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OPERATION, SERVICE & PARTS MANUAL
Before installing hoist, fill in the
information below. Refer to the
Hoist and Motor data plates.
Model No. _________________
Serial No. _________________
Purchase Date _____________
SERIES Y80
Voltage ___________________
Rated Load _______________
®
YALE
WIRE ROPE ELECTRIC HOISTS
INCLUDING
WEIGHT WATCHER OVERLOAD CLUTCH MODELS
RATED LOADS 1/2 THRU 5 TONS
Printed in U.S.A.
May, 2003 Copyright 2003, Yale� Lift-Tech, division of Columbus McKinnon Corporation Part
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FOREWORD provided on the front cover of this Manual for entering this information. This manual contains important information to help you install, operate, We recommend that you fill it out immediately so it is readily at hand maintain and service your new YALE electric hoist. We recommend when needed. that you study its contents thoroughly before putting the hoist into use. Read ANSI B30.16 safety code for hoists. Then, thru proper installation, The contents of this manual are of necessity, gen
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This brake requires periodic adjustment. SECTION I — GENERAL DESCRIPTION 1-1. GENERAL. YALE electric hoists are precision built wire SECTION II — INSTALLATION rope and drum type hoists which are made in five rated load sizes (1/2, 1, 2, 3 and 5 tons) with various lifts, lifting speeds 2-1. GENERAL. YALE electric hoists are lubricated and tested and electrical service. Equipped with an integrally welded before being shipped from the factory. To place hoist in service, mounting lug, they are desig
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For trolleys which are to be mounted along the span of a beam not having open ends, measure exact width of beam WARNING flange and assemble trolley to hoist so that spacing between Be certain that electrical power supply is off and locked wheel flanges is 1/4" (see Figure 2-1) greater than beam in the open position before attempting any electrical width (3/8" if beam has curves). This is accomplished by connections to the hoist. This equipment must be rearranging the spacer washers on the bolts
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b. Check Push Button Operation and Phasing. When floating rod is raised, stop switch is actuated first 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 WARNING manner, refer to trouble shooting chart Section Vl for possible On three phase hoists it is possible to have “Reverse remedy. Phasing” causing the lower block to lower when the button is d
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d. DO make sure hoist limit switches function properly. SECTION III — OPERATION e. DO maintain firm footing when operating a hoist. 3-1. GENERAL. Operation of Series 800 YALE electric hoists f. DO make sure that load slings or other approved is controlled by a convenient pendant push button station. single attachments are properly sized and seated in the With it, the hoist can be controlled to give fast lifting and hook saddle. lowering; or controlled to lift or lower load in small increments, p
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ak. DO NOT adjust or repair a hoist unless qualified to SECTION IV — LUBRICATION perform hoist maintenance. 4-1. GENERAL. The lubrication services outlined in al. DO NOT attempt to lengthen the wire rope or repair paragraphs 4-2 thru 4-6 should be performed at regular damaged wire rope. intervals to maintain top hoist performance and ensure long am. DO NOT allow personnel not physically fit or properly life. Intervals of at least six (6) months, coinciding with spring qualified to operate hoist.
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4-6. LUBRICATE LIMIT SWITCH. Provide a light film of reports. Inspections are recommended each month and should NLGI No. 2 grease on bevel gear of limit switch. 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 SECTION V may be used to record scheduled inspection and maintenance INSPECTION AND PREVENTIVE services required. MAINTENANCE The user should revise the inspect
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5-2. INSPECT LOWER BLOCK. c. Make certain that rope guide pins are not bent, loose or otherwise distorted; guide pins must have close clearance to a. Check lubrication of all parts. If the thrust bearing is not sheave flange to keep rope in sheave grooves. equipped with a grease fitting, lubricate with SAE No. 50 oil. d. Check hoist suspension bolts on lug suspended hoists; Also lubricate the shank of the hook which passes through make certain that bolts are secure, properly tightened and the lo
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INSPECTION SCHEDULE AND MAINTENANCE REPORT HOIST SERIAL NO. (MFGRS) _______________________ CUSTOMER CRANE IDENTITY NO. _______________________ RATED LOAD _________________ LOCATION IN PLANT __________________________________ TYPE ________________________ THIS INSPECTION IS MONTHLY ANNUAL VOLTAGE _____________________ SEMI-ANNUAL INSPECTED BY: ________________ DATE _____________ Recom- * CONDITION COMPONENT, UNIT OR PART mended (Check column best indicating condition when CORRECTIVE ACTION
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TIME INTERVAL INSPECTION OR MAINTENANCE Daily or start Check operation of all functional mechanisms including limit switch operation, of each shift brakes and control. Check hoist cable for kinks, abrasions, corrosion or broken (\/isual) wires or evidence of improper spooling on drum. Inspect hooks, upper and lower blocks, and all load bearing components for damage. 1 Month * HOIST CABLE — Inspect and lubricate per paragraph 5-8. * ELECTRICAL CONTROLS — Inspect per paragraph 5-4. 1 - 3 Months Ch
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(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). 11421 Figure 5-4. Removing Intermediate Gear and Pinion Assembly. 10334 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
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(4) The brake spring must be pre-loaded at assembly to (1) Before installing spring in its retainer (Figure 5-9), apply a torque of from 10 to 14 lb.-ft. This is accomplished using a a good grade of ball bearing grease to inside of retainer. Spring must be positioned exactly as illustrated, butted against plumber’s strap wrench to wind (rotate) load brake gear to pin at side of cam. set up spring (Figure 5-10) while pressing brake flange into place using an arbor press. Clamp pinion end of shaft
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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
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(5) Remove key plates or snap rings from upper block With new rope installed on the drum as described in paragraph sheave(s) and slide out upper block sheave pins, releasing 5-9c single reeved above, proceed with rereeving following upper block sheaves. Remove wire rope from sheaves. steps below: (6) Make certain all personnel are clear of hoist and (1) Pass other end of rope thru bottom opening of hoist, operate hoist to completely unwind all wire rope from between floating limit rod and
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(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. Figure 5-13. Upper Sheave Installed. (Typical 3 and 5 Ton) (3) Pass free end of rope thru bottom opening of hois
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(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. Figure 5-16. Upper Sheave Installed (Typical). (c) Rotate ro
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WARNING 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
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SECTION Vl - TROUBLE SHOOTING Trouble Probable Cause Remedy 6-1. Hoist Will Not Operate. a. No power to hoist. a. Check switches, circuit breakers or fuses and connections in power supply lines. Check power collectors. b. Check voltage required on motor data plate b. Wrong voltage. against power supply. c. Shut off power supply, remove electrical cover on c.Loose or broken wire connections in hoist electrical hoist and check wiring connections. Also check system. connections in push button stati
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SECTION Vl - TROUBLE SHOOTING (Continued) Trouble Probable Cause Remedy 6-5. Hoist Will Not Lift Rated a. Low voltage a. See that power supply current is same voltage Load. Iisted on motor data plate. Check hoist motor connections. Check size of power supply lines. b. Overload Clutch not properly b. See Section VII, paragraph 7-5. adjusted. 6-6. Hoist Motor Overheats. a. Excessive load. a. Reduce loading to rated load of hoist, shown on nameplate. b. Excessive duty-cycle. b. Reduce frequency of
