Yale Personal Lift Series Y80 User Manual

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 _____________

SERIESY80

Voltage ___________________

Rated Load _______________

YALE

WIRE ROPE ELECTRIC HOISTS

INCLUDING

WEIGHT WATCHER OVERLOAD CLUTCH MODELS

RATED LOADS 1/2THRU 5TONS

Printed in U.S.A.

May, 2003

Part No. 117404-10

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This brake requires periodic adjustment.

SECTION I — GENERAL DESCRIPTION

1-1. GENERAL. YALE electric hoists are precision built wire

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

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.

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).

WARNING

Before attempting installation of hoist or trolley, the

main power switch must be locked in the open position

(off).

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.

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 l-beam

attached to a building or crane, servicing a larger area (Trolley

Mounted).

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 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.

WARNING

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.

WARNING

Design and installation of hoist support shall be

performed only by qualified persons.

1-3. DIFFERENCES BETWEEN MODELS. The main

differences between models are in rope reeving and frame

size as described below.

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.

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. 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.

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" 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.

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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

flange and assemble trolley to hoist so that spacing between

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.

WARNING

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.

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.

a. Follow National, State and Local Electrical Codes

when providing electrical service to the hoist.

CAUTION

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.

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.

b. Make electrical connections using the appropriate wiring

diagrams furnished with the hoist. All electrical connections,

including connections to collectors or power cord, shall be

made only by qualified journeymen electricians.

WARNING

The green wire provided in the power supply cable

(when furnished) is a grounding wire and must be

connected to a proper ground.

WARNING

Mounting of the hoist-trolley unit on the monorail and

final pre-operation inspection shall be performed only

by qualified persons properly supervised.

c. When trolley is shipped separate from hoist, see special

instructions furnished with trolley for orientation and

installation.

2-4. PRE-OPERATION CHECKS.

11207A

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.

CAUTION

Overfilling of the gearcase may result in the excess fluid

being expelled through the breather.

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.

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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

manner, refer to trouble shooting chart Section Vl for possible

remedy.

WARNING

On three phase hoists it is possible to have “Reverse

Phasing” causing the lower block to lower when the

á 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” operate all the push buttons

and determine that they do not bind or stick in any position

WARNING

If any push button binds or sticks in any position —

DO NOT TURN POWER ON — determine the cause

and correct the malfunction before operating.

Figure 2-3. Electrical Compartment Cover Removed

Showing Limit Switch and Reversing Switch Arrangement.

WARNING

Do not attempt to make above test with hook in a

high position near hoist.

(2) Temporarily connect hoist to power source.

(3) Operate á button briefly to determine direction of

hook travel.

(4) If hook raises, phase is correct. Turn power off and

make temporary connections permanent.

(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 Vll.

(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.

d. Check Lower Block and Hoisting Cable. Depress â 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 hoist up and

down a few times. If lower block still rotates, repeat process

until twisting is corrected.

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 â. Now depress button marked á to

raise hook. While hook is traveling upward, manually (or with

an extension pole) raise limit stop mechanism (Figure 2-2).

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.

11403

Figure 2-2. Limit Stop Mechanism

Being Tripped By Lower Block.

Figure 2-4. Rope End Anchor.

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d. DO make sure hoist limit switches function properly.

e. DO maintain firm footing when operating a hoist.

SECTION III — 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.

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.

When first using hoist, break-in by operating under lighter

loads to full travel before applying maximum load.

i. DO take up slack carefully, check load balance, lift a

few inches and check load holding action before

continuing.

3-2. PUSH BUTTON OPERATION.

j. DO avoid swinging of load or load hook.

a. Depress push button marked á to raise load.

b. Depress push button marked â to lower load.

k. DO make sure that all persons stay clear of the

suspended 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.

l. 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.

d. On two-speed hoists, partial depression of button operates

the hoist at slow speed; depressing button completely operates

the hoist at fast speed.

o. DO inspect hoist regularly, replace damaged or worn

parts, and keep appropriate records of maintenance.

p. DO use the hoist manufacturer’s recommended parts

when repairing a hoist.

3-3. OVERLOAD CLUTCH 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 á button is depressed and rotate the load brake gear

without lifting the load. Whenever this slipping occurs,

immediately release the á push button to prevent overheating

of the clutch friction surfaces and the hoist motor.

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. DO NOT lift a load unless wire rope is properly seated

in its drum groove(s).

NOTICE

w. DO NOT use wire rope as a sling or wrap rope around

the load.

Always know load to be lifted. Lift-Tech does not

recommend lifting loads greater than the rated load of

your hoist.

x. DO NOT lift a load if any binding prevents equal

loading on all supporting ropes.

3-4. OPERATING PRECAUTIONS.

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.

WARNING

Equipment covered herein is not designed or suitable

as a power source for lifting or lowering persons.

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.

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.

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.

a. DO read ANSI B30.16 Safety Standard for Overhead

Hoists and the Operation, Service and Parts Manual.

ai. DO NOT allow the rope or hook to be touched by a

live welding electrode.

b. DO be familiar with hoist operating controls,

procedures and warnings.

aj. DO NOT remove or obscure the warnings on the hoist.

c. DO make sure hook travel is in the same direction as

shown on controls.

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ak. DO NOT adjust or repair a hoist unless qualified to

perform hoist maintenance.

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.

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.

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.)

WARNING

b. Flush out housing using petroleum solvent. Reinstall drain

plug.

DO NOT operate 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.

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.

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.

11413A

au. DO NOT use hoists in locations that will not allow

operator movement to be free of the load.

Figure 4-1. View Showing Location of

One Oil Drain Plug.

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.

4-3. LUBRICATE HOISTING CABLE. Hoists are shipped 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.

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.

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.

ax. DO NOT use the hoist load limiting 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.

b. Apply a few drops of S.A.E. No. 50 oil to hook thrust

bearings.

az. Observe recommended inspection and maintenance

procedures.

(*) National Lubricating Grease Institute.

4-5. LUBRICATE LIMIT STOP LEVER.

ba. DO use common sense and best judgement whenever

operating a hoist. Observe American National Standard

Safety standard, ANSI B30.16, Iatest issue.

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.

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4-6. LUBRICATE LIMIT SWITCH. Provide a light film of

NLGI No. 2 grease on bevel gear of limit switch.

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.

SECTION V

INSPECTION AND PREVENTIVE

MAINTENANCE

The user should revise the inspection interval, add additional

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.

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 performance and operation of your hoist.

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 (ü). Note

“during inspection” corrective action taken and date in space

provided. In this manner, items requiring further attention will

be checked (ü) 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

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 environmental conditions.

WARNING

Deficiencies may be hazardous to personnel and

equipment. Do not operate a hoist having deficiencies

unless a designated qualified person has determined

that these deficiencies 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.

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.

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.

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.

WARNING

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.

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

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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.

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.

d. Check hoist suspension bolts on lug suspended hoists;

make certain that bolts are secure, properly tightened and

free from damage.

b. Check each sheave to ensure rope groove is smooth and

free from burrs, or other surface defects.

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.

c. Check each sheave for freedom of rotation; replace

bearings if defective.

d. Make certain that dowel pin, holding the hook nut to the

hook, is securely in position.

e. If hook is equipped with a safety latch or rotational lock,

check to determine that they are in good operating condition.

WARNING

Do not operate a hoist having worn or damages

suspension bolts.

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.

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.

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.

a. Disconnect electrical power to hoist, remove 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.

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.

HOIST

RATED HOOK CORRECT "L"

LOAD

SIZE

DIMENSION

(NEW HOOK)

(IN TONS) (STANDARD)

1/2

1-1/8"

1-1/4"

1-1/2"

1-3/4"

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 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.

Page 9

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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 o

SEMI-ANNUAL o

ANNUAL o

VOLTAGE _____________________

INSPECTED BY: ________________

DATE _____________

Recom-

mended

CONDITION

(Check column best indicating condition when

COMPONENT, UNIT OR PART

and location

CORRECTIVE ACTION

Inspection part or unit is inspected. Use note column to

Interval the right if condition is not listed below.)

NOTES

(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

DATE

Motor

Motor Brake

Mechanical Load Brake

Overload Clutch

Couplings

Gears, Shafts & Bearings

Upper Block

Lower Block

Hook & Throat Opening

Hoist Rope

Record Hook Throat Opening

Rope Drum

Guards

Limit Switch

Pushbutton

Wiring

Motor

Brake (when so equipped)

Couplings

Gears, Shafts & Bearings

Frame

Wheels

Bumpers

Guards

Conductors

Collectors

Hoist

Trolley

Monorail Joints

Monorail

Main Conductors

Main Collectors

General Condition

Load Attachment Chains

Rope Slings & Connections

Change Gearcase Lub.

Grounding Faults

See text for DAILY & WEEKLY REQUIREMENTS.

INSPECTION INTERVAL.

SIGNED & DATED REPORT REQUIRED – OSHA.

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

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TIME INTERVAL

INSPECTION OR MAINTENANCE

Daily or start

of each shift

Check operation of all functional mechanisms including limit switch operation,

brakes and control. Check hoist cable for kinks, abrasions, corrosion or broken

wires or evidence of improper spooling on drum. Inspect hooks, upper and lower

blocks, and all load bearing components for damage.

(\/isual)

1 Month

* HOIST CABLE — Inspect and lubricate per paragraph 5-8.

* ELECTRICAL CONTROLS — Inspect per paragraph 5-4.

Check hoist gearcase oil level — add oil as required per paragraph 4-2.

1 - 3 Months

* LOWER BLOCK — Inspect per paragraph 5-2.

UPPER BLOCK — Inspect per paragraph 5-3.

6 Months

Annually

Motor brake and actuating mechanisms. Inspect and adjust per paragraph 5-5.

* 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

with oil per paragraph 4-2. Lubricate hoist cable per paragraph 4-3. Lubricate

* upper and lower hook block per paragraph 4-4. Lubricate limit stop lever per

paragraph 4-5. If a screw type limit switch is furnished, add a light film of

NLGI No. 2 grease to bevel gear.

6 Months or

500 - 750 hours

“on” time

5 Years elapsed

time or 5000

Complete inspection, disassembly, and maintenance required. It is recommended

* 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 parts in reverse of disassembly.

e. Adjust brake as explained in Section Vll.

11404A

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

cover from gearcase (Figure 5-3).

c. Inspect gears and pinions for signs of tooth wear and

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

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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 pawl and ratchet is a riveted

assembly and is not to be disassembled.

11422

Figure 5-5. Removed Load Brake Assembly.

(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.

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. It is recommended that load brake assembly be returned

to an Authorized Repair Station for inspection and repair. If it

is necessary 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).

10335A

Figure 5-8. Removing Pawl and Ratchet Assembly

From Load Brake Shaft.

10333

g. Reassemble gearing and load brake parts following

reverse procedure of disassembly. In assembling load brake,

observe assembly steps (1) through (4) below:

Figure 5-6. Remove Snap Ring From Load Brake Shaft.

Page 12

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(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 (viewing 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.

(1) Before installing spring in its retainer (Figure 5-9), apply

a good grade of ball bearing grease to inside of retainer.

Spring must be positioned exactly as illustrated, butted against

pin at side of cam.

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:

LOAD BRAKE — OVERLOAD CLUTCH

(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.

LOAD BRAKE — STANDARD

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.

Figure 5-9. Load Brake Gear Removed From

Load Brake Showing Load Brake Spring.

k. For hoists equipped with an overload clutch (optional)

which has been 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.

(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).

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.

Figure 5-10. Winding Load Brake Gear Using a Strap

Wrench to Set Up Load Brake Spring.

Page 13

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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 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.

Figure 5-11. Removing Bolt

Securing Gearcase to Frame.

Before replacing rope, check condition of grooves in sheaves

and drums to determine if they are excessively worn.

c. Check parts for wear and damage. Replace drum if there

are any signs of cracks or other damage.

WARNING

Use only factory approved rope with swagged wire

rope sockets.

5-8. ROPE INSPECTION, MAINTENANCE AND

REPLACEMENT.

WARNING

Wire rope improperly handled or abused can create a

SAFETY HAZARD. Read and comply with inspection,

maintenance and replacement information given herein.

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 of reel so rope can be pulled straight out

with the reel rotating.

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:

CAUTION

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.

(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.

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.)

(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.

(2) Remove bottom block sheave guard.

(8) Rope idle for month or more due to shutdown.

(3) Remove key plates from both sides of sheave pin

and slide sheave pin from bottom block.

Special attention should be exercised when inspecting rope

normally hidden during inspecting procedures.

(4) Lift out sheaves from the top of the bottom block and

remove wire rope.

Page 14

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(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.

With new rope installed on the drum as described in paragraph

5-9c single reeved above, proceed with rereeving following

steps below:

(6) Make certain all personnel are clear of hoist and

operate hoist â 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.

(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.

(7) TURN OFF POWER TO HOIST.

(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.

(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.

(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.

WARNING

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.

(4) Lubricate cable per paragraph 4-3.

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 á, 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".

(4) Proceed with reeving as described in appropriate

paragraph below and the reeving diagram for your hoist.

12203A

DOUBLE REEVED HOISTS

Stretch new cable on floor in one continuous length. Make

certain there are no twists in rope.

Figure 5-12. Hoist Reeving — Two Part Single.

e. Reeving — 4 part single.

See Figure 5-14 for diagram.

See Figure 9-13 for block parts.

(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.

With new rope installed on the drum as described in

paragraph 5-9c single reeved above, proceed with rereeving

following steps below:

(2) With all personnel clear of hoist — TURN ON

POWER.

(3) Operate hoist á 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.

(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.

(4) Proceed with reeving as described in appropriate

paragraph below and the reeving diagram for your hoist.

(2) Insert sheave pin into sheave. Replace key plates

and bolts to hold sheave pin in place.

d. Reeving — 2 part single.

See Figure 5-12 for diagram.

See Figure 9-11 for block parts.

Page 15

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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 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.

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.

12204A

(5) Repeat step 4 for remaining bottom block sheaves.

Install sheave pin through sheaves. Replace key plates and

bolts securing sheave pin.

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.

(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:

(5) Replace sheave guard.

(6) Lubricate cable per paragraph 4-3.

f. Reeving — 6 part single.

(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.

See Figure 5-15 for diagram.

See Figure 9-13 for block parts.

(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.

With new rope installed on the drum as described in paragraph

5-9c single reeved above, proceed with rereeving following

steps below:

Page 16

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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).

tending to correct block rotation. This rotates rope

end fittings in the drum.

(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.

(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.

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 II, paragraph 2-4.

12206A

Figure 5-17. Hoist Reeving — Two Part Double.

c. Check hoist with capacity load.

(1) Attach rated load to lower hook.

(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.

(2) Depress á push button and raise load. When push

button is released, hoist should immediately stop and hold

load at that level.

(5) Replace sheave guard.

(6) Lubricate rope per paragraph 4-3.

h. Checking for and removal of rope twisting.

(3) Depress â push button, lower load a short distance

and release button. Hoist should stop immediately and hold

load at that level.

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.

NOTE: If load drifts downward slowly in step 2 or

3 above, motor brake requires adjustment — see

MOTOR BRAKE ADJUSTMENT — Section Vll —

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. For test

procedure follow instructions listed below.

(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.

a direction tending to correct block rotation. This

rotates rope end fitting in the anchor.

Page 17

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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 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 and 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.

CAUTION

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.

WARNING

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

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SECTION Vl - TROUBLE SHOOTING

Probable Cause

Trouble

Remedy

a. Check switches, circuit breakers or fuses and

connections in power supply lines. Check power

collectors.

6-1. Hoist Will Not Operate.

a. No power to hoist.

b. Check voltage required on motor data plate

against power supply.

b. Wrong voltage.

c. Shut off power supply, remove electrical cover on

hoist and check wiring connections. Also check

connections in push button station and limit

switches.

c. Loose

broken

wire

connections in hoist electrical

system.

d. 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.

d. Contactor

functioning.

assembly

not

e. 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.

e. No control voltage.

f. Replace motor. Check input power supply. Check

hoist motor connections.

f. Motor burned out.

a. Interchange any two power supply line leads.

Refer to Section II, paragraph 2-4 b.

6-2. Hook Moves in Wrong

Direction.

a. Reverse phasing on three-

phase hoists.

b. Check wiring connections with appropriate wiring

diagram.

b. Hoist wired wrong.

a. Check for loose connections. See that necessary

jumper wires are properly installed on contactor.

6-3. Hook Will Raise But

Not Lower.

a. Lower electrical circuit open.

b. 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.

b. Contactor

functioning.

assembly

not

c. Check push button contacts and wires.

c. Down, push button inoperative.

a. Reduce loading to rated load of hoist, as shown

on nameplate.

a. Excessive load.

6-4. Hook Will Lower But

Not Raise.

b. Check for loose connections. See that necessary

jumper wires are properly installed on contactor.

Check limit switch mounting and connections.

b. Hoist electrical circuit open.

c. 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.

c. Contactor

functioning.

assembly

not

d. Check push button contacts and wires.

d. Up, push button inoperative.

Page 19

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SECTION Vl - TROUBLE SHOOTING (Continued)

Probable Cause Remedy

Trouble

6-5. Hoist Will Not Lift Rated

Load.

a. Low voltage

a. See that power supply current is same voltage

Iisted on motor data plate. Check hoist motor

connections. Check size of power supply lines.

b. Overload Clutch not properly

adjusted.

b. See Section VII, paragraph 7-5.

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 lifts or amount of jogging.

c. Wrong voltage or frequency.

c. Check current rating on motor data plate against

power supply. Check hoist motor connections.

d. Defective motor or worn bear-

ings in hoist frame.

d. Disassemble hoist and inspect for defective, worn

or damaged parts.

e. Overload Clutch slipping without

lifting load.

e. See Section VII, paragraph 7-5.

6-7. Load Drifts Excessively

When Hoist Is Stopped.

a. Excessive load.

a. Reduce loading to rated load, as shown on

nameplate.

b. Motor brake not holding.

b. 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.

c. Load brake not holding.

c. (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).

6-8. Hoist Operates

Intermittently

a. Collectors make poor contact.

b. Loose connections.

a. Check collectors for free movement of spring arm,

weak spring or electrical connections.

b. Check all wiring for loose connections.

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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.

SECTION Vll — 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.

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.

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.

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.

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

automatically 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).

12759C

Figure 7-1A. Motor Brake - Later Version.

WARNING

Before attempting actual adjustments, be certain main

power switch is OFF and locked in the open position.

12759

ADJUSTMENT

SWITCH

Figure 7-1. Motor Brake - Early Version.

SWITCH

DISCS

LOCKING

PLATE

12758B

a. Examine position of indicating tang located below the

solenoid coil (Figure 7-1 or 7-1A).

Figure 7-2. Screw-Type Limit Switch Adjustment.

(Wires not Shown for Clarity.)

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.

a. Remove four screws and lift off switch cover.

b. Loosen locking plate screws. Slide locking plate away from

adjustment discs.

Page 21

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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.

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.

d. Slide locking plate back into position ensuring slots on

adjustment discs are fully engaged, tighten locking plate screws

to 4 in-lbs.

WHEN ORDERING PARTS OR INFORMATION ON THIS

EQUIPMENT, ALWAYS INCLUDE MODEL AND SERIAL

NUMBER ON ORDER.

e. Replace cover.

SECTION IX — PARTS LIST

9-1. GENERAL. The parts lists and illustrations in this section

of the manual, cover 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.

WARNING

Check limit switch operation carefully, without load,

before placing hoist in service. If misadjusted, 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.

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 (†) symbol at the right side of the parts

reference numbers.

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.

WARNING

NON-FACTORY AUTHORIZATIONS OR MODIFICATION

OF EQUIPMENT AND USE OF NON-FACTORY REPAIR

PARTS CAN LEAD TO DANGEROUS OPERATION AND

INJURY.

SECTION VIII — WIRING DIAGRAMS

TO AVOID INJURY:

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

• 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.

9-2.

INDEX OF EXPLODED VIEW PARTS ILLUSTRATIONS

Title

Figure No.

9-1

Page No.

Frame, Gearcase and External Parts ...........................................................................................................23

Gearing and Load Brake Parts .....................................................................................................................26

Hoist Motor Brake - Later Version .................................................................................................................28

Hoist Motor Brake - Early Version............................................................................................ ..................30

Three Phase Motor Assembly .......................................................................................................................32

Upper Limit Switch Parts ...............................................................................................................................33

Electrical Control Equipment.........................................................................................................................34

Push Button Station Assembly and Conductor Cable (Single Speed) ........................................................35

Push Button Station Assembly and Conductor Cable (Two Speed) - Later Version ...................................36

Push Button Station Assembly and Conductor Cable (Two Speed) - Early Version ...................................38

Lower Block Assembly — 2 parts rope, single reeved ................................................................................40

Lower Block Assembly — 2 part double reeved...........................................................................................41

Upper and Lower Block Parts (3 & 5 Ton) ....................................................................................................42

Screw-Type Limit Switch Parts ......................................................................................................................43

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

Page 22

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11455C

Figure 9-1. Frame, Gearcase and External Parts.

Ref.

No.

Part

Number

Qty.

Req’d

Description

4†

800-197

800-192

800-105

800-106

800-107

Plug — Oil Level

Cover & Bearing Assembly — Gearcase

Dowel

Gasket — Gearcase

Gearcase & Bearing Assembly

Drum & Hub Assembly (Double Reeved Models)

1/2 & 1 Ton (3/6" Dia. Rope)

800-109

800-111

800-2100

18' Lift

34' Lift

47' Lift

2 Ton (1/4" Dia. Rope)

800-108

800-110

800-2101

14' Lift

25' Lift

36' Lift

Drum & Hub Assembly (Single Reeved Models)

1/2 & 1 Ton (1/4" Dia. Rope)

800-113

800-115

25' Lift

50' Lift

2 Ton (5/16" Dia. Rope)

20' Lift

40' Lift

800-112

800-114

3 Ton (5/16" Dia. Rope)

30' Lift

45' Lift

800-2102

800-2103

5 Ton (5/16" Dia. Rope)

20' Lift

30' Lift

800-2104

800-2105

Page 23

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Figure 9-1. Frame, Gearcase & External Parts. (Cont’d.)

Ref.

No.

Part

Number

Qty.

Req’d.

Description

800-116

Screw — Hex, Socket Button Head — Self-Locking

Frame Assembly (Single Reeved Models)

1/2, 1 & 2 Ton

800-117

800-118

Short Frame

Long Frame

3 Ton

800-2106

800-2107

First Extension

Second Extension

5 Ton

800-2108

800-2109

First Extension

Second Extension

Frame Assembly (Double Reeved Models)

1/2, 1 & 2 Ton

800-2110

800-2111

800-2112

800-121

800-124

800-125

Short Frame

Long Frame

First Extension

Closure — 1/2" Plug

Nut — Hex (Double Reeved Models)

Lockwasher (Double Reeved Models)

Shaft — Extension, Drum

Short Frame

800-130

800-131

800-2113

800-2114

800-132

800-133

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 & Brake

22† 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

& Fig. 9-4

800-155

800-156

45†

Screw — Hex Socket Head

Lockwasher

Rope & Thimble Assembly (Single Reeved Models)

1/2 & 1 Ton (1/4" Dia. Rope)

800-158

800-161

25' Lift

50' Lift

2 Ton (5/16" Dia. Rope)

20' Lift

40' Lift

800-157

800-160

3 Ton (5/16" Dia. Rope)

30' Lift

45' Lift

800-2115

800-2116

5 Ton (5/16" Dia. Rope)

20' Lift

30' Lift

Screw — Hex Socket Head

Roll Pin

800-2117

800-2118

800-164

800-165

Page 24

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Figure 9-1. Frame, Gearcase & External Parts. (Cont’d.)

Ref.

No.

Part

Number

Qty.

Req’d.

Description

800-166

800-167

800-168

800-169

800-170

800-171

800-172

Lockwasher

Screw — Hex Head Cap

Key Plate

Shaft — Sheave (Double Reeved Models)

Bracket, Sheave (Double Reeved Models)

Bearing, Sheave (Double Reeved Models)

Sheave Assembly, Upper (Double Reeved Models) Includes Bearing

Rope & Thimble Assembly (Double Reeved Models)

54†

55†

56†

1/2 & 1 Ton (3/16" Dia. Rope)

800-174

800-176

800-2119

18' Lift

34' Lift

47' Lift

2 Ton (1/4" Dia. Rope)

800-173

800-175

800-2120

800-177

800-178

800-196

14' Lift

25' Lift

36' Lift

Plug, Pin

Bolt, Hex Head

Label, Rated Load (Specify Rated Load)

†Recommended spares.

NOTES

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11456LC

Figure 9-2. Gearing and Load Brake Parts.

Ref.

No.

Part

Number

Qty.

Req’d.

Description

1† 800-201

2† 800-202

3† 800-203

Bearing Assembly — Needle, Intermediate & Drum Gear Shaft

Race — Thrust Bearing

Bearing Assembly — Needle Thrust

Gear — Intermediate

104 Teeth

800-204

800-205

109 Teeth

800-266

103 Teeth

800-206

90 Teeth

800-2205A

107 Teeth

800-207

Key — Woodruff

Gear — Drum

71 Teeth

61 Teeth

71 Teeth

800-209

800-210

800-2209

Shaft — Intermediate Gear

14 Teeth

24 Teeth

800-211

800-212

800-2211

14 Teeth

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Figure 9-2. Gearing and Load Brake Parts. (Cont’d.)

Ref.

No.

Part

Number

Qty.

Req’d.

Description

Ring — Retaining, Drum Shaft Bearing

Ring — Retaining

Bearing Assembly — Roller, Intermediate Shaft

Cover — Oil Hole

Pipe Plug — Hex Socket

Oil Seal — Motor Shaft

Bearing Assembly — Ball, Motor Shaft

Bearing Assembly — Needle, Load Brake Shaft

18†

21†

22†

23†

800-219

800-221

800-222

800-269

800-224

800-225

800-226

800-227

800-228

800-229

Ring — Retaining, Motor Shaft Bearing

Washer — Thrust (Steel)

Brake Assembly — Load, Complete (Includes Items 26 thru 37)

800-230

800-231

800-267

800-232

800-2232A

800-233

800-234

800-235

800-236

800-237

800-238

800-239

800-240

800-241

800-242

800-243

23 Teeth

36 Teeth

24 Teeth

18 Teeth

20 Teeth

28*

33†

34†

Ring — Retaining, Brake Flange

Flange — Load Brake

Washer — Friction

Pawl & Ratchet Assembly — Load Brake (Available Only As An Assembly)

Bushing — Ratchet

Gear & Center Assembly

Pin — Groove

Cam — Load Brake

Spring — Load Brake

Retainer — Spring, Load Brake

Key — Woodruff

Shaft & Integral Pinion — Load Brake

800-244

800-245

800-268

800-246

800-2246A

800-247

800-248

800-249

800-250

800-251

23 Teeth

36 Teeth

24 Teeth

18 Teeth

20 Teeth

38†

39†

40†

Washer — Thrust (Used With 800-246 Only)

Washer — Thrust (Bronze)

Bearing Assembly — Needle, Load Brake Shaft

Load Brake — Clutch Assembly With Bearings (Complete)

Load Brake — Clutch Assembly (Includes Items 26 thru 30, 34, 36 thru 38

and 43 thru 45)

800-254

800-253

800-252

800-260

800-263

800-261

800-262

Spring Retainer

Brake Gear, Center

Clutch Assembly

Ring — Retaining

Oil Seal — Drum Shaft

Bearing Assembly — Ball, Drum Shaft

Shaft — Drum

Available only as part of

800-250 or 800-251 above

}

†

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

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12756H

Figure 9-3. Hoist Motor Brake - Later Version.

Ref.

No.

Part

Number

Qty.

Req’d.

Description

800-2401

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

800-2402

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 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

800-2410†

800-2411

800-2403

800-2404

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.

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Figure 9-3. Hoist Motor Brake. (Cont’d.)

Kit Description

Brake Disc

Part Number

Reference Numbers Included

800-2405†

800-2406

23, 24, 26

Brake Lever

6, 15, 17, 18, 19, 20, 21 (Red Color), 22,

Adjusting Screw Label, Brake Adjust Label —

Discard Zinc Colored Spring

Rectifier

800-2407

800-2408

12, 13, 4 Wire Nuts

Hardware

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)

†

Recommended spares.

NOTES

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12756A

Figure 9-4. Hoist Motor Brake - Early Version.

Ref.

No.

Part

Number

Qty.

Req’d.

Description

Motor Brake Assembly (Includes Ref. Nos. 1 thru 32)

Short Frame Models Only

Other Models

800-1400

800-1401

Acorn Nut (#10-32)

Brake Cover Assembly (Includes Brake Cover and Label Inside Cover)

Cover Stud

800-1402

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

Hex Head Self-Locking Nut (#10-24)

Solenoid Support

Hex Washer Head Thread Forming Screw (#10-32 x 1/4)

Solenoid Plunger

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)

800-1403

800-1404

Brake Hub

Hex Socket Head Screw (3/8 - 16 x 3/4)

Brake Mounting Plate

800-1405

Wire Nuts — Not Shown (No. 22 thru 16 AWG)

* Not available as individual parts. See replacement kits listed below. Kits include quantities shown above.

Page 30

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Figure 9-4. Hoist Motor Brake. (Cont’d.)

Kit Description

Part Number

Reference Numbers Included

Brake Disc

800-1406

800-1407

800-1408

800-1409

800-1410

24, 25, 27

Solenoid

5, 6, 8, 11, 17

Brake Lever

Brake Hub

18, 20, 21, 22, 23

28, 29, Hub Drive Key (Shown Elsewhere)

Special Hardware

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

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12724

Figure 9-5. Three Phase Motor Assembly.

Ref.

No.

Part

Number

Qty.

Req’d.

Description

Motor Assembly (Includes Ref. Nos. 1 thru 8)

1 Horsepower (1 Speed)

200 Volt

800-1301

800-1302

800-1303

230/460 Volt

575 Volt

2 Horsepower (1 Speed)

200 Volt

230/460 Volt

800-1304

800-1305

800-1306

575 Volt

4 Horsepower (1 Speed)

200 Volt

230/460 Volt

800-1307

800-1308

800-1309

575 Volt

1 - 1/3 Horsepower (2 Speed)

200 Volt

230 Volt

460 Volt

575 Volt

800-1310

800-1311

800-1312

800-1313

2 - 2/3 Horsepower (2 Speed)

200 Volt

230 Volt

460 Volt

800-1314

800-1315

800-1316

800-1317

575 Volt

3 - 1 Horsepower (2 Speed)

200 Volt

230 Volt

460 Volt

575 Volt

800-1318

800-1319

800-1320

800-1321

4 - 2 Horsepower (2 Speed)

200 Volt

800-1322

800-1323

800-1324

230 Volt

460 Volt

800-1325

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

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11460

Figure 9-6. Upper Limit Switch Parts.

Ref.

No.

Part

Number

Qty.

Req’d.

Description

800-501

Pin — Pivot

Arm — Lever

Short Frame

Long Frame

First Extension

800-502

800-503

800-526

800-527

Second Extension

Lever — Floating

800-504

800-505

800-528

800-529

800-506

800-507

800-525

800-509

800-510

800-511

800-512

800-513

800-514

800-515

800-516

800-517

800-518

800-519

800-520

800-521

800-522

Short Frame

Long Frame

First Extension

Second Extension

Washer

Pin — Cotter

Coupling

Pin — Roll

8†

10†

Switch Assembly — Limit, Reversing (Includes Wire Leads)

Connector — Wire

Switch Assembly — Limit, Stop (Includes Wire Leads)

Screw — Round Head

Screw — Socket Head Shoulder

Shaft & Cam Assembly

Insulator — Limit Switch

Bearing — Nylon

Screw — Socket Head Cap

Lockwasher

Nut — Lock

Bracket Assembly — Mounting

Nut — Hex

† Recommended Spares.

Page 33

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12748A

Figure 9-7. Electrical Control Equipment.

Ref.

No.

Part

Number

Qty.

Req’d.

Description

6†

7†

9†

11†

800-670

800-654

800-655

800-656

800-657

800-671

800-663

800-672

800-673

800-674

800-675

800-676

Cord Grip — Conductor

Screw — Self-Tapping

Contactor — Two Speed

Contactor

Screw — Self-Tapping

Transformer

Screw — Self-Tapping

Terminal Board (Reconnectable Hoist Only)

Fuse, Fuse Holder and Wire Assembly

Fuse Only (2A, 300V)

Brake Module

Screw — Self Tapping

† Recommended Spares.

NOTES

Page 34

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12763

Figure 9-8. Push Button Station and Conductor Cable Assembly.

Single Speed Hoists.

Ref.

No.

Part

Number

Qty.

Req’d.

Description

800-2701

Push Button Station and Conductor Cable Assembly

(Includes Ref. Nos. 1 thru 17)

Push Button Station (Includes Ref. Nos. 1 thru 15)

Type 1 Pan Head Machine Screw (M 3.5 x 0.6 x 12 Pltd.)

Lockwasher (M 3.5 Pltd.)

800-2702

Rear Cover

Gasket

800-2703

Type 1 Pan Head Thread Cutting Screw (M 4 x 15 Pltd.)

Contact Assembly

Button Assembly

Type 1 Pan Head Machine Screw (M 6 x 1 x 12 Pltd.)

Lockwasher (M 6 Pltd.)

Plain Washer (M 6 Pltd.)

Type 1 Pan Head Machine Screw (M 3.5 x 1 x 14 Pltd.)

Lockwasher (M 3.5 Pltd.)

Housing Cap

Grommet

Housing

800-2704

800-2705

800-2706

800-2707

800-2708

Conductor Cable Assembly

Plastic Warning Tag

* Not available separately. Order Push Button Station.

Page 35

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12721A

Figure 9-9. Push Button Station and Conductor Cable Assembly.

Two Speed Hoists Only - Later Version.

Ref.

No.

Part

Number

Qty.

Req’d.

Description

800-1821

Push Button Station and Conductor Cable Assembly

(Includes Ref. Nos. 1 thru 30)

Grommet

800-1822

800-1823

Conductor Cable

As Req’d

800-1812

800-1813

800-1814

Operator Warning Label

Push Button Station (Includes Ref. Nos. 12 thru 30)

Sleeve — Conductor

Support — Strain Cable

Screw — Slotted Head

Lockwasher

Enclosure — Rear

Gasket

Screw — Slotted Head

Page 36

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Figure 9-9. Push Button Station and Conductor Cable Assembly. (Cont’d.)

Ref.

No.

Part

Number

Qty.

Req’d.

Description

Clamp — Conductor

Contact Block Assembly

Contact Block (ZB2-BE101)

Contact Block (ZB2-BE201)

Interlock—Mechanical

800-1815

800-1816

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

Plate — Push Button

Push Button — Up

Push Button — Down

* Not available separately. Order Push Button Station.

** Not available separately. Order Push Button Assembly.

NOTES

Page 37

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12721

Figure 9-10. Push Button Station and Conductor Cable Assembly.

Two Speed Hoists Only - Early Version.

Ref.

No.

Part

Number

Qty.

Req’d.

Description

800-1801

Push Button Station and Conductor Cable Assembly

(Includes Ref. Nos. 1 thru 30)

Anchor Bracket — Strain Cable

Grip Assembly — Conductor

Connector — Strain Cable

Thimble — Strain Cable

Connector — Conductor to Strain Cable

Clamp — Conductor

Conductor Cable

Strain Cable

Sleeve — Pressure

Tie — Conductor

Operator Warning Label

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

As Req’d.

Push Button Station (Includes Ref. Nos. 12 thru 30)

Sleeve — Conductor

Page 38

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Figure 9-10. Push Button Station and Conductor Cable Assembly. (Cont’d.)

Ref.

No.

Part

Number

Qty.

Req’d.

Description

Support — Strain Cable

Screw — Slotted Head

Lockwasher

Enclosure — Rear

Gasket

Screw — Slotted Head

Clamp — Conductor

Contact Block Assembly

Contact Block (ZB2-BE101)

Contact Block (ZB2-BE201)

Interlock — Mechanical

800-1815

800-1816

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

Plate — Push Button

Push Button — Up

Push Button — Down

* Not available separately. Order Push Button Station.

** Not available separately. Order Push Button Assembly.

NOTES

Page 39

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11464

Figure 9-11. Lower Block Assembly — Two Parts Rope, Single Reeved.

Ref.

No.

Part

Number

Qty.

Req’d.

Description

800-801

800-802

800-803

800-804

800-805

800-806

800-807

800-808

800-809

800-810

800-811

800-812

800-813

800-814

800-815

800-816

800-817

800-818

800-819

800-820

800-821

800-822

800-823

800-824

800-825

800-826

800-827

800-828

800-829

800-830

800-831

800-832

800-833

800-834

Block Assembly — Lower, Complete, 2 Ton

Block Assembly — Lower, Complete, 1 Ton

Block Assembly — Lower, Complete, 1/2 Ton

Screw — Flat Head, Self-Threading

Cover — 2 Ton

Cover — 1 Ton

Cover — 1/2 Ton

Ring — Retaining, 2 Ton

Ring — Retaining, 1/2 & 1 Ton

Lube Fitting

Pin — Sheave, 2 Ton

Pin — Sheave, 1/2 & 1 Ton

Spacers — 2 Ton

Spacers — 1/2 Ton & 1 Ton

Sheave Assembly — 2 Ton (Consists of Items 7 and 8)

Bearing

Sheave

Sheave Assembly — 1/2 & 1 Ton (Consists of Items 7 and 8)

Bearing

Sheave

Cover — Lower Block, 2 Ton

Cover — Lower Block, 1 Ton

Cover — Lower Block, 1/2 Ton

Hook Assembly — (Consists of Hook, Nut & Grooved Pin), 2 Ton

Hook Assembly — (Consists of Hook, Nut & Grooved Pin), 1/2 & 1 Ton

Shroud — Thrust Bearing, 2 Ton

Shroud — Thrust Bearing, 1/2 & 1 Ton

Bearing Washer -— Thrust, 2 Ton

Bearing Washer — Thrust, 1/2 & 1 Ton

Body — Lower Block, 2 Ton

†

10†

†

12†

†

Body — Lower Block, 1/2 & 1 Ton

*Safety Hook Latch Kit — 2 Ton

*Safety Hook Latch Kit — 1/2 & 1 Ton

Screw — Flat Head, Self-Threading

† Recommended Spares.

Page 40

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11465

Figure 9-12. Lower Block Assembly—Two Parts Double Reeved.

Ref.

No.

Part

Number

Qty.

Req’d.

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

800-827

800-828

800-829

800-857

800-858

800-832

800-833

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

†

11 †

†

Cover — Intermediate

Screw — Flat Head, Self-Threading

Hook Assembly — (Consists of Hook, Nut & Grooved Pin), 2 Ton

Hook Assembly — (Consists of Hook, Nut & Grooved Pin), 1/2 & 1 Ton

Shroud — Thrust Bearing, 2 Ton

Shroud — Thrust Bearing, 1/2 & 1 Ton

Bearing — Thrust, 2 Ton

Bearing — Thrust, 1/2 & 1 Ton

Body — Lower Block, 2 Ton

Body — Lower Block, 1/2 & 1 Ton

*Safety Hook Latch Assembly — 2 Ton

*Safety Hook Latch Assembly — 1/2 & 1 Ton

13 †

†

† Recommended Spares.

* Furnished as Standard with hook.

Page 41

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12197LA

Figure 9-13. Upper and Lower Block Parts (3 & 5 Ton — Typical).

Quantity Required

Reeving

Ref.

No.

Part

Number

Description

3-Ton/4 PS 5-Ton/6 PS

800-1501

800-1502

800-1503

800-1504

800-1505

800-1506

800-1507

800-1508

800-1509

800-1510

800-1535

800-1513

800-1514

800-1515

800-1516

800-1517

800-1518

800-1530

800-1531

800-1519

800-1520

800-1521

800-1522

800-1523

800-1524

800-1525

800-1526

800-1527

800-1528

800-1529

Block Assembly — Lower, 4 Part Single (Complete)

Block Assembly — Lower, 6 Part Single (Complete)

Screw — Hex Head Cap

Lockwasher

Key Plate

Fitting — Grease

Pin — Upper Sheave

Spacer Washer — Upper Sheave

Bearing — Upper Sheave (Includes Outer Race)

Sheave — Upper

—

7†

8†

12†

13†

16†

Pin — Rope Guide

Spacer Washer — Lower Sheave

Bearing — Lower Sheave (Includes Outer Race)

Sheave — Lower

Pin — Roll, Hook Nut

Nut — Hook*

Bearing — Thrust, Hook

Shield — Bearing (Not Shown)

Washer — Thrust (Not Shown)

Fitting — Grease

Hook Assembly — (includes Hook, Latch & Nut)

Plate — Capacity

Screw — Round Head, Self-Tapping (Capacity Plate)

Guard — Sheave

Body — Lower Block

18†

Pin — Lower Sheave

Screw — Button Head Cap, Self-Locking (Sheave Guard)

Ring — Retaining, External

Lockwasher — (Capacity Plate)

Spacer — Upper Block, 9/16"

† Recommended Spares.

* Hook Nuts with roll pins are not interchangeable — Available only as an assembly.

Page 42

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12757A

Figure 9-14. Screw-Type Limit Switch Parts.

Ref.

No.

Part

Number

Qty.

Req’d.

Description

800-1655

800-1651

800-1652

800-1657

Limit Switch Assembly (Includes Ref. Nos. 2, 3 and 4)

Cap Screw — Hex Socket Head

Sealing Washer

Drum Shaft Insert

For switch element replacement order 800-1654.

NOTES

Page 43

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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

YaleŸLift-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

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

Seller’s authorized service station nearest Buyer or (ii) refund an

equitable portion of the purchase price.

A. Seller warrants that its products and parts, when shipped, and its

work(includinginstallation,constructionandstart-up),whenperformed,

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) 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.

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, 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

hereunderbywayofbreachofcontract, tort, strictliabilityorotherwise.

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.

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