Yale HOISTS YEL Series, Operating, Maintenance & Parts Manual

Page 1: ...d Before using this hoist each operator should become thoroughly familiar with all warnings instructions and recommendations in this manual Retain this manual for future reference and use Forward this manual to the hoist operator Failure to operate the equipment as directed in the manual may cause injury Should you have any questions or have problems with this product please call Yale Hoists at 86...

Page 2: ...portation prepaid This warranty does not apply where deterioration is caused by normal wear abuse improper or inadequate power supply improper or inadequate maintenance eccentric or side loading overloading chemical or abrasive actions excessive heat unauthorized modifications or repairs or use of non Yale repair parts EXCEPT AS STATED HEREIN YALE HOISTS MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIE...

Page 3: ...eave load supported by the hoist unattended unless specific precautions have been taken 19 NOT allow the load chain or hook to be used as an electrical or welding ground 20 NOT allow the load chain or hook to be touched by a live welding electrode 21 NOT remove or obscure the warnings on the hoist 22 NOT operate a hoist on which the safety placards or decals are missing or illegible 23 NOT operate...

Page 4: ...ow 10 of the nominal voltage while lifting a load Low voltage will result in higher amp draw damage to the hoist and potential fire hazards Yale Hoists is not responsible for any damages caused by an inadequate power source Lifting Model Capacity Speed HP Reeving Number lbs fpm YEL1 8 TH32S1 250 32 1 4 Single chained YEL2 TH8S1 4000 8 1 Double chained YEL1 TH16S1 2000 16 1 Single chained YEL1 4 TH...

Page 5: ...e unit daily before operating hoist 8 Cluttered areas and benches invite accidents 9 The operator should not engage in any practice which will divert his attention while operating the hoist 10 Before using the hoist the operator should be certain that all personnel are clear 11 Do not operate hoist with loads exceeding its rated capacity 12 Supporting frames or beams used as a hoist hanger must ha...

Page 6: ... bottom If either switch is not correct adjust according to LIMIT SWITCH ADJUSTMENT page 8 CHAIN CONTAINER Optional Accessary Refer to Table 4 For installations where the slack chain hanging from the hoist may be objectionable or hazardous the use of a chain container is recommended Available chain containers include the standard metal containers designed for lifts of up to 50 ft on single chained...

Page 7: ... while the hoist is being operated If the load being lifted exceeds the lifting capability of the overload clutch the hoist motor will continue to run causing overheating of both the clutch and hoist motor This condition should be avoided by immediately releasing the UP button and reducing the load to within the rated capacity of the hoist See GEARING page 11 for additional instructions on this de...

Page 8: ...cover 3 Using a screwdriver pry the spring guide plate out of the slots in the limit switch nuts See Figure 3 Turn the gold nut back to about the center of the threaded screw Do not disconnect the wires from the limit switches 4 Remove the load block assembly from the old chain On double chained hoists detach the chain from the chain support and pull it through the load block assembly See Figure 4...

Page 9: ...on its side and replace the four screws and tighten securely 9 Follow steps 11 through 14 in the previous section CHAIN REPLACEMENT WITH CHAIN IN HOIST to complete the chain replacement procedure LIMIT SWITCH ADJUSTMENT IMPORTANT Before placing hoist in operation check the limit switch adjustment Limit switches are provided to protect the hoist against damage resulting from overtravel or to allow ...

Page 10: ...WER SUPPLY and remove the electrical cover 2 With reference to Figure 6 the gap between the brake armature A and the field B should be checked The correct gap is 0 015 Adjustment should not be necessary until gap reaches 0 040 3 Adjust the gap using a 9 16 socket on the 3 locknuts F Check with a feeler gauge to be sure the gap is the same on both ends of the solenoid 4 Adjustment is now complete a...

Page 11: ...igure 13 The terminal blocks and end clamps snap off of the rails on the plate using a small screwdriver DO NOT SLIDE THE END CLAMPS The reversing contactor can be slid off the rail but it must be snapped on Where the contactor fits the rail one side has springs or pads that apply pressure against the edge of the rail By pressing against that side at the base of the contactor you can snap the part...

Page 12: ...es See CHAIN REPLACEMENT WITH NO CHAIN IN HOIST page 8 While this section is apart check the following Load Sheave Chain Chain guides and plates Bearings Chain support on 2 ton models Replace parts as necessary including screws lockwashers etc When reassembled recheck the limit switch settings See LIMIT SWITCH ADJUSTMENT page 8 Figure 8 Assembled Gearing M a x i m u m L e n g t h o f P o w e r C o...

Page 13: ...or short circuit Check all connections in control circuit Check for burned contacts Replace as needed 4 Loose screw clamps 4 Ensure that screw clamps are tightened on the terminal blocks and reversing contactor Hook raises but will not lower 1 Hoist overloaded 1 Reduce load to within rated capacity of hoist 2 Low voltage 2 Determine cause of low voltage and bring up to within plus or minus 10 of t...

Page 14: ...ent 1 See BRAKE ADJUSTMENT page 9 2 Low voltage 2 Ensure that the voltage at the reversing contactor is within 10 of the nominal voltage while lifting a load Motor brake noise or chatter while starting hoist 1 Hoist overloaded 1 Reduce load to within rated capacity of hoist 2 Brake dragging 2 Check for proper brake adjustment or other defects 3 Low voltage 3 Ensure that the voltage at the reversin...

Page 15: ...L 800 477 5003 FAX 800 374 6853 Figure 9B Wiring Diagram for 1 Speed 230 460V 3 Phase Models Figure 9C Wiring Diagram for 1 Speed 208V 380V 575V 3 Phase Models Factory supplied diagrams will be numbered beginning with 985 for 575V 987 for 208V and 988 for 380V ...

Page 16: ...79 Wadesboro NC 28170 USA TEL 800 477 5003 FAX 800 374 6853 Figure 9D Wiring Diagram for 2 Speed 3 Phase Models Factory supplied diagrams will be numbered beginning with 983 for 230 or 460V 985 for 575V 987 for 208V and 988 for 380V ...

Page 17: ...Looseness stripped and damaged threads corrosion Sheaves Distortion cracks and excessive wear Build up of foreign substances Housings Load Block Cracks distortion Excessive wear internal build up of foreign substances Wiring and Terminals Fraying defective insulation Hoist Reversing Contactor other Electrical Loose connections burned or pitted contacts Apparatus Supporting Structure and Trolley Da...

Page 18: ...y Figure 11 Recommended Lubrication Schedule RECOMMENDED LUBRICATION SCHEDULE YALE ELECTRIC POWERED CHAIN HOIST PAGE AND COMPONENT TYPE OF LUBRICANT TYPE OF SERVICE AND REFERENCE NO FREQUENCY OF LUBRICATION HEAVY NORMAL INFREQUENT Pages 32 33 Load Chain SAE 90 gear oil Daily Weekly Monthly Ref No 18 Pages 30 31 Gearing SAE 90 extreme pressure EP gear oil At periodic inspection see Figure 12A Pages...

Page 19: ...X 3 4 Screw H1106P 1 11 10 24UNC X 1 2 Screw H2970 2 12 Top Hook Assembly w Latch Rigid Hook std 3M205A02S 1 Swivel Hook 3M205A01S 1 13 Latch Kit Assembly 4X1305 1 14 Hook Hole Cover JF277 1 1 15 Suspension Lug 50KG84 1 16 Yale Decal YJL677 2 17 Capacity Decal 250 lbs YJL675 1 1 1 4 Ton YJL675 2 1 1 2 Ton YJL675 3 1 1 Ton YJL675 4 1 2 Ton YJL675 5 1 Plain Trolley Lug Mounted 1 Ton Under 09292 1 2 ...

Page 20: ...0V 1Ph 861JL14 1 2 Stator Assembly 1 3 Rotor Assembly 1 4 End Shield JL021209 20 1 5 Rear Bearing 500K3 1 6 Front Bearing 732012C 1 7 Shim Washer JL4301 01 1 8 Capacitor 1 4 1 2 hp JL810 7 1 1 hp JL810 4 1 9 SINPAC Starting Switch 839J2 1 10 Capacitor Start Switch Cover JL3108 03 2 11 Gasket JL564 1 12 Thru Bolt 1 4 1 2 hp JL003801 41 4 1 hp JL003801 19 4 13 10 Spring Lockwasher H4082P 4 14 8 32UN...

Page 21: ...V 3Ph 60Hz 873JL6 1 1 hp 460V 3Ph 60Hz 873JL8 1 1 4 hp 575V 3Ph 60Hz 873JL9 1 1 2 hp 575V 3Ph 60Hz 873JL10 1 1 hp 575V 3Ph 60Hz 873JL12 1 1 4 hp 208V 3Ph 60Hz 873JL13 1 1 2 hp 208V 3Ph 60Hz 873JL14 1 1 hp 208V 3Ph 60Hz 873JL16 1 2 Stator Assembly 1 3 Rotor Assembly 1 4 End Shield JL021209 20 1 5 Rear Bearing 500K3 1 6 Front Bearing 732012C 1 7 Shim Washer JL4301 01 1 8 Thru Bolt 1 Speed 1 4 1 2 hp...

Page 22: ...ke Plate for 1 2 hp 1hp JF291 2 5 Plate Armature Assembly JF858 1 6 Spring 344J6 3 7 Retainer JF710 1 8 Plate Frame Assembly JF857 1 9 Brake Coil 115V 853JL1 1 230V 853JL2 1 460V 853JL3 1 575V 853JL4 1 208V 853JL5 1 380V 853JL6 1 415V 853JL7 1 10 Locknut H3978 3 11 Adapter JL142 1 12 Screw H2976P 2 13 Retaining Ring H5501 2 14 Shading Coil 860J1 2 Shading Coil Adhesive H7812 1 15 Spacer for 1 4 hp...

Page 23: ... 1 230 460V 909J12 1 8 End Clamp 115 230V 230 460V 909J13 3 Single Voltage Models 909J13 1 9 Marking Strip 909J11 1 10 15 ft Power Cord Assembly 115 230V 1 2 hp 3 cond 951JL1 1 115 230V 1 hp 3 cond 952JL1 1 3 Phase 4 cond 953JL1 1 11 PB Cable Assembly See Figures 18 19 1 12 Panel Standoff Spacer 110JL1 2 13 1 4 Internal tooth Lockwasher H4134 2 14 1 4 20UNC X 4 Screw H1110P 2 15 8 32UNC X 5 16 Scr...

Page 24: ...21J431 1 5 Pri 575V Sec 24V 821J452 1 Pri 575V Sec 115V 821J451 1 Pri 208V Sec 24V 821J472 1 Pri 208V Sec 115V 821J471 1 Pri 380V Sec 24V 821J482 1 Pri 380V Sec 115V 821J481 1 6 15 ft Power Cord Assembly 953JL1 1 7 PB Cable Assembly 1 See Figures 18 19 8 Panel Standoff 110JL1 2 9 1 4 Internal tooth Lockwasher H4134 2 10 1 4 20UNC X 4 Screw H1110P 2 11 8 32UNC X 5 16 Screw H2751 2 12 8 External too...

Page 25: ...24 Figure 18 1 Speed Pushbutton Station 12 6 7 10 11 4 5 13 14 15 4 8 4 9 16 3 2 1 ...

Page 26: ...Cable Length PBC299 6 1 11 ft Cable Length PBC299 11 1 16 ft Cable Length PBC299 16 1 Special Drop PBCS299 1 4 Enclosure 36998 1 5 Gasket 36986 1 6 Contact Assembly Includes items 6 7 when ordered 36987 1 7 Button Assembly 36988 1 8 Grommet 36989 1 Hardware Kit 36939 1 Includes items 9 16 Warning Tag 687K3W 1 Parts List for 1 Speed Pushbutton Station Ref Part No Description No Qty Equal to cable l...

Page 27: ...26 4 19 15 23 18 22 8 20 25 13 12 5 17 30 31 29 23 25 28 13 27 26 14 11 6 20 16 9 24 30 7 10 2 19 21 31 3 1 Figure 19 2 Speed Pushbutton Station ...

Page 28: ...eed black PB285 1 1 9 Boot PB286 2 10 Compression Spring PB287 2 11 Conical Spring PB288 2 12 Contact Plate PB289 2 13 Common Contact Plate PB290 3 14 Contact Washer PB291 2 15 Screw H1852P 2 16 Boot Washer PB293 2 17 Grommet PB294 1 1 18 Enclosure Cap PB295 1 19 O Ring X6477 1 3 20 Rubber Seal H7851 1 21 Screw H2925 3 22 Screw H2992 4 23 Screw H2993 8 24 Warning Tag PB296 1 25 Lockwasher H4160 8 ...

Page 29: ...ch Bracket JF900 3 1 Includes Item 8 8 Bushing JF531 4 1 9 Limit Switch Shaft JF117 3S 1 10 Limit Switch Nut silver SK6000 63Z 1 11 Limit Switch Nut gold SK6000 63W 1 12 Retaining Ring H5520 1 13 Insulator JF754 1 14 Limit Switch Stub Shaft JL140 1 15 E Ring H5563 1 16 Spring JF343 3 1 17 10 24UNC X 1 2 Screw H2970 2 Parts List for Limit Switch Assembly Ref Description Part Qty Ref Description Par...

Page 30: ... 4 2 13 Switch 815J1 2 14 6 32UNC X 1 Screw H1402P 4 15 6 32UNC Elastic Locknut H3944 4 16 Mounting Plate 129J1 1 17 Frame and Guide Assembly 258JG7 1 18 End Plate 258J8 1 19 8 32UNC X 3 8 Screw H2741P 2 20 Drive Pinion 427J1 1 21 Retaining Ring H5520 1 22 Limit Switch Stub Shaft JL140 1 23 E Ring H5563 1 24 10 24UNC X 3 8 Screw H2981P 2 Ref Description Part Qty Ref Description Part Qty No No No N...

Page 31: ...30 5 18 20 21 17 15 31 18 22 14 15 16 16 18 19 6 10 26 32 27 28 29 7 13 NOTE Orient output gear 32 with long boss towards gear housing 2 on 1 2 ton under models and towards gear box cover 3 on 1 2 ton models NOTE This stage of gearing is not required on 32 FPM models ...

Page 32: ... 1 1 18 Retaining Ring H5501 3 19 Brake Adapter JL142 1 20 Bearing for 8 16 fpm 500K34 2 21 High Speed Gear for 8 16 fpm JL426 1 22 Intermediate Pinion 1 2 Ton Under 16 fpm JL402A 1 1 2 Ton JL403A 1 23 Bearing 500K36 2 24 Output Pinion JL401 1 25 Overload Clutch Assembly 1 8 Ton 32 fpm 591JG22 1 1 4 Ton 16 fpm 591JG25 1 1 4 Ton 32 fpm 591JG22 1 1 2 Ton 16 fpm 591JG16 1 1 2 Ton 32 fpm 591JG21 1 1 2...

Page 33: ...n Models 1 Ton Models 2 Ton Models 1 2 Ton Under Models 1 17 16 15 18 14 22 11 29 6 9 12 27 13 20 5 3 4 8 28 23 21 25 35 36 35 34 7 10 32 31 36 46 47 41 24 44 33 50 19 45 48 37 38 38 37 49 42 40 43 26 30 39 13 8 12 3 14 31 11 33 32 2 ...

Page 34: ...Support Screw JF703 1 26 Bottom Block Assembly 1 2 Ton Under 913JG4AS 1 27 Load Block Frame JF20 2 1 28 Load Block Frame threaded JF20 3 1 29 Load Block Screw JF700 1 30 Bottom Block Assembly 1 Ton 913JG3AS 1 31 Load Block Frame 30J14 2 32 1 4 20UNC x 1 Socket Head Cap Screw S49 77 2 33 1 4 Internal tooth Lockwasher H4134 2 34 Load Block Pin 18J8 1 35 Bottom Hook Assembly W Latch 1 Ton Under 3JG20...