly and inspect for wear and damage Replace all parts that are excessively worn or damaged Hard surface or glazed friction discs should be replaced PAWL amp RATCHET _ ASSEMBLY o gt FRICTION DISC Figure 5 8 Removing Pawl and Ratchet Assembly From Load Brake Shaft g Reassemble gearing and load brake parts following reverse procedure of disassembly In assembling load brake observe assembly steps 1 through 4 below 1 Before installing spring in its retainer Figure 5 9 apply a good grade of ball bearing grease
67. st Y to completely unwind all wire rope from drum Stop hoist so drum anchor slot s is accessible Remove live rope and socket s from drum 7 TURN OFF POWER TO HOIST 8 Remove the bolt and lockwasher in the end of the rope anchor fitting Remove rope from slot in top of anchor c Installing new rope AWARNING Winding rope on rope drums with power can be hazardous Keep hands safe distance from drum wear gloves and use extreme care when handling rope SINGLE REEVED HOISTS Stretch new cable on floor in one continuous length Make certain there is no twist in rope 1 Place one end of rope in rope drum anchor slot Be sure end fitting is properly seated 2 With all personnel clear of hoist TURN ON POWER 3 Operate hoist guiding new rope into drum grooves with gloved hand until the following lengths remain unwound a 2 part single reeved about 14 0 b 4 part single reeved about 28 0 c 6 part single reeved about 42 0 4 Proceed with reeving as described in appropriate paragraph below and the reeving diagram for your hoist DOUBLE REEVED HOISTS Stretch new cable on floor in one continuous length Make certain there are no twists in rope 1 Pull far end of rope toward end of rope nearest hoist until both ends are even and a loop is formed Place fittings on both ends of rope in anchor slots on rope drum Be sure end fittings are properly seated 2 With all perso
68. tdown Special attention should be exercised when inspecting rope normally hidden during inspecting procedures Page 14 b Maintenance Keep rope well lubricated to help reduce internal friction and prevent corrosion Lubricant as described in paragraph 4 3 should be applied as a part of the regular maintenance program Special attention is required to lubricate sections of rope over equalizing sheaves and other hidden areas Avoid dragging ropes in dirt or around sharp objects which will scrape nick crush or induce sharp bends in the rope c Replacement When recommended by an authorized inspector the rope should be replaced Replacement rope assemblies are shipped from the factory carefully coiled to prevent damage by kinking Care must be taken to avoid twisting or kinking when uncoiling and handling during reeving Before replacing rope check condition of grooves in sheaves and drums to determine if they are excessively worn AWARNING Use only factory approved rope with swagged wire rope sockets When first using the hoist after rope replacement break in rope by operating under lighter loads to full travel before applying maximum load 5 9 ROPE REEVING a General Before unreeling rope from a coil or reel be sure floor is clean Dirt picked up by the rope can cause excessive wear and abrasion Uncoil the rope by rolling the coil or reel along the floor or place reel on a stand with a shaft thru the center
69. to inside of retainer Spring must be positioned exactly as illustrated butted against pin at side of cam BUTT THES END OF SPRING ACANET Pi SIO OF C i LOAD BRACE SPAING SPIN Me TAINE A ore LOAD BRAKE GEAM AND SPRING OVERLOAD CLUTCH ASSY RETAINER LOAD BRAKE SPRING i BUTT THIS END OF SPRING AGAINST PIN IM CLUTCH CONE RECESS LOAD BRAKE STANDARD Figure 5 9 Load Brake Gear Removed From Load Brake Showing Load Brake Spring 2 When installing pawl and ratchet assembly on load brake shaft be certain that teeth on ratchet face are in the same direction as shown in Figure 5 8 The ratchet assembly should rotate freely when turned counterclockwise and the pawl should engage ratchet teeth when unit is turned clockwise 3 When installing brake flange position it with chamfer facing friction disc Figure 5 7 PLUMBERS STRAP WRENOH PORTABLE PPI Vite With SOT Jaw PLATES Figure 5 10 Winding Load Brake Gear Using a Strap Wrench to Set Up Load Brake Spring 4 The brake spring must be pre loaded at assembly to a torque of from 10 to 14 lb ft This is accomplished using a plumber s strap wrench to wind rotate load brake gear to set up spring Figure 5 10 while pressing brake flange into place using an arbor press Clamp pinion end of shaft into a portable vise to keep brake from rotating in press Use brass or copper jaw plates on vise to protect pinion gear teeth Wind gear counterclockwise v
70. ty Number Description Req d Motor Brake Assembly Includes Ref Nos 1 thru 32 800 1400 Short Frame Models Only 800 1401 Other Models j Acorn Nut 10 32 800 1402 Brake Cover Assembly Includes Brake Cover and Label Inside Cover Cover Stud Gasket Hex Washer Head Thread Forming Screw 10 32 x 1 3 4 Solenoid Frame Cover Assembly Hex Key 1 8 3 4 x 2 1 4 Solenoid Coil Assembly Tubing Hex Nut 10 32 Pltd Solenoid Frame ia Hex Head Self Locking Nut 10 24 800 1403 Solenoid Support j Hex Washer Head Thread Forming Screw 10 32 x 1 4 Solenoid Plunger 800 1404 Hex Socket Head Self Locking Set Screw Oval Point 1 4 28 x 1 Clevis Pin 3 16 x 1 1 4 Flat Washer Brake Spring Brake Lever Assembly Pressure Pad Brake Disc Non asbestos Brake Support Stud Separating Spring Hex Socket Head Self Locking Set Screw Cup Point 1 4 20 x 3 8 Brake Hub ig Hex Socket Head Screw 3 8 16 x 3 4 800 1405 Brake Mounting Plate i Wire Nuts Not Shown No 22 thru 16 AWG Not available as individual parts See replacement kits listed below Kits include quantities shown above E So ONOORHOOONDOAARWN NNN N O NN AU HRA POH PO NMNM_NDH_ NH HANH NH NWO HH H CR Kt ZO iP WWWNMNNNDND PP yw OOOND UO Page 30 Figure 9 4 Hoist Motor Brake Cont d Kit Description Part Number Reference Numbers Included Brake Disc 800 1406 24 25 27 Solenoid 800 1

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