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Yale Series Y80 manual

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Table of contents for the manual

  • Page 1

    Page 1 May , 2003 Copyright 2003, Y ale • Lift-T e ch , division of Columb us McKinnon Corporation P art No. 117404-10 Printed in U.S.A. OPERA TION, SERVICE & P AR TS MANUAL SERIES Y80 Y ALE ® WIRE R OPE ELECTRIC HOISTS INCLUDING WEIGHT W A TCHER O VERLO AD CLUTCH MODELS RA TED LO ADS 1/2 THRU 5 T ONS Before installing hoist, fill in the inf[...]

  • Page 2

    Page 2 INDEX SECTION I GENERAL DESCRIPTION P age P aragraph 1-1 General . ................................................................................................................................................................ 3 P aragraph 1-2 Basic Constr uction ..............................................................................[...]

  • Page 3

    Page 3 This brak e requires periodic adjustment. SECTION II — INST ALLA TION 2-1. GENERAL. Y ALE electric hoists are lubr icated and tested bef ore being shipped from the f actor y . T o place hoist in ser vice, attach to a suitable suspension (par agraph 2-2), connect to electrical ser vice (paragraph 2-3) and perf orm pre-operation tests and ch[...]

  • Page 4

    Page 4 F or trolleys which are to be mounted along the span of a beam not having open ends, measure e xact width of beam flange and assemble trolle y to hoist so that spacing between wheel flanges is 1/4" (see Figure 2-1) greater than beam width (3/8" if beam has cur ves). This is accomplished by rearranging the spacer w ashers on the bol[...]

  • Page 5

    Page 5 (2) T emporarily connect hoist to power source . (3) Operate á b utton briefly to deter mine direction of hook tra vel. (4) If hook raises, phase is correct. T ur n power off and make tempora r y connections per manent. (5) If hook lowers , hoist is “Re v erse Phased”. TURN POWER OFF and correct b y interchanging an y two leads at po w [...]

  • Page 6

    Page 6 Saf e operation of an o verhead hoist is the oper ator’ s responsibility . Listed below are some basic rules that can make an oper ator aw are of dangerous practices to avoid and precautions to take f or his own safety and the saf ety of others . Observance of these rules in addition to frequent examinations and periodic inspection of the [...]

  • Page 7

    Page 7 ak. DO NOT adjust or repair a hoist unless qualified to perform hoist maintenance. al. DO NOT attempt to lengthen the wire r ope or repair damaged wire r ope . am . DO NO T allow per sonnel not physicall y fit or properl y qualified to operate hoist. an. DO NO T operate hoist unless limit switch is operating properl y . ao. DO be sure there [...]

  • Page 8

    Page 8 repor ts. Inspections are recommended each month and should be performed thoroughly enough to info r m the hoist user of deficiencies f or any item listed. This f or m does not supersede the Inspection and Maintenance Schedule listed below but ma y be used to record scheduled inspection and maintenance ser vices required. The user should re [...]

  • Page 9

    Page 9 5-2. INSPECT LO WER BLOCK. a. Chec k lubr ication of all par ts. If the thr ust bear ing 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 b lock body . b . Check each shea v e to ensure rope groov e is smooth and free from burrs , or other surface def e[...]

  • Page 10

    Page 10 * See te xt for D AIL Y & WEEKL Y REQUIREMENTS. SIGNED & D A TED REPORT REQ UIRED – OSHA. INSPECTION INTER V AL. X MAGNETIC P ARTICLE OR EQ UIV ALENT EXAMINA TION REQUIRED . INSPECTION SCHEDULE AND MAINTENANCE REPOR T HOIST SERIAL NO . (MFGRS) _______________________ CUSTOMER CRANE IDENTITY NO . _______________________ RA TED LO A[...]

  • Page 11

    Page 11 Figure 5-3. Vie w of Gearcase – Cover Remo v ed. b . T o inspect gear ing, pull out intermediate gear and pinion assembly and roller thrust bearings (Figure 5-4), and load brak e assemb ly (Figure 5-5). Do not remov e drum gear unless visual inspection indicates replacement is necessar y . c. Inspect gears and pinions for signs of tooth w[...]

  • Page 12

    Page 12 Figure 5-4. Removing Intermediate Gear and Pinion Assembly . Figure 5-5. Remo ved Load Br ake Assemb ly . d. T o disassemble drum gear , remov e e xternal snap r ing from splined shaft, using heavy-duty snap ring pliers, and pull off gear . e. T o disassemble intermediate gear and pinion, press pinion shaft from gear using an arbor press. f[...]

  • Page 13

    Page 13 (4) The brak e 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 br ake 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 por tab le vise to keep br ake from r[...]

  • Page 14

    Page 14 Bef ore removing the old rope, ref er to ree ving diagr ams, (Figures 5-12, 5-14, 5-15 and 5-17). F ace the rope drum on y our hoist from the side which the rope comes off dr um. T o assist with reree ving your hoist, select the ree ving diagram f or your hoist. Note the description (such as 2 par t double ree ved, Figure 5-17) and ref er t[...]

  • Page 15

    Page 15 With ne w rope installed on the drum as described in paragraph 5-9c single reev ed above , proceed with reree ving follo wing steps below: (1) P ass 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 . Rei[...]

  • Page 16

    Page 16 Figure 5-13. Upper Sheave Installed. (T ypical 3 and 5 T on) (3) P ass free end of rope thru bottom opening of hoist between floating limit rod and motor , and inser t rope in anchor fitting at hoist frame . Be cer tain power is off bef ore attempting to place rope in anchor fitting. With end fitting properly seated in anchor , replace bolt[...]

  • Page 17

    Page 17 Figure 5-16. Upper Sheave Installed (T ypical). (3) Place sheav e with rope into upper shea ve poc ket and slide pin par tially thr u shea ve . Install remaining washer and push pin thru side plates. Install snap r ing on each end of pin to secure pin in place. Figure 5-17. Hoist Ree ving — T wo P ar t Doub le. (4) Inser t lower sheav e p[...]

  • Page 18

    Page 18 (1) Using a kno wn load, equal to the hoist rated load, energiz e hoist to lift the load. Raise this load just high enough to be cer tain 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 parag raph 7-5. — “O VERLO AD C[...]

  • Page 19

    Page 19 SECTION Vl - TR OUBLE SHOO TING T rouble Probab le Cause Remedy a. Check s witches, circuit break ers or fuses and connections in power supply lines . Check pow er collectors. b . Chec k voltage required on motor data plate against power supply . c. Shut off power supply , remov e electrical cover on hoist and check wiring connections. Also[...]

  • Page 20

    Page 20 SECTION Vl - TROUBLE SHOO TING (Continued) T rouble Probab le Cause Remedy 6-5. Hoist Will Not Lift Rated Load. 6-6. Hoist Motor Overheats . 6-7. Load Drifts Excessively When Hoist Is Stopped. 6-8. Hoist Operates Intermittently a . See that power supply current is same voltage Iisted on motor data plate. Check hoist motor connections. Check[...]

  • Page 21

    Page 21 SECTION Vll — ADJUSTMENTS 7-1. MECHANICAL LO AD BRAKE. The mechanical load brak e on Series 800 Y ALE hoists is a pa wl and ratchet “Weston” type automatic brak e. The brake is not adjustab le and requires only periodic inspection and occasional replacement of the friction washers. 7-2. MO T OR BRAKE. Instructions for adjusting the br[...]

  • Page 22

    Page 22 9-2. INDEX OF EXPLODED VIEW P AR TS ILLUSTRA TIONS Figure No. Title P age No. 9-1 Frame , Gearcase and External Part s ........................................................................................................... 23 9-2 Gear ing and Load Br ake P ar ts ...........................................................................[...]

  • Page 23

    Page 23 Ref. P art Qty . No. Number Description Req’ d 1 800-197 Plug — Oil Lev el 2 2 800-192 Cov er & Bearing Assemb ly — Gearcase 1 3 800-105 Dowel 2 4† 800-106 Gask et — Gearcase 1 5 800-107 Gearcase & Bear ing Assembl y 1 6 Drum & Hub Assembly (Doub le Ree ved Models) 1 1/2 & 1 T on (3/6" Dia. Rope) 800-109 18&ap[...]

  • Page 24

    Page 24 Figure 9-1. F rame, Gearcase & External Parts. (Cont’ d.) Ref. P ar t Qty . No. Number Description Req’ d . 8 800-116 Screw — He x, Sock et Button Head — Self-Loc king 4 9 F rame Assemb ly (Single Reev ed Models) 1 1/2, 1 & 2 T on 800-117 Shor t F rame 800-118 Long F rame 3 T on 800-2106 First Extension 800-2107 Second Exten[...]

  • Page 25

    Page 25 NO TES Figure 9-1. F rame, Gearcase & External Parts. (Cont’ d.) Ref. P a rt Qty . No. Number Description Req’ d. 49 800-166 Loc kwasher 2 50 800-167 Screw — He x Head Cap 2 51 800-168 K e y Pla te 1 52 800-169 Shaft — Shea v e ( Double Ree v ed Models) 1 53 800-170 Br ack et, Sheave (Doub le Ree ved Models) 1 54† 800-171 Bear[...]

  • Page 26

    Page 26 Figure 9-2. Gear ing and Load Br ake P ar ts . Ref. P ar t Qty . No. Number Description Req’ d. 1† 800-201 Bearing Assembly — Needle , Intermediate & Dr um Gear Shaft 2 2† 800-202 R ace — Thr ust Bearing 4 3† 800-203 Bearing Assembly — Needle Thrust 2 4 Gear — Intermediate 1 800-204 104 T eeth 800-205 109 T eeth 800-266 [...]

  • Page 27

    Page 27 Figure 9-2. Gearing and Load Brake P ar ts. (Cont’ d.) Ref. P a rt Qty . No. Number Description Req’ d. 15 800-219 Ring — Retaining, Drum Shaft Bearing 1 17 800-221 Ring — Retaining 1 18† 800-222 Bearing Assembly — Roller , Inter mediate Shaft 1 19 800-269 Co v er — Oil Hole 1 20 800-224 Pi pe Pl ug — H e x So c ket 1 21† [...]

  • Page 28

    Page 28 Figure 9-3. Hoist Motor Brake - Later V ersion. Ref. P ar t Qty . No. Number Description Req’ d. 800-2401 Mot or Brak e Assemb ly (Includes Ref. Nos. 1 thru 31) 1 1 * Acor n Nut - Plated (#10-32) 2 2 800-2402 Brak e Cov er Assembly (Includes Brak e Cov er and Label Inside Cov er) 1 3 * Cov er Stud 2 4 * Gasket 1 5 * Phillips P an Head Sel[...]

  • Page 29

    Page 29 NO TES Figure 9-3. Hoist Motor Bra ke . (Cont’ d.) Kit Description P art Number Reference Numbers Included Brak e Disc 800-2405† 23, 24, 26 Brak e Le v er 800-2406 6, 15, 17, 18, 19, 20, 21 (Red Color), 22, Adjusting Screw Label, Br ake Adjust Label — Discard Zinc Colored Spring Rectifier 800-2407 12, 13, 4 Wire Nuts Hardware 800-2408[...]

  • Page 30

    Page 30 Figure 9-4. Hoist Motor Bra ke - Early V ersion. Ref. P a rt Qty . No. Number Description Req’ d . Motor Brak e Assembly (Includes Ref . Nos. 1 thru 32) 1 800-1400 Shor t F rame Models Only 800-1401 O ther Models 1 * Acor n Nut (#10-32) 2 2 800-1402 Brak e Cov er Assembly (Includes Brak e Cov er and Label Inside Cov er) 1 3 * Cov er Stud [...]

  • Page 31

    Page 31 NO TES Figure 9-4. Hoist Motor Brake . (Cont’d.) Kit Description P ar t Number Reference Numbers Included Brak e Disc 800-1406 24, 25, 27 Solenoid 800-1407 5, 6, 8, 11, 17 Brak e Le v er 800-1408 18, 20, 21, 22, 23 Brak e Hub 800-1409 28, 29, Hub Drive K ey (Sho wn Else where) Spec ial Ha rdw are 800-1410 3, 4, 9, 26, Instr uction Label i[...]

  • Page 32

    Page 32 Figure 9-5. Three Phase Motor Assembly . Ref. P ar t Qty . No. Number Description Req’ d. Motor Assembly (Includes Ref . Nos. 1 thru 8) 1 1 Horsepow er (1 Speed) 800-1301 200 V olt 800-1302 230/460 V olt 800-1303 575 V olt 2 Horsepow er (1 Speed) 800-1304 200 V olt 800-1305 230/460 V olt 800-1306 575 V olt 4 Horsepow er (1 Speed) 800-1307[...]

  • Page 33

    Page 33 Figure 9-6. Upper Limit Switch Parts. Ref. P ar t Qty . No. Number Description Req’ d. 1 800-501 Pin — Pivot 2 2 Arm — Lev er 1 800-502 Shor t F rame 800-503 Long F rame 800-526 First Extension 800-527 Second Extension 3 Le v er — Floating 1 800-504 Shor t F rame 800-505 Long F rame 800-528 First Extension 800-529 Second Extension 4[...]

  • Page 34

    Page 34 Figure 9-7. Electr ical Control Equipment. Ref. P a rt Qty . No. Number Description Req’ d . 3 800-670 Cord Grip — Conductor 2 5 800-654 Scre w — Self-T apping 4 6† 800-655 Contactor — T wo Speed 1 7† 800-656 Contactor 1 8 800-657 Scre w — Self-T apping 2 9† 800-671 T ransformer 1 10 800-663 Screw — Self-T apping 4 11† 8[...]

  • Page 35

    Page 35 Figure 9-8. Push Button Station and Conductor Cab le Assembly . Single Speed Hoists. Ref. P a rt Qty . No. Number Description Req’ d. 800-2701 Push Button Station and Conductor Cable Assemb ly (Includes Ref. Nos. 1 thru 17) 1 800-2702 Push Button Station (Includes Ref . Nos. 1 thru 15) 1 1 * T ype 1 P an Head Machine Scre w (M 3.5 x 0.6 x[...]

  • Page 36

    Page 36 Ref. P ar t Qty . No. Number Description Req’ d . 800-1821 Push Button Station and Conductor Cable Assemb ly (Includes Ref . Nos. 1 thru 30) 1 1 800-1822 Grommet 1 7 800-1823 Conductor Cab le As Req’ d 11 800-1812 Operator W ar ning Label 1 800-1813 Push Button Station (Includes Ref . Nos. 12 thru 30) 1 12 800-1814 Slee ve — Conductor[...]

  • Page 37

    Page 37 Figure 9-9. Push Button Station and Conductor Cab le Assembly . (Cont’ d.) Ref. P a rt Qty . No. Number Description Req’ d. 20 * Clamp — Conductor 1 21 * Contact Bloc k Assemb ly 1 800-1815 Contact Block (ZB2-BE101) 2 800-1816 Contact Block (ZB2-BE201) 2 22 * Interlock—Mechanical 1 800-1817 Up Push Button Assembly (Includes 1 Each o[...]

  • Page 38

    Page 38 Figure 9-10. Push Button Station and Conductor Cable Assembly . T wo Speed Hoists Only - Early V ersion. Ref. P a rt Qty . No. Number Description Req’ d. 800-1801 Push Button Station and Conductor Cable Assemb ly (Includes Ref . Nos. 1 thru 30) 1 1 800-1802 Anchor Brac ket — Strain Cable 1 2 800-1803 Grip Assembly — Conductor 1 3 800-[...]

  • Page 39

    Page 39 Figure 9-10. Push Button Station and Conductor Cable Assembly . (Cont’ d.) Ref. P a rt Qty . No. Number Description Req’ d. 13 * Suppor t — Strain Cab le 1 14 * Screw — Slotted Head 4 15 * Loc kwasher 4 16 * Enclosure — Rear 1 17 * Gask et 1 18 * Screw — Slotted Head 2 19 * Screw — Slotted Head 2 20 * Clamp — Conductor 1 21 [...]

  • Page 40

    Page 40 Figure 9-11. Lower Bloc k Assembly — T wo P ar ts Rope , Single Reev ed. Ref. P ar t Qty . No. Number Description Req’ d. 800-801 Block Assemb ly — Lower , Complete , 2 T on 1 800-802 Block Assemb ly — Lower , Complete , 1 T on 1 800-803 Block Assemb ly — Lower , Complete, 1/2 T on 1 1 800-804 Screw — Flat Head, Self-Threading 2[...]

  • Page 41

    Page 41 Figure 9-12. Lower Block Assemb ly—T wo P ar ts Doub le Ree ved. Ref. P ar t Qty . No. Number Description Req’ d . 800-851 Bloc k Assembly — Lo wer , Complete , 2 T on 1 800-852 Bloc k Assembly — Lo wer , Complete , 1 T on 1 800-853 Bloc k Assembly — Lo wer , Complete, 1/2 T on 1 1 800-804 Screw — Flat Heads Self-Threading 4 2 8[...]

  • Page 42

    Page 42 Quantity Required Ref. P ar t Reeving No. Number Description 3-T on/4 PS 5-T on/6 PS 800-1501 Bloc k Assembly — Lo wer , 4 P ar t Single (Complete) 1 — 800-1502 Bloc k Assembly — Lo wer , 6 P ar t Single (Complete) — 1 1 800-1503 Scre w — Hex Head Cap 2 2 2 800-1504 Loc kwasher 2 2 3 800-1505 K e y Pl ate 1 1 4 800-1506 Fi tting ?[...]

  • Page 43

    Page 43 Figure 9-14. Screw-T ype Limit Switch P ar ts. Ref. P a rt Qty . No. Number Description Req’ d. 1 800-1655 Lim it Switch Assembly (Includes Ref . Nos. 2, 3 and 4) 1 2 800-1651 Cap Screw — He x Soc ket Head 3 3 800-1652 Sealing Washer 3 4 800-1657 Dr um Shaft Inser t 1 F or switch element replacement order 800-1654. NO TES 12757A[...]

  • Page 44

    A. Seller warrants that its products and parts, when shipped, and its work (including installation, construction and start-up), when performed, will meet applicable specifications, will be of good quality and will be free from defects in material and workmanship. All claims for defective products or parts under this warranty must be made in writing[...]