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Electric Chain

YJC680

Operating, Maintenance & Parts Manual

YJL Series
Capacities 1/8 Ton 1/4 Ton 1/2 Ton 1 Ton 2 Ton

Follow all instructions and warnings for

inspecting, maintaining and operating this hoist.
The use of any hoist presents some risk of personal injury or property damage. That risk is greatly increased if proper instructions and warnings are not followed. 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 regarding this product, please call Yale Hoists at (866) 805-2962. Made in the U.S.A. Before using the hoist, fill in the information below:
Model No. Serial No. Purchase Date

414 Broadway Avenue P.O. Box 769 Muskegon, Michigan USA Tel: 866.805.2962 Fax: 800.742.9270 www.yalehoists.net

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SAFETY PRECAUTIONS
Each Yale YJL Series Electric Chain Hoist is built in accordance with the specifications contained herein and at the time of manufacture complies with our interpretation of applicable sections of *American Society of Mechanical Engineers Code (ASME) B30.16 Overhead Hoists, the National Electrical Code (ANSI/NFPA 70) and the Occupational Safety and Health Act (OSHA). Since OSHA states the National Electrical Code applies to all electric hoists, installers are required to provide current overload protection and grounding on the branch circuit section in keeping with the code. Check each installation for compliance with the application, operation and maintenance sections of these articles. *Copies of this standard can be obtained from ASME Order Department, 22 Law Drive, PO Box 2300, Fairfield, NJ 070072300, U.S.A., www.asme.org, 800-843-2763.

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 a hoist unless it has been securely attached to a suitable support. 24. NOT operate a hoist unless load slings or other approved single attachments are properly sized and seated in the hook saddle. 25. Take up slack carefully - make sure load is balanced and load holding action is secure before continuing. 26. Shut down a hoist that malfunctions or performs unusually and report such malfunction. 27. Make sure hoist limit switches function properly. 28. Warn personnel of an approaching load.

Improper operation of a hoist can create a potentially hazardous situation which, if not avoided, could result in death or serious injury. To avoid such a potentially hazardous situation, THE OPERATOR SHALL:

Improper operation of a hoist can create a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. To avoid such a potentially hazardous situation, THE OPERATOR SHALL:

1. NOT operate a damaged, malfunctioning or unusually performing hoist. 2. NOT operate the hoist until you have thoroughly read and understood the manufacturers Operating and Maintenance Instructions or Manuals. 3. NOT operate a hoist which has been modified without the manufacturers approval or without certification that it is in conformity with ANSI/ASME B30 volumes. 4. NOT lift more than rated load for the hoist. 5. NOT use hoist with twisted, kinked, damaged, or worn load chain. 6. NOT use the hoist to lift, support, or transport people. 7. NOT lift loads over people. 8. NOT operate a hoist unless all persons are and remain clear of the supported load. 9. NOT operate unless load is centered under hoist. 10. NOT attempt to lengthen the load chain or repair damaged load chain. 11. Protect the hoists load chain from weld splatter or other damaging contaminants. 12. NOT operate hoist when it is restricted from forming a straight line from hook to hook in the direction of loading. 13. NOT use load chain as a sling, or wrap chain around load. 14. NOT apply the load to the tip of the hook or to the hook latch. 15. NOT apply load unless load chain is properly seated in the chain sprocket(s). 16. NOT apply load if bearing prevents equal loading on all load supporting chains. 17. NOT operate beyond the limits of the load chain travel. 18. NOT leave 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.

1. Maintain firm footing or be otherwise secured when operating the hoist. 2. Check brake function by tensioning the hoist prior to each lift operation. 3. Use hook latches. Latches are to retain slings, chains, etc. under slack conditions only. 4. Make sure the hook latches are closed and not supporting any parts of the load. 5. Make sure the load is free to move and will clear all obstructions. 6. Avoid swinging the load or hook. 7. Make sure hook travel is in the same direction as shown on the controls. 8. Inspect the hoist regularly, replace damaged or worn parts, and keep appropriate records of maintenance. 9. Use Yale Hoists recommended parts when repairing the unit. 10. Lubricate load chain per hoist manufacturers recommendations. 11. NOT use the hoists overload limiting clutch to measure load. 12. NOT use limit switches as routine operating stops. They are emergency devices only. 13. NOT allow your attention to be diverted from operating the hoist. 14. NOT allow the hoist to be subjected to sharp contact with other hoists, structures, or objects through misuse. 15. NOT adjust or repair the hoist unless qualified to perform such adjustments or repairs.

TABLE OF CONTENTS
Safety Precautions ......................................................................................................................................................................2 Hoist Specifications.....................................................................................................................................................................3 Application Information ...............................................................................................................................................................4 Safety Information .......................................................................................................................................................................4 Installation ...................................................................................................................................................................................4 Operation ....................................................................................................................................................................................6 Maintenance ...............................................................................................................................................................................6 Trouble Shooting .......................................................................................................................................................................12 Wiring Diagrams .......................................................................................................................................................................13 Inspection and Maintenance Check List ...................................................................................................................................16 Recommended Lubrication Schedule.......................................................................................................................................17 Replacement Parts List.............................................................................................................................................................18 Warranty .....................................................................................................................................................................Back Cover

HOIST SPECIFICATIONS
Yale YJL series electric chain hoists are rugged, portable hoists that provide quick, precise lifting. The hoists are constructed of tough, but lightweight, die cast aluminum alloy housings. An oil bath transmission, equipped with heat-treated, alloy steel gears and an overload limiting clutch, provides smooth and reliable operation. With a pushbutton station that fits comfortably in one hand, the operator can safely control the hoist while the other hand is free to guide the load. The electrical controls use a low voltage circuit (24V standard, 115V optional). Terminal blocks allow for easy voltage conversions on dual-voltage models. Other features that ensure the safe operation of Yale electric chain hoists include a magnetic disc brake that delivers sure stopping and secure holding of the load. Adjustable upper and lower limit switches regulate the load travel. As a standard, hooks are supplied with safety latches. For additional safety, a chain stop is attached to the slack end of the load chain. Yale electric chain hoists are designed and tested in accordance with the American Society of Mechanical Engineers Code B30.16, Safety Standard for Overhead Hoists. Hoists are built in compliance with CSA, file number LR 44484. Made in U.S.A.
Table 1 - Hoist Specifications
Model* Number YJL1/8-**TH32S1 YJL1/4-**TH16S1 YJL1/4-**TH32S1 YJL1/2-**TH16S1 YJL1/2-**TH32S1 YJL1-**TH16S1 YJL2-**TH8S1 Capacity Lifting Speed (lbs) 32 16 32 16 32 16 8 HP (fpm) 1/4 1/4 1/2 1/2 1 1 1 Reeving

Table 2 - Motor Amperage of 1-Speed Hoist Models

Hoist Horsepower 1/4 HP 1/2 HP 1 HP Full Load Amps 1-Phase 3-Phase 115/230V 208V 230/460V 380V 4.3/2.2 7.6/3.8 14/7* 1.3 2.3 3.6 1.2/.6 2/1 3.2/1.6 .73 1.2 1.9

575V .35 .76 1.2

* The 1HP, 115/230V models must have a dedicated power circuit rated for at least 20A, 125V when they are wired for 115V. It is not unusual for these models to draw up to 20 amps at 115V when lifting at rated capacity depending on the quality of the voltage source.
Table 3 - Motor Amperage of 2-Speed Hoist Models
Hoist Horsepower (fast/slow) .25/.083 .5/.17 1/.33 Full Load Amps (fast/slow) 3-Phase Only 230V 380V 460V 1/1.1 1.7/2.1 3.2/3.8 .61/.67 1.1/1.3 1.9/2.3 .5/.55 .88/1.1 1.6/1.9

208V 1.2/1.3 1.9/2.4 3.6/4.3

575V .4/.44 .7/.85 1.3/1.5

250 500 500 1000 1000 2000 4000

Single-chained Single-chained Single-chained Single-chained Single-chained Single-chained Double-chained

NOTE: The above data is the nominal motor current at full load. At full load, it is not unusual for the hoist to draw in excess of the values listed when lifting. It is critical to ensure that the voltage at the reversing contactor does not drop below 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.

*Note: YJL*PT models are equivalent to the corresponding YJL*TH, but are supplied with a plain trolley and lug suspension. Model numbers for these units are the same as above except TH is replaced by PT. Similarly lug mounted units are noted as LG. **Note: To complete Model Number, insert lift in place of asterisks.

Failure to comply with Safety Precautions outlined throughout this manual can result in serious injuries or death. Before using this hoist, each operator should become thoroughly familiar with all warnings, instructions and recommendations in this manual.

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APPLICATION INFORMATION
This hoist is intended for general industrial use for lifting and transporting freely suspended material loads within its rated capacity. Yale Hoists cannot be responsible for applications other than those for which Yale equipment is recommended. Prior to installation and operation, we caution the user to review his application for abnormal environmental or handling conditions and to observe the applicable recommendations as follows:

ADVERSE ENVIRONMENTAL CONDITIONS

Do not use the hoist in areas containing flammable vapors, liquids, gases or any combustible dusts or fibers. Refer to Article 500 of the National Electrical Code. Do not use this hoist in highly corrosive, abrasive or wet environments. Do not use this hoist in applications involving extended exposure to ambient temperatures below -10F or above 130F.

LIFTING OF HAZARDOUS LOADS

This hoist is not recommended for use in lifting or transporting hazardous loads or materials which could cause widespread damage if dropped. The lifting of loads which could explode or create chemical or radioactive contamination if dropped requires fail-safe redundant supporting devices which are not incorporated into this hoist.

LIFTING OF GUIDED LOADS

This hoist is not recommended for use in the lifting of guided loads, including dumbwaiters and elevators. Such applications require additional protective devices which are not incorporated into this hoist. For such applications, refer to the requirements of applicable state and local codes, and the American National Safety Code for elevators, dumbwaiters, escalators and moving walks (ASME A17.1).

5. Do not kink power cable and control cable and never allow the cable to come in contact with oil, grease, hot surfaces, or chemicals. 6. Make certain that the power source conforms to the requirements of your equipment. 7. Inspect the unit daily before operating the 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 have a greater load capacity than the hoist. 13. Do not attempt to operate the hoist beyond normal maximum lift range. 14. Align hoist for a straight line pull. Avoid side pull or end pull. 15. Do not operate hoist with twisted or damaged chain. 16. Do not operate a damaged or malfunctioning hoist until necessary adjustments or repairs have been made. 17. Do not use hoist to lift people or to carry loads over people. 18. Do not leave a load suspended in the air unattended. 19. Always remove load before making repairs. 20. Do not remove or obscure capacity or warning decals.

INSTALLATION
1. Before installing the hoist, check the following: a. Make sure all supporting structures and attaching devices are strong enough to hold your intended loads. If in doubt, consult a qualified structural engineer. b. Provide proper branch circuit protection for the hoist as recommended in the National Electrical Code. c. The power supply should be plus or minus 10% of the voltage specified on the motor nameplate. It is critical to use adequate sized power cables, especially with 1-phase hoists (See Table 5, page 11). Be sure dual voltage hoists are connected or wired to correspond with your power supply (See WIRING, page 9). d. Installation area must provide operating conditions for the operator including sufficient room for the operator and other personnel to stand clear of the load at all times. e. For installations where the slack chain hanging from the unit may be objectionable or hazardous, the use of a chain container is recommended (See CHAIN CONTAINER, page 5). 2. YJLPT models come with a Yale FWE push-type trolley and an adaptable suspension lug. FWE trolleys are made to run on American Standard I-Beams and Wide Flange Beams with flange widths up to 8". For assembly refer to the instructions provided with the trolley. The hoist lug must be centered with the sideplates (1 washer). Due to the lug thickness, the washer placement between each sideplate and the lug may differ by 1 less washer than the generic instructions specify.

SAFETY INFORMATION
1. Follow all local electrical and safety codes, as well as the National Electrical Code (NEC) and the Occupational Safety and Health Act (OSHA) in the United States. 2. Hoist must be securely and adequately grounded. Hoist power cable is provided with an additional lead (green) for grounding purposes.

Always disconnect power source before working on or near a hoist or its connected load. If the power disconnect point is out of sight, lock it in the open position and tag to prevent unexpected application of power.

3. Be careful when touching the exterior of an operating motor; it may be hot enough to be painful or cause injury. With modern motors this condition is normal if operated at rated load and voltage (modern motors are built to operate at higher temperatures). 4. Protect the power cable and control cable from coming in contact with sharp objects.

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For installations where the trolley can not be slid onto the end of a beam, leave the load pin nuts loose enough to get the wheels around the beam flange. Check the flange width setting before tightening the nuts to 125 ft-lbs. Be sure to have end stops on your beam. 3. Before operating the hoist, be sure to observe the following: a. ALWAYS DISCONNECT HOIST FROM POWER SUPPLY before removing electrical cover or when making any electrical connection in the hoist or pushbutton station. b. The ground wire (green colored) of the power cable should always be connected to a suitable ground by means of a screw or clamp. An alligator clip does not make a safe ground connection. c. When installing a three-phase hoist, make only temporary connections at the power source. Push the UP button and observe the direction of the load block. If it raises, the phasing is correct and permanent connections may be made at the power source. If the load block lowers when the UP button is pushed, release the button immediately since the limit switches will not operate to protect the hoist from over-travel. Reverse any two wires (except the green ground wire) at the power source to correct the load hook direction (phasing). Do not change connections in the hoist or pushbutton assembly. d. Make sure load chain is not twisted as it travels into the hoist. e. Operate hoist in a hanging position only. Hoist should be permitted to align itself for a straight line pull. Do not attempt to pull around corners. f. Read ASME-B30.16 Safety Code for Hoists. 4. Lubricate the chain if necessary, see LUBRICATION, page 9. 5. Check the function of the limit switches. Before placing hoist in operation, check limit switch settings. Operate pushbutton until near stop point and inch into stop limit, both top and 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 containers designed for lifts of up to 50 ft on single-chained hoists and 25 ft on double-chained hoists. For longer lifts, the JLC927-5 container is available. For applications where a fabric bag is preferred, the JLC927-20F, JLC927-40F and the JLC927-70F are all options.

Do not attempt to store more chain in chain container than that specified in the table below or serious damage to hoist may result and hazardous conditions may be created.

Instructions are provided with each of these chain containers and must be adhered to closely to ensure a proper installation. To install the long lift chain container or a fabric chain container, you must follow instruction sheets provided with the chain container. The following instructions are for the standard metal chain containers only.

Installation of Standard Chain Containers (JLC927-1)

Refer to Figure 1. 1. Remove retaining clip and attachment pin and let the slack chain hang free.

Retainer Clip Attachment Pin

Figure 1 Installing Chain Container Assembly

Table 4 - Optional Chain Containers

Chain Container Model JLC927-1 JLC927- 2 JLC927- 3 JLC927- 4 JLC927-20F JLC927-40F JLC927-70F Recommended for Use With: Hoist Maximum Capacity Lift (ft) 1 Ton & Under 2 Ton 1 Ton & Under 2 Ton 1 Ton & Under 2 Ton 1 Ton & Under 2 Ton 1 Ton & Under 2 Ton 1 Ton & Under 2 Ton 1 Ton & Under 2 Ton 20 10 35 17 50 25 143 71 20 10 40 20 70 35 Container Material Molded Container Molded Container Molded Container Steel or Molded Container Open Weave Vinyl Coated Polyester Open Weave Vinyl Coated Polyester Open Weave Vinyl Coated Polyester Dimensions in Inches Length Depth 6 6 6 * 7 7 7 10 16 20 1 / 4 * 10 16 20

Width 6 7/ 8 6 6 * 7 7 7

* Dimensions depend on length of lift. Contact Factory.

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2. Run load hook down to its lowest position. Place the slack end of chain in chain container. Do not remove the chain stop. 3. Place chain container flush against housing with chain stripper between top lugs. Insert long attachment pin and replace retaining clip. 4. Feed the remainder of chain into container by operating hoist in the UP direction to the top limit. This will permit the chain to pile freely and prevent the chain from kinking, which may occur if the chain is placed in the container by hand.

OVERLOAD LIMITING PROTECTION

This hoist is equipped with a factory-calibrated overload limiting clutch that will permit the lifting of loads within its rated capacity, but will prevent the lifting of damaging overloads 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 10, for additional instructions on this device.

Do not allow load to come in contact with the chain container. If this situation exists reset the UP limit switch so that the hook block stops below the chain container (See LIMIT SWITCH ADJUSTMENT, page 8).

OPERATION
This hoist is designed for safe operation within the limits of its rated capacity. It is controlled by the UP and DOWN buttons of the pushbutton station. Two-speed models utilize 2-step buttons, the first step for operating the slow speed and the second for the fast speed. Although the Yale YJL is built with many features to ensure safety, it is a requirement that a hoist operator understands safe lifting practices. The following points must be observed. 1. Do not overload the hoist. 2. Do not make extreme side pulls with the hoist. 3. Operate the hoist only in a hanging position with adequate support. 4. Do not sling the load hook and chain around the load. Use an approved sling. 5. Be sure there are no twists in the load chain as it travels into the hoist housing. This condition should be constantly checked on double chain hoists because it is possible for the load block to be capsized or turned over one or more times.

The overload limiting clutch is an emergency protective device and should not be used to measure the maximum load to be lifted, or to sense the overload imposed by a constrained load. While the overload limiting clutch will protect the hoist from damaging overloads, it will not ensure that a load is within the rated capacity of the hoist.

MAINTENANCE
INSPECTIONS
A planned inspection routine should be established for this hoist based upon frequency of use, severity of use, and environmental conditions (Reference ASME Standard B30.16). Some inspections should be made frequently (daily to monthly) and others periodically (monthly to yearly). It is strongly recommended that an Inspection and Maintenance Check List and an Inspectors Report, similar to those shown in Figures 10A and 10B, be used and filed for reference. All inspections should be performed or overseen by a designated inspector. Special inspections should be made following any significant repairs or any operating occurrence leading one to suspect that the hoists capability may have been impaired.

LOWERING WITHOUT POWER

If the power fails with a load suspended, the hoist will automatically stop. In an emergency the load can be lowered without power as follows: 1. DISCONNECT HOIST FROM POWER SUPPLY AND REMOVE ELECTRICAL COVER. 2. Refer to Figure 5. Open disc brake manually by using two screwdriver blades, one on each side of the brake at a point close to the brake spring posts. Apply pressure to the underside of the armature plate (points X) to close the solenoid and release the brake.

Do not use hoist to lift, support or otherwise transport people.

6. Before raising a load, always check to see that it is held securely in the hook or sling chains, etc. Raise the load only until the load chain is taut and then double check the rigging before continuing to raise the load. 7. Do not stand beneath a load! Do not move a load in such a manner as to endanger personnel. 8. Dont lower into areas where visibility is obscured unless someone else is guiding the operation. 9. Use common sense at all times when operating a hoist. 10. Do not operate if direction of hook travel is not the same as indicated on button being pushed. 11. Do not operate unless hook travel limit devices function. Test without load each shift. 12. Do not operate when hoist is not centered over load. 13. Do not operate if chain is not seated properly in sprockets or sheave grooves. 14. Do not operate damaged or malfunctioning hoist.

Do not allow screwdriver blades to touch rotating friction disc C.

Do not allow the load to descend rapidly. This causes the motor to race and serious damage may result.

3. Use several quick releases instead of holding brake open continuously. Do not exceed normal lowering speed.

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HOOKS
Refer to Figure 2. 1. Inspect hooks once daily for cracking, extreme wear or spreading. Replace hooks showing any of these signs. If the throat openings are spread wider than the maximum permissible 15% increase listed here, the hooks have been overstressed and must be replaced. Any hook that is bent or twisted more than 10 degrees from the plane of an unbent hook must also be replaced. 2. The hook latches should be inspected to ensure that they close the hook throat opening in a secure manner when a load is applied. Inspect the hook shank and nut for any stripping of the threads or other damage. The hook nut should be fully restrained by the retaining pin. 3. In addition to above, load hooks should be inspected for cracks by the magnetic particle, dye penetrant or other suitable crack testing inspection method. This should be done at least once a year.
Hoist Capacity Top Hook X Dimension* Bottom Hook

1 Ton & Under 111/32" 17/32" 11 2 ton 1 /32" 111/32" (*) Maximum permissible throat opening of hook.
Figure 2 Hook Inspection

CHAIN
Chain is to be kept clean and lubricated (See LUBRICATION, page 9). Visually check chain every time hoist is used. Hoist must not be operated when chain is twisted or kinked. An important phase of hoist maintenance is chain inspection. Check individual links and check for chain elongation. 1. Check the chain for overall wear or stretch by selecting an unworn, unstretched length of chain (at the slack end for example). Let the chain hang vertically with a light load (about 20 pounds) on the chain to pull it taut. Use a large caliper to measure the outside length of a convenient number of links (about 12 inches). Measure the same number of links in a used section of chain and calculate the percentage increase in length of the worn chain. 2. If the length of the worn chain is more than 1% longer than the unused chain (0.015" per inch of chain measured), then the chain should be replaced. If the chain is worn less than 1%, check it at several more places along its length. If any section is worn more than 1%, the chain should be replaced.

Chain Replacement with Chain in Hoist Refer to Figures 3 & 4. 1. Run hook up to its top limit. 2. DISCONNECT HOIST FROM POWER SUPPLY and remove the electrical 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). 5. Make a C shaped chain link by grinding through the end link on the load end of the old chain. 6. Using the C link, attach the new chain to the load end of the old chain. Be sure that the welds of the upstanding links of the new chain will face outward from the load sheave. The end links must be oriented for attachment to the deadend screw and the chain support (double-chained only) without any twist in the chain. 7. With the electrical cover off, connect the hoist to the power supply. Be sure that the green ground wire is properly grounded (See INSTALLATION, page 4). 8. Carefully jog the UP button and run the joined pieces of chain into the hoist until about 15" of the new chain comes out the other side. 9. DISCONNECT HOIST FROM POWER SUPPLY. 10. Remove the C link and the old chain. Remove the chain stop by prying off its retaining ring with a flathead screwdriver. If attached, remove the old chain from the chain stripper by removing the retainer clip and attachment pin. 11. Attach the chain stop to the slack end of the new chain by capturing the 12th link with the two stop halves positioned with their tapered ends pointing towards the hoist. Slide the sleeve over the halves and attach the retaining ring. If you are not using a chain container, attach the slack end of the new chain to the side of the hoist using the attachment pin and retainer clip. DO NOT allow twists in the chain. 12. Adjust the lower limit switch (See ADJUSTING LOWER LIMIT, page 8).

Silver Nut (Down)

Gold Nut (Up)

Figure 3 Limit Switch Assembly

Spring Guide Plate

The chain used on this hoist has very carefully controlled dimensions and has been heat treated. Do not attempt to substitute other manufacturers chain.

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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 setting the hook travel within the factory-set limits of travel. The standard limit switch is designed for lifts of 50 ft or less on single-chained hoists and 25 ft or less on the 2 ton, double-chained models. The long lift limit switch allows for the maximum amount of lift, which is 134 ft on 1/2 ton and under models, 143 ft on the 1 ton models, and 71 ft on the 2 ton models. The upper and lower limit switch adjusting nuts are color-coded gold and silver respectively. Each limit nut has 10 slots for fine adjustment, and the increment of adjustment is such that one slot is equivalent to approximately one link of chain travel with the standard limit switch. Movement of the limit switch nuts toward or away from each other increases or decreases the hook travel respectively. Adjusting Upper Limit (Gold Nut) Refer to Figure 3. 1. Suspend the hoist. For single chain models raise the load block until there is a minimum clearance of 2" from the hoist housing and the top of the block. Double chain models require a minimum clearance of 1" from the chain support to the top of the load block. 2. DISCONNECT HOIST FROM POWER SUPPLY and remove the electrical cover. 3. With a screwdriver, pry the spring guide plate out of the slots in the limit switch nuts. 4. Turn the slotted gold nut toward its limit switch until the switch clicks then turn two slots farther. Release the spring guide plate and be sure it slips back into the slots in both limit switch nuts. Do not disturb the silver slotted nut if it has been set previously. Adjusting Lower Limit (Silver Nut) Refer to Figure 3. 1. Suspend the hoist. Carefully lower the load block to a point where the slack-end loop of the chain hangs down 6" or more from the hoist housing (or the limit desired in any particular application allowing the minimum 6"). There should be a minimum clearance of 1" between the chain stop and bottom of hoist. 2. DISCONNECT HOIST FROM POWER SUPPLY and remove the electrical cover. 3. With a screwdriver, pry the spring guide plate out of the slots in the limit switch nuts. 4. Turn the slotted silver nut toward its limit switch until the switch clicks, then turn two slots farther. Release the spring guide plate and be sure it slips back in the slots in both limit switch nuts. Do not disturb the gold slotted nut if it has been set previously.

Double-Chain Only

Figure 4 Chain Replacement Diagram

13. Attach the bottom block on single-chained hoists using a new load block screw (See Figure 23). On double-chained hoists, feed the chain through the load block (welds of the upstanding links will be in towards the sheave) and fasten the end of the chain to the chain support using a new chain support pin (See Figure 23). Be sure there are no twists in the chain. 14. Adjust the upper limit switch (See ADJUSTING UPPER LIMIT, page 8). Chain Replacement with No Chain in Hoist Refer to Figure 4. 1. DISCONNECT HOIST FROM POWER SUPPLY and move hoist to a work table. Remove the electrical cover, electrical panel and the electric brake assembly. 2. Detach the chain stripper from the bottom of the hoist. 3. Insert the new chain between the load sheave and the chain guide. Feed the chain into the hoist by manually turning the brake hub. Allow about 15" of chain below the hoist on the slack end. Be sure the welds of the upstanding links are out away from the load sheave and that proper orientation is observed for attachment of the slack end. Also be sure the load hook assembly (if already attached to the chain) is toward the center of the hoist or to your right looking from the transmission end.

There are wires running through the hoist. Carefully ease the hoist sections apart. Do not jerk them apart.

4. Reinstall the chain stripper (with the chain anchor on doublechained hoists, See Figure 4) observing proper chain alignment and avoiding any twist in the chain. 5. Follow steps 11 through 14 in previous section, CHAIN REPLACEMENT WITH CHAIN IN HOIST, to complete the chain replacement procedure. NOTE: Inspect chain guides and load sheave for wear, replace as needed.

If the wires running to the limit switches are ever disconnected for any purpose, be sure to replace wires in accordance with the correct wiring diagram (See Figures 9A, 9B, 9C & 9D).

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Check Both Upper and Lower Limits 1. Connect the hoist to the power supply. Be sure the green ground wire is properly grounded (See Installation 3-b, page 5). 2. Check load hook direction (See Installation 3-c, page 5). 3. Carefully raise load block to upper limit and observe if it stops automatically at desired level. Do not allow load block to run into hoist housing this will damage the hoist. Maintain a minimum clearance of 2" from the hoist housing and the top of the load block on single-chained models and 1" from the chain support to the top of the load block on double-chained models. 4. Carefully lower load block to lower limit and observe if it stops automatically at the desired level. Do not allow slackend loop of chain to become taut against hoist housing. This will damage the hoist. There should be a minimum clearance of 1" between the chain stop and the bottom of the hoist. 5. If upper and lower limits operate satisfactorily, hoist is ready for use. If they are not as desired, repeat adjustment.

Be sure the bottom of the armature does not bear against the splined adapter H. As adjustments are made, the built-in clearance will be reduced. When this clearance is gone REPLACE BRAKE DISCS. Minimum allowable disc thickness is .162".

HOIST CONTROLS
Both the pushbutton and the reversing contactor are mechanically interlocked to prevent shorting the circuit and causing serious damage. As part of maintenance, always check for proper closure of contact points as well as for burned contacts. If replacement is necessary, see Figures 16, 17, 18, and 19 for replacement parts.

WIRING
Refer to Figures 9A, 9B, 9C & 9D. Single-phase units (115/230V) are shipped wired for 115V and the 1-speed, 230/460V-3 phase units are wired for 460V unless otherwise specified when ordered. Hoists wired for other voltages and 2-speed units are single voltage only. Conversion of dual-voltage hoists to either the higher or lower voltage can be done simply and quickly as follows: 1. DISCONNECT HOIST FROM POWER SUPPLY and remove the electrical cover. 2. Each dual-voltage hoist has a terminal block assembly for the interconnection of the electrical components of the hoist. To convert the voltage, reconnect the leads to the terminal blocks according to the wiring diagram located inside the electrical cover or Figures 9A, 9B, 9C and 9D. DO NOT move any wires or make any changes to the electrical circuit except at the terminal block assembly. Tug on wires to ensure they are securely connected. 3. After converting the voltage, recheck phasing and limit switch operation (See INSTALLATION 3-c & 5, page 5). IMPORTANT: Always refer to the wiring diagram located on the inside of the electrical cover or Figures 9A, 9B, 9C and 9D when performing electrical repairs. Make sure all connections are secure and check for damaged insulation. It is also imperative that the power circuit has conductors of adequate size (See Table 5).

BRAKE
Properly adjusted, this brake will release promptly when energized. It is capable of both smoothly stopping and securely holding the rated capacity of the hoist. If the hoist develops either undesirable over-travel after the pushbutton is released (this condition is most noticeable in the lowering direction) or hesitates to lift the load promptly when the pushbutton is depressed (this condition is most noticeable in the hoisting direction), the brake should be adjusted. Brake Adjustment Refer to Figure 5. 1. DISCONNECT HOIST FROM POWER SUPPLY and remove the electrical cover. 2. With reference to Figure 5, 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 and the brake properly set. Replace the electrical cover, reconnect the power supply, and check hoist brake action.

LUBRICATION
Refer to Figure 11. Proper lubrication is necessary for a long and relatively troublefree hoist operation. Refer to the following and the RECOMMENDED LUBRICATION SCHEDULE for lubrication points, type of lubricant, and frequency of lubrication. Load Chain Clean the load chain with acid-free solvent and coat with SAE 90 gear oil. Wipe excess oil to prevent dripping. Never apply grease to the chain. Gearing The gear case of this hoist is filled at assembly with approximately 1 pints of SAE 90 EP gear oil. Check oil level by removing the oil level check plug from the side of the hoist. With the hoist hanging level, gear oil should be even with the hole. Change oil periodically depending on the severity of the application and the environmental conditions (at least every 200 hours of run time).

B E A X D H
Figure 5 Brake Assembly

F G
Gap

X C

Go To Index

Bearings All bearings except hook and idler sheave bearings are lubricated at the factory and should not require additional lubrication. Noisy or worn bearings should be replaced. Limit Switch Shaft Remove any dirt accumulation and spray with a general purpose lubricant. Hook Bearing Apply a few drops of SAE 30 gear or motor oil around the edge of the bearing. Idler Sheave Bearing (Bushing) Disassemble load block and apply a light coat of NLGI #2 grease, or equivalent, inside of bearing.

Figure 6 - Electrical Panel Removed

HOIST REPAIRS
1. For major repairs or when the hoist is to be sectioned in the suspension area, it will be necessary to move the hoist to a workbench or table. 2. For repairs which can be done by removing the electrical cover only, the hoist need not be moved. Lowering the hoist to a convenient working level is desirable. NOTE: If you do not have an experienced mechanic to do your repair work, we recommend that you send your hoist to an approved service station for repairs. Use authorized repair parts only.

5. Refer to Figures 20 and 21 to disassemble the limit switch. See LIMIT SWITCH ADJUSTMENT on page 8 to properly set the upper and lower limits of travel. 6. Refer to Figures 18 and 19 for repairs on the pushbutton station. Also refer to the wiring diagram inside the electrical cover or Figures 9A, 9B, 9C and 9D for wiring instructions. Motor Refer to Figures 12, 13 and 14. The hoist motor is located on the opposite end to that of the electrical parts, but the two are tied together with electrical leads running through the housing. 1. If it is necessary to replace or repair the motor, DISCONNECT THE HOIST FROM THE POWER SUPPLY and remove the electrical cover. 2. Loosen the screw clamps on the terminal blocks and reversing contactor to disconnect the motor leads (See Figures 16 and 17). 3. Remove the four motor mounting bolts attaching the motor to the housing. It will come loose at the motor coupling. 4. Inspect the motor coupling, motor shaft and all the bearings. Replace as necessary. 5. Install new or repaired motor according to the wiring diagram located inside the electrical cover or Figures 9A, 9B, 9C and 9D. Gearing Refer to Figures 7, 12 and 22. As disassembly is extensive for gearing, disconnect the hoist and move it to a workbench. 1. Remove the electrical cover. 2. Remove the electrical panel. 3. Remove the brake assembly and the limit switch assembly. 4. Drain the oil from the transmission. 5. Remove the four screws that attach the transmission cover to the gear housing and remove the transmission cover. The limit switch drive shaft will come along with the cover.

Remove load and disconnect hoist from power supply before starting to do any repairs or to take any sections apart.

The following repair instructions will help you in understanding repair procedures, when related to the Replacement Parts List starting on page 18. For clarity these are broken down into areas. Electrical Parts and Brake 1. Refer to Figures 15, 16 and 17. Remove the cover to access the controls. Single-phase models also have a starting switch and capacitor mounted on the panel as shown in Figure 16. 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 on or off using a rotating action. Note the numbers that label the terminals on the contactor and orient the part as shown in Figures 9A-9D. Single-phase contactors have a small jumper that is not present on the 3-phase (note the 3 and 5 terminals on the reversing contactor in Figure 9A). 2. Remove the electrical panel by removing the stand-off screws (See Figures 16 & 17). The limit switch and brake are now accessible as shown in Figure 6. 3. Remove the transformer bolted to the back of the panel plate if it requires replacement. 4. Refer to Figure 15 to disassemble the brake. See BRAKE ADJUSTMENT on page 9 to properly set the brake.

Do not disassemble or readjust the clutch, or replace it with a clutch assembly from another hoist. Doing so will void the warranty and may create an unsafe condition. If replacement is needed due to wear or loss of adjustment, always use a new clutch assembly.

10

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6. Inspect gears for broken or severely worn teeth and inspect all bearings. Replace as necessary. The overload slip clutch is factory calibrated and must not be disassembled or readjusted. 7. Reassemble in reverse order of disassembly, making sure that the gasket is in place and in good condition. Coat gasket with Permatex or other gasket cement. Extreme care should be taken to avoid damage to oil seals. 8. Check all wire terminals to be sure that they are properly seated and in accordance with the correct wiring diagram. Before placing the hoist back into service, check the brake adjustment and limit switch settings.

Periodic inspections of the top suspensions can be made without disassembly. For more extensive inspections the lug maybe removed as follows: 1. Disconnect the hoist and remove it to workbench. 2. Remove the lug retaining screw. 3. Remove the lug retainer. 4. Remove the lug.

Figure 8A - Single Chain Lug Orientation

Figure 7 - Assembled Gearing

Suspension Refer to Figures 8A & 8B. The hoist sections must be separated at the top hook line in order to inspect the load sheave and chain guides. 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 8B - Double Chain Lug Orientation

Care must be taken during reassembly to have the hook in proper orientation. Refer to figures 8A & 8B for proper orientation. The transmission must be disassembled in order to inspect load sheave and chain guide (see CHAIN REPLACEMENT WITH NO CHAIN IN HOIST, page 8). When reassembled, recheck the limit switch settings (See LIMIT SWITCH ADJUSTMENT, page 8).

POWER CORD PRECAUTIONS WITH 1-PHASE HOISTS

Electric hoists require a sufficient power supply. It is especially important with single-phase voltage to ensure that the conductors running to the hoist from the power source are adequate in size to handle the power requirements of the hoist. Inadequate power cables and branch circuits will cause low voltage, high amperage, damage to the hoist, and potential fire hazards. Such problems can be minimized by using 230V power on 115/230V hoists. The following are recommendations for the conductor gage size depending on the length, horsepower, and voltage.
Table 5 - Recommended Conductor Sizes for 1-Phase Hoists Maximum Length of Power Cord in Feet
HP Voltage (1-Phase) 115V 230V 115V 230V 115V 230V 14 AWG 12 AWG 10 AWG 8 AWG

1/4 1/2 1

75 350 40 200 0 120

120 560 60 330 30 190

190 900 100 520 50 310

300 150 810 75 490

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TROUBLE SHOOTING
Always disconnect unit from the power supply system before removing hoist covers or the back cover of control station.
Probable Cause
Hook fails to stop at end of travel

Failure to follow proper lockout/tagout procedures may present the danger of electrical shock. TO AVOID INJURY: Disconnect power and lockout/tagout disconnecting means before removing cover or servicing this equipment. Remedy

1. 2. 3.

Limit switch not operating Brass limit switch nuts not moving on shaft Hoist reversing contactor malfunctioning

1. Check adjustment (See LIMIT SWITCH ADJUSTMENT, page 8). Check connections against wiring diagram. Tighten loose connections or replace. 2. Check for stripped threads or bent nut guide. 3. Remove electrical cover and check reversing contactor.

Hoist does not respond to pushbutton

1. 2. 3. 4. 5.

Power failure in supply lines Wrong voltage or frequency Improper connections in hoist or pushbutton station Brake does not release Faulty hoist reversing contactor

1. Check circuit breakers, switches and connections in power supply lines. 2. Check voltage and frequency of power supply against the rating on the nameplate of the motor. 3. Check all connections at line connectors and on terminal block. Check terminal block on dual voltage hoists for proper voltage connections. 4. Check connections to the solenoid coil. Check for open or short circuit. Check for proper adjustment (See BRAKE ADJUSTMENT, page 9). 5. Check coils for open or short circuit. Check all connections in control circuit. Check for burned contacts. Replace as needed.

Hook does not stop promptly

1. 2.

Hoist overloaded Brake not holding

1. Reduce load to within rated capacity of hoist. 2. Check brake adjustment (See BRAKE ADJUSTMENT, page 9). It may be necessary to replace discs.

Hook moves in wrong direction

1. 2.

Three phase reversal Improper connections

1. Reverse any two wires (except the green ground wire) at the power source (See INSTALLATION 3c, page 5). 2. Check all connections against wiring diagram.

Hoist hesitates to lift when energized

1. 2. 3. 4. 5.

Hoist overloaded Motor brake requires adjustment Worn overload limiting clutch Low voltage Faulty SINPAC starting switch or start capacitor (single phase hoists only)

1. 2. 3. 4.

Reduce load within rated capacity of hoist. Check motor brake adjustment (See BRAKE ADJUSTMENT, page 9). Replace clutch. Determine cause of low voltage and bring up to within plus or minus 10% of the voltage specified on the motor. Measure voltage at the hoist reversing contactor while lifting a load. 5. Replace faulty component.

Hook raises but will not lower

1. 2. 3. 4.

DOWN circuit open Broken conductor in pushbutton cable Faulty hoist reversing contactor Loose screw clamps

1. Check circuit for loose connections. Check DOWN limit switch for malfunction. 2. Check each conductor in the cable. If one is broken, replace entire cable. 3. Check coils for open or short circuit. Check all connections in control circuit. Check for burned contacts. Replace as needed. 4. Ensure that screw clamps are tightened on the terminal blocks and reversing contactor.

Hook lowers but will not raise

1. 2. 3. 4. 5. 6. 7. 8.

Hoist overloaded Low voltage UP circuit open Broken conductor in pushbutton cable Faulty hoist reversing contactor Faulty capacitor (single phase hoist only) Worn overload limiting clutch Loose screw clamps

1. Reduce load to within rated capacity of hoist. 2. Determine cause of low voltage and bring up to within plus or minus 10% of the voltage specified on the motor. Measure voltage at the hoist reversing contactor while lifting a load. 3. Check circuit for loose connections. Check UP limit switch for malfunction. 4. Check each conductor in the cable. If one is broken, replace entire cable. 5. Check coils for open or short circuit, check all connections in control circuit. Check for burned contacts. Replace as needed. 6. Check starting capacitor on motor. Replace if necessary. 7. Replace overload clutch assembly. 8. Ensure that screw clamps are tightened on the terminal blocks and reversing contactor.

Motor overheats

1. 2. 3. 4. 5.

Excessive load Low voltage Extreme external heating Frequent starting or reversing Brake dragging

1. Reduce load to within rated capacity of hoist. 2. Determine cause of low voltage and bring up to within plus or minus 10% of the voltage specified on the motor. Measure voltage at the hoist reversing contactor while lifting a load. 3. As the ambient temperature rises towards the 130F limitation of the unit, frequency of the hoist operation must be limited to avoid overheating of the motor. See ADVERSE ENVIRONMENTAL CONDITIONS, page 4. 4. Excessive inching, jogging or reversing should be avoided since this type of operation will drastically shorten the life of motor, contactor and brake. 5. Check brake adjustment (See BRAKE ADJUSTMENT, page 9).

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TROUBLE SHOOTING CONTINUED

Lack of proper lifting speed

1. 2. 3 4.

Hoist overloaded Brake dragging Low voltage Overload limiting clutch intermittently slipping

1. 2. 3. 4.

Reduce load to within rated capacity of hoist. Check for proper brake adjustment or other defects. Ensure that the voltage at the reversing contactor is within 10% of the nominal voltage while lifting a load. Replace overload clutch assembly.

Motor brake noise or chatter (while starting hoist)

1. 2.

Brake needs adjustment Low voltage

1. See BRAKE ADJUSTMENT, page 9. 2. Ensure that the voltage at the reversing contactor is within 10% of the nominal voltage while lifting a load.

Motor brake buzz (anytime hoist is running)

1. 2.

Brake needs adjustment Broken shading coil on brake frame

1. See BRAKE ADJUSTMENT, page 9. 2. Replace shading coil or complete brake frame assembly.

Figure 9A Wiring Diagram for 115/230V - 1 Phase Models

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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.

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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.

15

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INSPECTION AND MAINTENANCE CHECK LIST ELECTRIC POWERED OVERHEAD CHAIN HOIST
Type of Hoist ___________________________________________________________ Location _______________________________________________________________ Manufacturer___________________________________________________________ Item Frequency of Inspection Frequent Daily Operating Controls Limit Switches Brake Mechanism * * * * Hooks * Suspension Lug (if used) Chain Hook and Suspension Lug Connections Pins, Bearings, Bushings Shafts, Couplings Nuts, Bolts, Rivets Sheaves Housings, Load Block Wiring and Terminals Hoist Reversing Contactor, other Electrical Apparatus Supporting Structure and Trolley (if used) Nameplates, Decals, Warning Labels Transmission Lubricant * * * * * * * * * * * * * * * Monthly * * * * Periodic 1-12 Mo. * * * * Any deficiency causing improper operation 1. Any deficiency causing improper operation 2. Pitting or deterioration 1. Slippage or excessive drift 2. Glazing, contamination or excessive wear Excessive throat opening 15% bent or twisted more than 10 degrees, damaged hook latch, wear, chemical damage, worn hook bearing. Cracks (use dye penetrant, magnetic or other suitable detection method) Cracks, excessive wear or other damage which may impair the strength of the lug. Cracks (use dye penetrant, magnetic particle or other suitable detection method) Inadequate lubrication, excessive wear or stretch, cracked, damaged or twisted links, corrosion or foreign substance Cracks, bending, stripped threads Excessive wear, corrosion, cracks, distortion Looseness, stripped and damaged threads, corrosion Distortion, cracks, and excessive wear. Build-up of foreign substances Cracks, distortion. Excessive wear, internal build-up of foreign substances Fraying, defective insulation Loose connections, burned or pitted contacts Damage or wear which restricts ability to support imposed loads Missing, damaged or illegible Low level requires changing Capacity (Tons) _________________________________________________ Original Installation Date _______________________________________ Manufacturers Serial No. _______________________________________ Possible Deficiencies OK Action Required

NOTE: Refer to Maintenance and Inspection Sections of the Hoist-Maintenance Manual for further details. FREQUENCY OF INSPECTION Frequent Indicates items requiring inspection daily to monthly. Daily inspections may be performed by the operator if properly designated. Periodic Indicates items requiring inspection monthly to yearly. Inspections to be performed by or under the direction of a properly designated period. The exact period of inspection will depend on frequency and type of usage. Determination of this period will be based on the users experience. It is recommended that the user begin with a monthly inspection and extend the periods to quarterly, semi-annually or annually based on users monthly experience.

Figure 10A Recommended Inspection and Maintenance Check List

NOTE: This inspection and maintenance check list is in accordance with our interpretation of the requirements of the Safety Standard for Overhead Hoists ASME B30.16. It is, however, the ultimate responsibility of the employer/user to interpret and adhere to the applicable requirements of this safety standard.

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INSPECTORS REPORT
ITEM REMARKS (LIST DEFICIENCIES AND RECOMMENDED ACTION)

Inspectors Signature

Date Inspected

Approved by

Date

Figure 10B Recommended Inspectors Report

RECOMMENDED LUBRICATION SCHEDULE* YALE ELECTRIC POWERED CHAIN HOIST

PAGE AND REFERENCE NO. Pages 32 & 33 Ref. No. 8 Pages 30 & 31 Pages 28 & 29 Ref. Nos. 9 & 7 Pages 32 & 33 Ref. No. 18, 30 Pages 32 & 33 Ref. No. 27 COMPONENT TYPE OF LUBRICANT TYPE OF SERVICE AND FREQUENCY OF LUBRICATION HEAVY Load Chain Gearing Limit Switch Shaft Load Hook Bearing Idler Sheave Bearing (Bushing) Assembly SAE 90 gear oil SAE 90 extreme pressure (EP) gear oil Multi-purpose oil or general purpose spray SAE 30 gear oil or motor oil Daily NORMAL Weekly INFREQUENT Monthly

At periodic inspection (see Figure 10A) Monthly Weekly Yearly Monthly Yearly Yearly

Multi-purpose lithium base bearing grease - NLGI #2

At periodic inspection (see Figure 10A)

NOTE: All bearings except hook and idler sheave bearings are prelubricated and sealed. (*) This lubrication schedule is based on a hoist operating in normal environment conditions. Hoists operating in adverse atmospheres containing excessive heat, corrosive fumes or vapors, abrasive dust, etc., should be lubricated more frequently.
Figure 11 Recommended Lubrication Schedule

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Figure 12 - Basic Hoist

12 9 11

10

2 1

2 3 4 5 6 7 14 8 13
Parts List for Basic Hoist Ref Description No. 1 Motor (See Figures 13 & 14) 2 Cover Screw 3 Trim Cover 4 Transmission Housing 5 Transmission Case Gasket 6 Transmission Cover 7 Electrical Cover Gasket 8 Electrical Cover 9 Hook Retainer Screw 10 Top Hook Assembly with Latch Rigid Hook (std.) Swivel Hook 11 Latch Kit Assembly 12 Hook Retainer 13 Yale Decal 14 Capacity Decal 250 lbs. 1/4 ton 1/2 ton ( ) N o t S h ow n
() Optional

Part No. H2976P JM37 JM3533 JM560 JM34 JM563 JM36 H2709P 3M405A01S 51JM1 4X1305 JM285 YJL677 JLC675K-01 JLC675K-02 JLC675K-05

Qty 1 7 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1

Ref No.

Description

1 ton 2 ton Nylon Cover 1/8 ton 08770W 1/4 ton 08771W 1/2 ton 08772W 1 ton 08773W 2 ton 08774W Chain Container 08348W Plain Trolley (Lug Mounted) 1 Ton & Under 09292 2 Ton 09293 (Also requires Suspension Lug)* Suspension Lug Cross Mounted JM50C Parallel Mounted 50JM1

Part No. JLC675K-10 JLC675K-20

Qty 1 1 1 1 1 1 1 1 1 1

1 1

Suspension lug is an option for YJL Models and standard for YJL*PT Models.

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Figure 13 - Hoist Motor, 115/230V - 1 Phase

8 9 7 4 5 3 6
() Refer to the motor nameplate for part number voltage, full load amperage, horsepower, and other motor information.

2
Parts List for Hoist Motor, 115/230V - 1 Phase Ref Description Part Qty No. No. 1 Hoist Motor 1/4 hp, 115/230V-1Ph 1/2 hp, 115/230V-1Ph 1 hp, 115/230V-1Ph 2 3 4 5 Stator Assembly Rotor Assembly End Shield Rear Bearing 861JM11 861JM12 861JM14 * * 1 1 1 1 1

Ref No. 6 7 8 9

Description Front Bearing Shim Washer Thru Bolt #10 Spring Lockwasher

Part No. 732012C JL4301-01 HA3100A56 H4082P

Qty 1 1 4 4

35EP3100D09 1 500K3 1

* Not available as an individual part.

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Figure 14 - Hoist Motor, 3 Phase

8 9 4 7 5

3
() Refer to the motor nameplate for part number voltage, full load amperage, horsepower, and other motor information.

2
Parts List for Hoist Motor, 3 Phase Ref Description Part No. No. 1 Hoist Motor (1-Speed) 1/4 hp, 230/460V-3Ph-60Hz 1/2 hp, 230/460V-3Ph-60Hz 1 hp, 230/460V-3Ph-60Hz 1/4 hp, 575V-3Ph-60Hz 1/2 hp, 575V-3Ph-60Hz 1 hp, 575V-3Ph-60Hz 1/4 hp, 208V-3Ph-60Hz 1/2 hp, 208V-3Ph-60Hz 1 hp, 208V-3Ph-60Hz Hoist Motor (2-Speed) 1/4 hp, 230V-3Ph-60Hz 1/2 hp, 230V-3Ph-60Hz 1 hp, 230V-3Ph-60Hz 1/4 hp, 460V-3Ph-60Hz 1/2 hp, 460V-3Ph-60Hz 1 hp, 460V-3Ph-60Hz 1/4 hp, 575V-3Ph-60Hz 863JM1 863JM2 863JM4 863JM5 863JM6 863JM8 863JM9 863JM10 863JM12 873JM1 873JM2 873JM4 873JM5 873JM6 873JM8 873JM9 Qty Ref No. Description 1/2 hp, 575V-3Ph-60Hz 1 hp, 575V-3Ph-60Hz 1/4 hp, 208V-3Ph-60Hz 1/2 hp, 208V-3Ph-60Hz 1 hp, 208V-3Ph-60Hz Stator Assembly Rotor Assembly End Shield Rear Bearing Front Bearing Shim Washer Thru Bolt (1-Speed) Thru Bolt (2-Speed) #10 Spring Lockwasher Part No. Qty 1 1 1 1 1 1 1 1 1 1 1 4 4 4

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

2 3 4 5 6 7 8 9

873JM10 873JM12 873JM13 873JM14 873JM16 * * 35EP3100D09 500K3 732012C JL4301-01 HA3100A56 HA3100A71 H4082P

* Not available as an individual part.

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Figure 15 - Brake & Solenoid Parts

2 15 11 13 15

13

12 16 4 3 4 3 5 6

12 16 15 12

14 9 1
NOTE: Refer to wiring diagram inside electrical cover of hoist or Figures 9A, 9B, 9C or 9D, when connecting any wires.

8 10 6 7

10
Parts List for Brake & Solenoid Parts Ref Description Part No. No. 1 Disc Brake Assembly* 1 hp,115 Volt 1/4 & 1/2 hp, 115 Volt 1 hp, 230 Volt 1/4 & 1/2 hp, 230 Volt 1 hp, 460 Volt 1/4 & 1/2 hp, 460 Volt 1 hp, 575 Volt 1/4 & 1/2 hp, 575 Volt 1 hp, 208 Volt 1/4 & 1/2 hp, 208 Volt 1 hp, 380 Volt 1/4 & 1/2 hp, 380 Volt Plate & Stud Assembly Brake Disc 1/4 & 1/2 hp 1 hp Brake Plate Plate & Armature Assembly Spring Retainer 854JM1 854JM12 854JM2 854JM22 854JM3 854JM32 854JM4 854JM42 854JM5 854JM52 854JM6 854JM62 859JG1 581J1A 581J1A JF291 JF858 344J6 JF710 Qty Ref No. 8 9 Description Plate & Frame Assembly Brake Coil* 115V* 230V* 460V 575V 208V 380V 415V Locknut Adapter Screw Retaining Ring Shading Coil Shading Coil Adhesive Lockwasher Spacer for 1/4 & 1/2 hp Part No. JF857 853JL1 853JL2 853JL3 853JL4 853JL5 853JL6 853JL7 H3978 JL142 H2976P H5501 860J1 H7812 H4134 141J2 Qty 1 1 1 1 1 1 1 1 3 1 3 2 2 1 3 3

2 3

1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 2 1 3 1

10 11 12 13 14 15 16

4 5 6 7

* Dual-voltage 115/230V models use 115V Brake Assembly and Coil. Dual-voltage 230/460V models use 230V Brake Assembly and Coil.

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Figure 16 - Electrical Parts, 1-Speed Models

8 1 5 9 6 20 8 12 10 18 12 13 15 2 16 13 16 17 11 18 4 3 8
Parts List for Electrical Parts, 1-Speed Models Ref Description Part Qty No. No. 1 2 3 Transmission Cover Panel Plate Reversing Contactor* 1/2 hp & under: 24V Coil 115V Coil 1 hp, 1-Phase: 24V Coil 115V Coil 1 hp, 3-Phase: 24V Coil 115V Coil Transformer* Pri.: 115/230V, Sec.: 24V Pri.: 115/230V, Sec.: 115V Pri.: 230/460V, Sec.: 24V Pri.: 230/460V, Sec.: 115V Pri.: 575V, Sec.: 24V Pri.: 575V, Sec.: 115V Pri.: 208V, Sec.: 24V Pri.: 208V, Sec.: 115V Pri.: 380V, Sec.: 24V Pri.: 380V, Sec.: 115V Terminal Block 115/230V 230/460V JM34 257JM200 28860 24799 24791 28905 25943 24729 821J412 821J411 821J432 821J431 821J452 821J451 821J472 821J471 821J482 821J481 909J10 909J10 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8 11 12 13 14 15 16 17 18 19 20 21

19

21

14

14

Ref No. 6 7 8 9 10

Description Terminal Block 115/230V End Plate 115/230V 230/460V End Clamp 115/230V & 230/460V Single Voltage Models Marking Strip 15 ft Power Cord Assembly 115/230V, 1/2 hp (3 cond.) 115/230V, 1 hp (3 cond.) 3-Phase (4 cond.) PB & Cable Assembly (See Figures 18 & 19) Panel Standoff Spacer 1/4" Internal-tooth Lockwasher 1/4-20UNC X 4" Screw 8-32UNC X 5/16" Screw #8 External-tooth Lockwasher 1/4" Flatwasher 10-24UNC X 1/2" Screw Can Mounting Bracket SINPAC Starting Switch Capacitor

Part No. 909J14 909J15 909J12 909J13 909J13 909J11 951JM1 952JM1 953JM1 200J4 H4134 H1027P H2751 H4158 H4002P H2970 JM811 839J3 JL810-4

Qty

4 1 1 3 1 1 1 1 1 1 3 3 3 2 2 1 1 2 1 1

* Coil voltage of the contactor and the secondary voltage of the transformer are the same. This is referred to as the control voltage. Standard units are supplied with 24V Control. ()Single Phase units only.

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Figure 17 - Electrical Parts, 2-Speed Models

1 4

15 2

8 14 8

11

12

10 9 10

12 7 13 14 5 3

15

Parts Ref No. 1 2 3

List for Electrical Parts, 2-Speed Models Description Part Qty No. Transmission Cover JM34 1 Panel Plate 257JM200 1 Reversing Contactor* 1/2 hp & under: 24V Coil 28860 1 115V Coil 24799 1 1 hp, 3-Phase: 24V Coil 25943 1 115V Coil 24729 1 Speed Control Relay* 1/2 hp, 24V Coil 28878 1 1/2 hp, 115V Coil 28870 1 1 hp, 24V Coil 28885 1 1 hp, 115V Coil 28879 1 Transformer* Pri.: 230/460V, Sec.: 24V 821J432 1 Pri.: 230/460V, Sec.: 115V 821J431 1

Ref No. 5

Description Pri.: 575V, Sec.: 24V Pri.: 575V, Sec.: 115V Pri.: 208V, Sec.: 24V Pri.: 208V, Sec.: 115V Pri.: 380V, Sec.: 24V Pri.: 380V, Sec.: 115V 15 ft Power Cord Assembly PB & Cable Assembly (See Figures 18 & 19) Panel Standoff 1/4" Internal-tooth Lockwasher 1/4-20UNC X 4" Screw 8-32UNC X 5/16" Screw #8 External-tooth Lockwasher 1/4" Flatwasher 10-24UNC X 1/2" Screw End Clamp

6 7 8 9 10 11 12 13 14 15

Part No. 821J452 821J451 821J472 821J471 821J482 821J481 953JM1 200J4 H4134 H1027P H2751 H4158 H4002P H2970 909J13

Qty 1 1 1 1 1 1 1 1 3 3 3 2 2 1 1 2

* The coil voltage of the contactors and secondary voltage of the transformer are the same. This is referred to as the control voltage. Standard units are supplied with 24V Control.

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Figure 18 - 1-Speed Pushbutton Station

1 2 3 4

16 9

10 11

13 14 15 12 4 6

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Parts List for 1-Speed Pushbutton Station Ref. Description No. 1 Pushbutton Station & Control Cable Assembly 6 ft Cable Length 11 ft Cable Length 16 ft Cable Length Special Drop 2 3 Pushbutton Station Assembly Control Cable Assembly 6 ft Cable Length 11 ft Cable Length 16 ft Cable Length Special Drop 4 5 6 7 8 * Enclosure Gasket Contact Assembly (Includes item 7) Button Assembly Grommet Hardware Kit (Includes items 9 - 16) Warning Tag

Part No.

Qty

PB2100-6 PB2100-11 PB2100-16 PB2100-S 36900R

1 1 1 1 1

PBC2100-6 PBC2100-11 PBC2100-16 PBC2100-S 36998 36986 36987 36988 36989 36939

1 1 1 1 1 1 1 1 1 1

687K3W

() Equal to cable length (pushbutton drop). ( ) Not shown.

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Figure 19 - 2-Speed Pushbutton Station

1 2 3

16 4 9 10 11 5

4 8

13 14 12 6 7 15 4

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Parts List for 2-Speed Pushbutton Station Ref. Description No. 1 Pushbutton Station & Control Cable Assembly 6 ft Cable Length 11 ft Cable Length 16 ft Cable Length Special Drop 2 3 Pushbutton Station Assembly Control Cable Assembly 6 ft Cable Length 11 ft Cable Length 16 ft Cable Length Special Drop 4 5 6 7 8 * Enclosure Gasket Contact Assembly (Includes item 7) Button Assembly Grommet Hardware Kit (Includes items 9 - 16) Warning Tag

Part No.

Qty

PB2200-6 PB2200-11 PB2200-16 PB2200- S 36800R

1 1 1 1 1

PBC2200-6 PBC2200-11 PBC2200-16 PBC2200- S 36998 36986 36868 36869 36866 36939

1 1 1 1 1 1 1 1 1 1

687K3W

() Equal to cable length (pushbutton drop). ( ) Not shown.

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Figure 20 - Limit Switch Assembly

1

3 5 5 4 6 13 6 4 15 7 12

14 9 10 2
Parts List for Limit Switch Assembly Ref Description Part No. No. 1 2 Transmission Cover Limit Switch Assembly (Includes items 4-12) 3 Limit Switch Bracket Assembly (Includes items 4-8) 4 5 6 7 Switch 6-32UNC X 1" Screw 6-32UNC Elastic Locknut Limit Switch Bracket (Includes Item 8) 815J1 H1402P H3944 JF900-3 2 4 4 1 918JG3 1 JM34 918JG4

11

8
Part No. JF531-4 JF117-3S SK6000-63Z SK6000-63W H5520 JF754 JF343-3 H2970 Qty 1 1 1 1 1 1 1 2

Qty 1 1

Ref No. 8 9 10 11 12 13 14 15

Description Bushing Limit Switch Shaft Limit Switch Nut (silver) Limit Switch Nut (gold) Retaining Ring Insulator Spring 10-24UNC X 1/2" Screw

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Figure 21 - Long Lift Limit Switch Parts

1 2 4 16 15 13 22 22 3 5 8 9 6 20 5 7 19 6 21 17 12 18 11 10 15

12 14 14
Parts List for Long Lift Limit Switch Parts Ref Description Part No. No. 1 2 Transmission Cover Limit Switch Assembly (Includes items 3-21) 3 4 5 6 7 8 9 10 11 12 Post 8-32UNC X 1/2" Screw #8 External-tooth Lockwasher 8-32UNC X 1/4" Screw Limit Switch Shaft & Gear Limit Switch Nut (gold) Limit Switch Nut (silver) Thrust Washer Spring Bushing 110J14 H1210 H4158 854823 117JG2 SK6000-63W SK6000-63Z 255K16 PB287 JF531-4 1 1 3 3 1 1 1 1 1 2 JM34 944JG6 Qty 1 1 Ref No. 13 14 15 16 17 18 19 20 21 22 Description Switch 6-32UNC X 1" Screw 6-32UNC Elastic Locknut Mounting Plate Frame and Guide Assembly End Plate 8-32UNC X 3/8" Screw Drive Pinion Retaining Ring 10-24UNC X 3/8" Screw Part No. 815J1 H1402P H3944 129J1 258JG7 258J8 H2741P 427J1 H5520 H2981P Qty 2 4 4 1 1 1 2 1 1 2

29

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Figure 22 - Transmission
13 11 14 *18 *16 9 5 6 *19 *20 *18 15 14 11

21 4 22 16 23 1 34 2 7 10 34 3 24 21 17 16

11

12

25 27 28 29 30 31 26 32 12 **33

(*) NOTE: This stage of gearing is not required on 32 FPM models. (**) NOTE: Orient output gear (32) with long boss towards gear housing (2) on 1/2 ton & under models and towards transmission cover (3) on 1 & 2 ton models.

24

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Parts List for Transmission Ref. Description No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Sheave Housing Transmission Gasket Transmission Cover (Includes Oil Seals) Spring Washer O-ring Pressure Relief Fitting Chain Guide Oil Plug - Drain Oil Plug - Fill Oil Plug - Level Oil Seal Screw, HWH Self-threading Motor Coupling Bearing Input Pinion 8 & 16 fpm 32 fpm Retaining Ring Brake Adapter Bearing for 8 & 16 fpm High Speed Pinion for 8 & 16 fpm Intermediate Pinion 1/4 & 1/2 ton, 16 fpm 1 & 2 ton Bearing Output Pinion Overload Clutch Assembly 1/8 ton, 32 fpm 1/4 ton, 16 fpm 1/4 ton, 32 fpm 1/2 ton, 16 fpm 1/2 ton, 32 fpm 1 & 2 ton Retaining Ring Bearing Bearing Spacer - Load Sheave Load Sheave-9/32" Chain Load Sheave Shaft Stub Shaft - Limit Switch Drive Oil Seal Retaining Ring Output Gear Dowel Pin Gear Oil

Part No. JM3533 JM560 JM34 360J1 H5605 SK1912-21W JM273 H6297 H6296 H6295 561K2 H2693P JM107 500K33 JL400B JL400-1 H5501 JL142 500K34 JL426 JL402A JL403A 500K39 JL401 591JG22 591JG25 591JG22 591JG16 591JG21 591JG17 H5503 500K28 P003255 JM127 JF16-3 JM132 JM140 011612800 H5598 JL421 H5382 H7642

Qty 1 1 1 1 1 1 1 1 1 1 3 5 1 2 1 1 3 1 2 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 1 pt

16 17 18 19 20

21 22 23

24 25 26 27 28 29 30 31 32 33 34 *

* Not Shown

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Figure 23 - Chaining Parts

2 3

10 4 5 9 6 11 15 14 7 13 8 7 18 19 20 12 16 17 15 14 13

24 22 26 25 24

1 Ton Under Models

21

28 29 23 30 31 32

2-Ton Models

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Parts List for Chaining Parts Ref Description No. 1 2 3 4 5 6 7 Housing Transmission Cover Electrical Cover Anchor Pin (2 ton only) Anchor (2 ton only) Chain Stripper Chain Stop Kit

Part No. JM3533 JM34 JM36 JM111 JM109 JM254 75JG6K

Qty 1 1 1 1 1 1 1

Ref No. 20

Description Bottom Hook Assembly with Latch for 1 Ton & Under

Part No.

Qty

3JG20S

21

Bottom Block Assembly for 2 Ton JF914-6 H3964P H2403P JF30-1 JF917-1 JF122-1 JF916 H5234 H3991P JF511 4X1305 1 2 2 2 1 1 1 2 1 1 1

22 23 24 25

3/8-24 Hex Locknut Load Block Screw Load Block Frame Sheave Shaft Assembly Sheave Shaft Sheave & Bearing Assembly Roll Pin 3/8-24 Hex Locknut Bearing Latch Kit Bottom Hook Assembly with Latch for 2 Ton

(Kits include halves, sleeve and retaining ring) 8 9 10 11 Load Chain Attachment Pin Retaining Clip 1/4-20UNC x 1" Socket Head Cap Screw 12 Bottom Block Assembly 1 ton & Under 13 1/4-20UNC x 1" Socket Head Cap Screw 14 1/4" Internal-tooth Lockwasher 15 16 17 18 19 Load Block Frame Load Block Pin Slotted Hex Nut Bearing Latch Kit H4134 30J14 18J8 H3986P JF510 4X1304 2 2 1 1 1 1 913JG3AS S49-77 1 2 S49-77 1 JL19-1 JM18-1 H5597 1 1

26 27 28 29 30 31 32

3KG1W

* Replacement chain is sold by the foot. For single-chained models, add 2 ft to the lift for the total amount of feet. For double-chained models, double the lift and add 3 ft.

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NOTES

34

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NOTES

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WARRANTY
Every hoist is thoroughly inspected and performance tested prior to shipment from the factory. If any properly installed, maintained and operated hoist as outlined in the applicable accompanying Yale Hoists manual develops a performance problem due to defective materials or workmanship as verified by Yale Hoists, repair or replacement of the hoist will be made to the original purchaser without charge and the hoist will be returned, transportation 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 IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Yale Hoists 414 Broadway Avenue P.O. Box 769 Muskegon, Michigan USA Tel: 866.805.2962 Fax: 800.742.9270 www.yalehoists.net

2004 Yale Hoists

Printed in USA