Yale Electric Hoist Operating & Maintenance Instructions with Parts List

OPERATING &
MAINTENANCE
INSTRUCTIONS
WITH PARTS LIST
Publication Part No. 117404-18
Published May 2003
KELB
Electric
Hoists
For Capacities:
¼, ½, 1, 2, & 3 Ton
IMPORTANT - CAUTION
To safeguard against the possibility of personal injury or property damage, follow the recommendations and instructions
of this manual. This manual contains important information for the correct installation, operation and maintenance of this
equipment. All persons involved in the installation, operation and maintenance of this equipment should be thoroughly
familiar with the contents of this manual. Keep this manual for reference and further use.
WARNING
To prevent personal injury, do not use the equipment shown in this manual to lift, support or otherwise transport people,
or to suspend unattended loads over people.
FOREWORD
This book contains important information to help you install, operate,
maintain and service your new Electric Hoist. We recommend that you
study its content thoroughly before putting your hoist into use. Then,
thru proper installation, application of correct operating procedures,
and by practicing the recommended maintenance suggestions you will
be assured maximum lifting service from the hoist.
The “Accident Prevention Manual for Industrial Operations’ (8th Edition)
by the National Safety Council states:
Complete inspection, maintenance and overhaul service is available
for Yale Electric Hoists at Authorized Repair Stations. All are staffed
by qualified factory-trained service men; have authorized testing
equipment; and stock a complete inventory of factory approved Yale
replacement parts.
From safety standpoint, one factor is paramount: conduct all lifting
operations in such a manner that if there were an equipment failure,
no personnel would be injured. This means keep out from under raised
loads!”
Complete replacement parts information is given in Section IX. It will
likely be a long time before parts information is needed, therefore,
after you completely familiarized yourself with operation and preventive
maintenance procedures, we suggest that this instruction and parts
manual be carefully filed for future reference.
Notice: Use only factory approved Yale replacement parts, available
from Authorized Repair Stations or Yale Hoist Distributors.
“Employees who work near cranes or assist in hooking on or arranging
loads should be instructed to keep out from under loads. Supervisors
should watch closely to see that this rule is strictly followed.
THE INFORMATION CONTAINED IN THIS MANUAL IS FOR
INFORMATIONAL PURPOSES ONLY AND YALE HOISTS DOES NOT
WARRANT OR OTHERWISE GUARANTEE (IMPLIEDLY OR
EXPRESSLY) ANYTHING OTHER THAN THE COMPONENTS THAT
YALE MANUFACTURES AND ASSUMES NO LEGAL
RESPONSIBILITY (INCLUDING, BUT NOT LIMITED TO
CONSEQUENTIAL DAMAGES) FOR INFORMATION CONTAINED IN
THIS MANUAL.
INDEX
SECTION I
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
GENERAL DESCRIPTION ........................................................................................................................................................ Page
1 -1 General ..................................................................................................................................................................................... 3
1 -2 Hoist Service Classification ..................................................................................................................................................... 3
1-3 Basic Construction .................................................................................................................................................................... 3
1 -4 Differences Between Models and Sizes ................................................................................................................................. 4
1-5 Overload Clutch ......................................................................................................................................................................... 4
SECTION II
Paragraph
Paragraph
Paragraph
Paragraph
INSTALLATION
2-1 General .......................................................................................................................................................................................
2-2 Installation ..................................................................................................................................................................................
2-3 Pre-Installation Checks .............................................................................................................................................................
2-4 Connecting Hoist to Electrical Service ....................................................................................................................................
4
4
5
5
SECTION III
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
OPERATION
3-1 General .......................................................................................................................................................................................
3-2 Operating Hoist ..........................................................................................................................................................................
3-3 Pulling and Pivoting Hoist and Load ........................................................................................................................................
3-4 Upper and Lower Limit Stops ...................................................................................................................................................
3-5 Overload Clutch Operations .....................................................................................................................................................
3-6 Operating Precautions ...............................................................................................................................................................
6
6
6
6
7
7
SECTION IV
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
LUBRICATION
4-1 General .......................................................................................................................................................................................
4-2 Change Gear Case Oil ..............................................................................................................................................................
4-3 Lubricate Load Chain ................................................................................................................................................................
4-4 Lubricate Upper Hook and Lower Block Assembly .................................................................................................................
4-5 Lubricate Limit Lever Control Shaft and Gears .......................................................................................................................
8
8
8
8
9
SECTION V
Paragraph
Paragraph
Paragraph
Paragraph
MAINTENANCE
5-1 General ....................................................................................................................................................................................... 9
5-2 Thirty-Day Inspection ................................................................................................................................................................ 9
5-3 Six-Month Inspection ............................................................................................................................................................... 12
5-4 Inspection 5000 Hour or Five Year ......................................................................................................................................... 12
SECTION VI
TROUBLE SHOOTING CHART ............................................................................................................................................... 13-14
SECTION VII
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
DISASSEMBLY AND REASSEMBLY
7-1 General ..................................................................................................................................................................................... 14
7-2 Disassembly of Hoist Into Subassemblies ............................................................................................................................ 15
7-3 Rebuild of Hoist Frame, Sprocket Gear, Sprocket Shaft and Chain Guide ......................................................................... 17
7-4 Rebuild of Load Brake and Overload Clutch Assembly ........................................................................................................ 20
7-5 Rebuild of Lower Block and Load Chain Assembly .............................................................................................................. 22
7-6 Rebuild of Electrical Controls and Gear Case Cover Subassembly .................................................................................... 23
7-7 Rebuild of Push Button Station and Conductor Cable Assembly ........................................................................................ 23
7-8 Rebuild of Contactor Assembly (Push Button Models) ......................................................................................................... 24
7-9 Rebuild of Single Phase Motor Assembly ............................................................................................................................. 24
7-10 Rebuild of Three Phase Motor Assembly ............................................................................................................................ 24
7-11 Reassembly of Hoist From Subassemblies ......................................................................................................................... 24
7-12 Testing Hoist .......................................................................................................................................................................... 26
7-13 Test Procedure For Checking Operation of Overload Clutch ............................................................................................. 26
SECTION IX
REPLACEMENT PARTS ........................................................................................................................................................... 27-66
Notice: Information contained in this book is subject to change without notice.
12773A
Figure 1-1. Cutaway View Of Typical Yale Electric Hoist
SECTION I - GENERAL DESCRIPTION
1-1. GENERAL. Yale Portable Electric Hoists are precision built
chain type hoists ranging in six rated load sizes from 1/4 ton
thru 3 tons with various lifting speeds and electrical power
supplies. In addition to the capacities, there are model variations
with roller or link type load chains, hook or lug type suspension,
and single or two speed. In addition to standard models, there
are four rated load sizes of Yale Electric Hoists ranging from 1/
4 ton thru 2 tons suitable for plating hoist service with various
lifting speeds and electrical power.
1-2. HOIST SERVICE CLASSIFICATION
a. Yale electric hoists at the time of manufacture comply with
our interpretation of applicable sections of ANSI B30.16
“Overhead Hoists”, National Electric Code ANSI/ NFPA 70 and
Occupational Safety and Health Act, 1992.
b. OSHA places the burden of compliance for hoist installations
on the user. The user must install the equipment in accordance
with the National Electric Code ANSI/NFPA 70 as well as other
federal, state and local regulations which apply to the installation
and application in your particular area.
WARNING
This equipment is not designed or suitable as a power
source for lifting or lowering persons.
c. These hoists meet ANSI/ASME HST-1M “Performance
Standard for Electric Chain Hoists” hoist duty class ratings as
outlined in the sales bulletin.
1-3. BASIC CONSTRUCTION. All sizes and models of these
Yale Electric Hoists are of the same basic designs, having
many common and interchangeable parts. They consist primarily
of an aluminum alloy frame and gear case cover which houses
an automatic load brake and gear train. An electric driving
motor and external motor brake are mounted on the rear of the
frame, Electrical control components are mounted on front of
the gear case cover and encased by aluminum alloy end cover.
An upper hook or lug bracket for suspending the hoist is
attached to the top of the frame. Either a special nickel steel
roller load chain or high strength low alloy coil load chain with
lower block assembly is employed to raise and lower loads. A
block and chain operated limit stop lever is mounted on the
Page 3
bottom of the hoist frame and is connected, by linkage, to a
limit switch. Hoist operation is controlled by a pendant push
button station.
1-4. DIFFERENCES BETWEEN MODEL AND SIZES. The main
differences between hoist models are in the ser vice
classification, type of load chain and the suspension employed.
These are described in paragraphs (a) thru (d), below. The
differences between sizes of hoists are in the number of gear
reductions used and the reeving of the load chain. Two-reduction
gearing is used for 1/4 thru 1/2 ton rated load hoists; threereduction gearing for 1, 2 and 3 ton rated hoists. On 1/4 thru 1
ton rated load hoists, the load chain is single reeved (one part
of chain); on 2 ton rated loads, the chain is double reeved (two
parts of chain); on three ton rated loads, the chain is triple
reeved (three parts of chain).
a. Two different types of load chains are used as the lifting
medium, roller chain and link chain. The roller type chain is a
special precision manufactured nickel steel chain. Link type
chain is full-flexing electric welded link chain. Both are especially
designed for use in Yale Electric Hoists and only factory
approved chain of the correct size, pitch, hardness, and strength
can be used with these hoists.
b. Suspension differences include a conventional hook type
mounting and a lug type mounting. Hook suspension allows
portability permitting hoist to be easily moved from job to job.
Lug suspension permits hoist to be rigidly mounted to overhead
structure or attached to Yale Rigid Mount Trolleys, affording
unusual headroom advantage.
c. Some hoists are adaptations of standard model hoists to
permit use in some mildly corrosive atmospheres, high ambient
temperatures and high duty cycle operation. They are available
only in link chain models in either hook or lug suspension.
Construction variations from standard models are as follows:
(1) Load chain is zinc plated for corrosion resistance.
(2) All exposed aluminum parts are prime painted with
corrosion resistant paint.
(3) Aluminum castings are specially treated.
1-5. OVERLOAD CLUTCH. Yale Electric Hoists are equipped
with an overload clutch that is designed to help guard against
excessive overloads. The clutch is built into the load brake
gear. It is a cone-friction clutch that connects the first reduction
gear (load brake gear) to the load brake output pinion shaft. A
belleville disc spring provides clutch pressure between the gear
and its cone shaped gear center. An excessive overload causes
the load brake gear to rotate without turning the gear center
and output pinion shaft. The clutch is located between the load
brake and the motor, thus allowing both load brake and motor
brake to function in their normal manner. See paragraph 3-5
for operation.
WARNING
THE OVERLOAD CLUTCH IS A PROTECTIVE DEVICE
THAT WILL PERMIT OPERATION OF YOUR HOIST
WITHIN ITS RATED LOAD AND WILL PREVENT LIFTING
OF EXCESSIVE OVERLOADS WHICH CAN CAUSE
PERMANENT DEFORMATION OR WEAKENING OF A
PROPERLY MAINTAINED HOIST AND/OR ITS
SUSPENSION.
Page 4
SECTION II - INSTALLATION
2-1. GENERAL. Yale Electric Hoists are completely lubricated
and load tested under their own power before being shipped
from the factory. To place hoist in service, attach to suitable
overhead suspension (par. 2-2) in area to be used; make preinstallation check (par. 2-3); and connect to the proper power
supply.
2-2. INSTALLATION.
CAUTION
Lubricate load chain before operating hoist. See paragraph
4.3
a. On hook suspended hoists, select a suitable overhead
support in area hoist is to be used (one capable of holding
weight of hoist and its rated load) and hang up hoist. Be certain
upper hook is firmly seated in center of hook saddle. Upper
hook is equipped with a spring type hook latch; it may be
necessary to remove latch to attach hook to support. Replace
latch after hoist is installed.
b. On lug suspended hoists, select a suitable overhead support
in area hoist is to be used (one capable of holding weight of
hoist and its rated load). Mount hoist using thru bolts, of
appropriate size, to fit mounting holes in suspension lug at top
of hoist frame. (See table below.) The structure used to suspend
hoist must be of sufficient strength to withstand reasonable
forces to which hoist and support may be subjected. Hoist
must be aligned with load to avoid side pulls.
c. On lug suspended hoists, the suspension lug is installed for
cross mounting, the recommended condition. To rotate hoist
90° for parallel mounting (a special condition), follow instructions
below:
(1) On 1/4 thru 1 ton hoists remove suspension lug per
instructions in Section VII, paragraph 7-3. c. (1) and figure 720.
Lift lug from hoist frame, rotate to desired position and replace
on locating pins. Insert suspension bolt and nut. Turn nut on
top of lug while holding nut inside of hoist frame with drift until
grooved pin holes are aligned. On later model hoists, loosen
set screw, rotate hoists in 90° increments and tighten set screw.
WARNING
Be certain to replace grooved pin thru nut and
suspension bolt.
(2) On 2 ton hoists, remove hex socket head screw in lower
lock plate. Remove lower lock plate. Rotate suspension lug to
selected position and replace lock plate and hex socket head
screw.
(3) On 3 ton hoists, the hanger bracket must first be removed
from the hoist to provide access to suspension nut per Section
VII, par. 7-2. a. (4) and figures 7-2 and 7-3. To remove lug bolt,
follow instructions in Section VII, par. 7-3. b. (3). With bolt
removed lift lug from hanger and reposition as desired. The lug
is located and prevented from turning by integral lugs on
adjacent surfaces of the lug and the hanger. Reinstall
suspension bolt, spherical washers and nut. Align hole in nut
and suspension bolt. Reassemble hanger bracket to hoist.
WARNING
Be certain to replace grooved pin thru nut and
suspension bolt.
d. On rigid mount trolley suspended hoists, the trolley side
plates must be properly spaced so trolley will fit I-beam on
which hoist will operate. Adjustment for various I-beam sizes is
accomplished by rearrangement of spacer washers on thru
bolts which connect trolley side plates to suspension lug on
hoist. Refer to instruction sheet furnished with Yale Rigid Mount
Trolleys for complete instructions.
Figure 2-1. Branch Circuit Conductor Size. Maximum length in
feet for maximum wire size based on Horsepower and power
supply. Wire size for entire length of branch circuit and
permanent wiring to main feeder. Power supply measured at
hoist, while running and with normal load, must not vary more
than ±5% of voltage on motor nameplate.
b. Follow local & National Electrical Codes when providing
electrical service to hoist. Connect power wires in accordance
with appropriate wiring diagram. Power supply must be the
same voltage, frequency and phase as specified on the hoist
nameplate.
WARNING
SUSPENSION LUG BOLT SIZES AND SPACING
Hoist
Rated Load
(tons)
Bolt Diameter
(in)
Distance
Between Holes
(in)
1/4, 1/2 &1
5/8
3-1/8
2
1
5
3
1-1/4
6
2-3. PRE-INSTALLATION CHECK.
Check Oil Level (Fig. 4-1). The gear case has been filled with
oil, to the proper level at the factory. However, the oil level
should be checked before hoist is operated. Remove and
discard felt shipping plug from oil filler on side of hoist frame.
Check oil level by removing oil level plug (side of frame).
Observe if oil level is even with bottom of tapped hole. If it is
not, add oil, as specified in paragraph 4-2. c. Also check load
chain. Be sure it is properly lubricated. See paragraph 4-3.
2-4. CONNECTING HOIST TO ELECTRICAL SERVICE.
a. All hoists are equipped with a flexible power cable extending
from the hoist. A grounding type male plug or permanent
connection in an outlet box may be used for connecting hoist
to power supply. See table (fig. 2-1) for branch circuit conductor
sizes.
AWG Wire Size
H.P.
1/4
Power Supply
1
2½
#14
#12
115-1-60
80
130
210
230-1-60
230
330
835
465
740 1180
200, 230-3-60
460, 575-3-60
1/2
#16
#10
#8
330
75
120
190
230-1-60
195
305
490
775 1235
200, 230-3-60
280
450
715 1135
310
460, 575-3-60
860 1440
115-1-60
*
45
75
120
190
230-1-60
120
190
300
475
720
200, 230-3-60
180
290
460
730
460, 575-3-60
560
900
150
250
60
100
420
WARNING
Serious damage to the hoist can occur with resulting
hazard to operator and load. Three phase hoists must
be properly phased each time they are installed or
moved to a new power source or when service is
performed on mainline (power source).
(1) Temporarily connect hoist to power source.
45
260
d. Dual voltage hoists with reconnected 115/230 volts, 1 phase,
60 hertz are (unless otherwise specified on customer’s order)
shipped from factory pre-connected for operation on 230 volts.
If hoists are to be operated on 115 volts convert wiring by
changing connections on ter minal board. With hoist
disconnected from power source, remove electrical
compartment cover and reconnect terminal board leads, Also
refer to Wiring Diagram.
e. To properly phase the hoist follow these steps:
115-1-60
460, 575-3-60
c. Dual voltage hoists with reconnected 230/460 volts, 3 phase,
60 hertz are (unless otherwise specified on customer’s order)
shipped from factory pre-connected for operation on 460 volts.
If hoist is to be operated on 230 volts convert wiring by changing
connections on terminal board. With hoist disconnected from
power source, remove electrical compartment cover and
reconnect terminal board leads. Also refer to Wiring Diagram.
#6
1440 2390
200, 230-3-60
The green wire provided in the power supply cable
is a grounding wire and must be connected to a
proper ground. (Follow local code requirements and/
or National Electrical Code Par. 250-57 or 250-59).
490
(2) Operate “” button briefly to determine direction of
travel.
(3) If hook raises, phase is correct and temporary
connections should be made permanent.
300
(4) IF HOOK LOWERS, HOIST IS “REVERSE PHASED”
AND MUST BE CORRECTED BY INTERCHANGING
ANY TWO LEADS AT POWER SOURCE
CONNECTION. DO NOT CHANGE INTERNAL
WIRING OF HOIST.
f. For connecting hoist to a motor driven trolley, refer to
instructions furnished in trolley manual.
*Do not use
Page 5
SECTION III - OPERATION
3-1. GENERAL. Operation of Yale Electric Hoists is controlled
by a push button station suspended from the hoist electrical
compartment. The station has a built-in mechanical interlock to
prevent depressing both buttons simultaneously.
3-2. OPERATING HOIST.
a. Depress push button marked “” to raise load. b. Depress
push button marked “” to lower loads.
c. Jogging the push buttons will give “hairline” load movement.
The quickness of the depressing motion will determine the
amount of movement. Excessive use of this “jogging” feature
will cause premature burning of contact points, motor
overheating, and rapid motor brake wear.
3-3. PULLING AND PIVOTING HOIST AND LOAD.
a. The push button station conductor cable has a built-in strain
cable suitable for pulling trolley suspended hoists when not
loaded. Do not use for pulling bridge cranes. Push on load or
load chain or use a hand geared or motor driven type trolley to
traverse loaded hoists.
b. To pivot hoist and load, push on one corner of load. The
lower hook will pivot thru 360 degrees to permit load to be
swung to the desired position. The upper hook (hook suspension
models) is also designed to rotate so that side pulls will swing
hoist to face load, thus reducing side thrust.
Figure 3-2. Limit Lever Being Tripped By Actuator on
Tail End of a Load Chain
NOTE: On lug type, link chain hoists, the limit lever may
be tripped by the load chain during side pulls. Load must
be lined up with hoist. If moderate side pulls cannot be
avoided, rotate hoist 90' so it is mounted with side of
hoist facing direction of side pull. See appropriate
instruction in Section II, paragraph 2-2. c.
3-5. OVERLOAD CLUTCH OPERATION. The overload clutch
is factory preset at assembly so that the hoist will lift its full
rated load but will refuse to lift overloads within a range of 110
percent rated load to 180 percent rated load. If the load to be
lifted exceeds the clutch factory setting, the motor will continue
to run and will rotate the load brake gear without lifting the
load. Whenever this occurs, immediately release the “” push
button to prevent overheating of the clutch friction surfaces
and motor, and reduce the load to rated hoist capacity. Should
it be impractical to reduce the load, replace the hoist with one
of suitable rated capacity.
NOTE: Always know load to be lifted. Yale does not recommend
lifting loads greater than the rated load of your hoist.
3-6. OPERATING PRECAUTIONS.
WARNING
11925A
Figure 3-1. Limit Lever Being Tripped By Actuator
Above Lower Block on Single Line Hoist
3-4. UPPER AND LOWER LIMIT STOPS. A lower block and
chain operated limit stop is provided to guard against overtravel
of load in either raising or lowering direction, which can cause
damage to hoist. When highest position is reached, limit actuator
on the load chain, above the lower block, trips the limit lever
(fig. 3-1). When lowest position is reached, a limit actuator on
the tail end of load chain trips the limit lever (fig. 3-2). The limit
lever is connected to a limit switch that automatically stops the
hoist motor. This is intended as a safety device and should not
be used on a routine basis to stop travel of lower block or shut
off hoist.
Page 6
Equipment covered herein is not designed or suitable
as a power source for lifting or lowering persons. Do
not use as an elevator.
Safe operation of an overhead hoist is the operator’s
responsibility. Listed below are some basic rules that can make
an operator aware of dangerous practices to avoid and
precautions to take for his own safety and the safety of others.
Observance of these rules in addition to frequent examinations
and periodic inspection of the equipment may save injury to
personnel and damage to equipment.
a. DO read ANSI B30.16 Safety Standard for Overhead
Hoists and the Operation, Service and Parts Manual
ac. DO NOT operate the hoist beyond limits of load chain
travel.
b. DO be familiar with hoist operating controls, procedures
and warnings.
ad. DO NOT use limit switches as routine operating stops
unless recommended. They are emergency devices only.
c. DO make sure hook travel is in the same direction as
shown on controls.
ae. DO NOT use hoist to lift, support or transport people.
d. DO make sure hoist limit switches function properly.
e. DO maintain firm footing when operating hoist.
f. DO make sure that load slings or other approved single
attachments are properly sized and seated in the hook
saddle.
g. DO make sure that the hook latch, if used, is closed and
not supporting any part of the load.
h. DO make sure that load is free to move and will clear all
obstructions.
i. DO take up slack carefully, check load balance, lift a few
inches and check load holding action before continuing.
j. DO avoid swinging of load or load hook.
k. DO make sure that all persons stay clear of the
suspended load.
af. DO NOT lift loads over people.
ag. DO NOT leave a suspended load unattended unless
specific precautions have been taken.
ah. DO NOT allow sharp contact between two hoists or
between hoist and obstructions.
ai. DO NOT allow the chain or hook to be used as a ground
for welding.
aj. DO NOT allow the chain or hook to be touched by a live
welding electrode.
ak. DO NOT remove or obscure the warnings on the hoist.
al. DO NOT adjust or repair a hoist unless qualified to
perform hoist maintenance.
am. DO NOT attempt to lengthen the load chain or repair
damaged load chain.
I. DO warn personnel of an approaching load.
an. DO NOT allow personnel not physically fit or properly
qualified to operate the hoist.
m. DO protect load chain from weld splatter or other
damaging contaminants.
ao. DO NOT operate hoist unless upper and lower limit
switch stops are operating properly.
n. DO promptly repor t any malfunction, unusual
performance, or damage of the hoist.
ap. DO always be sure there is not twist in link load chain.
On 2 & 3 ton link chain hoists, check to see that lower
block is not capsized between strands of chain.
o. DO inspect hoist regularly, replace damaged or worn
parts, and keep appropriate records of maintenance.
p. DO use the hoist manufacturer’s recommended parts
when repairing a hoist.
q. DO use hook latches wherever possible.
r. DO apply lubricant to load chain as recommendeds. DO
NOT lift more than rated load.
t. DO NOT use the hoist load limiting device to measure
the load.
u. DO NOT use damaged hoist or hoist that is not working
correctly.
v. DO NOT use the hoist with twisted, kinked, damaged or
worn chain.
w. DO NOT lift a load unless chain is properly seated in
chain wheel(s) or sprocket(s).
x. DO NOT use load chain as a sling or wrap chain around
the load.
y. DO NOT lift a load if any binding prevents equal loading
on all supporting chains.
z. DO NOT apply the load to the tip of the hook.
aa. DO NOT operate unless load is centered under hoist.
ab. DO NOT allow your attention to be diverted from
operating the hoist.
aq. DO avoid operating hoist when hook is not centered
under hoist. Be sure that hoist trolley or other support
mechanism is correctly positioned for handling the load
before lifting.
ar. DO operate hoist within recommended duty cycle and
do not “jog” unnecessarily.
as. DO conduct regular visual inspections for signs of
damage or wear.
at. DO NOT operate hoist with hooks that have opened up.
See Figures 5-5 and 5-6.
au. DO provide supporting structure or anchoring means
that has a load rating at least equal to that of the hoist.
av. DO NOT use hoists in locations that will not allow
operator movement to be free of the load.
aw. DO when starting to lift or pull, move the load a few
inches at which time the hoist should be checked for proper
load holding action. The operation shall be continued only
after the operator is assured that the hoist is operating
properly.
ax. DO NOT leave a loaded hoist unattended at the end of
a work shift or for extended periods during the work shift.
Where operations are such that this condition cannot be
avoided the operator must be assured that the condition
does not create a hazard to personnel or property.
Page 7
ay. DO use common sense and best judgement whenever
operating a hoist. Observe American National Standard
Safety standard, ANSI B30.16, latest issue.
SECTION IV - LUBRICATION
4-1. GENERAL. The lubrication services outlined in paragraphs
4-2 thru 4-5 should be performed at regular intervals to maintain
top hoist performance and insure long life. The frequency for
lubrication services will depend on the type of hoisting service
that hoist is subjected to and should coincide with periodic
preventive maintenance inspection. See Section V-Maintenance.
a. Link Chain. Under ordinary conditions only weekly attention
will be necessary. Under hot and dirty conditions it may be
necessary to clean chain at least once a day and lubricate it
several times between cleanings. Thoroughly clean chain with
an oil solvent and re-lubricate by coating it lightly with oil.
Make sure that lubricant coats wear surfaces between links.
Zinc plated load chain should be cleaned and lubricated daily.
4-2. CHANGE GEAR CASE OIL (Fig. 4-1).
b. Roller Chain. Under ordinary conditions only monthly attention
will be necessary. Under hot and dirty conditions weekly
attention may be required. Thoroughly clean chain with an oil
solvent and apply oil. Wipe off excess oil. When subjected to
excessive moisture or corrosive atmospheres, DO (dripless oil)
lubr icant from American Grease Stick Company is
recommended for use on roller chain in place of regular oil.
a. Remove drain plug from bottom of hoist frame and drain oil
from gear case. Replace plug.
4-4. LUBRICATE UPPER HOOK AND LOWER BLOCK
ASSEMBLY.
b. Remove oil level plug from side of hoist.
a. Apply a few drops of Bar and Chain Oil on shank of upper
hook where it enters frame.
c. Refill gearcase thru oil filler to proper level (bottom of oil
level plug hole) using Automatic Transmission Fluid - DEXRON
Type. This is an all-weather oil available from all major oil
companies. 1-1/2 pints of oil are required.
d. Reinstall oil level plug.
4-3. LUBRICATE LOAD CHAIN. A small amount of lubricant
will greatly increase load chain life, therefore, chain should not
be allowed to run without lubricant. Chain should be cleaned
and lubricated as directed in paragraphs a. and b. below,
depending upon type of chain. User should set up a regular
schedule for chain lubrication after observing operating
conditions for a few days. Use Bar and Chain Oil (LUBRIPLATE
or equal) on load chain.
b. Apply a few drops of Bar and Chain Oil on shank of lower
hook where it enters lower block. Hook rotation bearing may
be removed for cleaning and re-lubricating if necessary. See
paragraph 7-5.
c. On lower block assemblies of 2 thru 5 ton capacity hoists,
also apply heavy duty lithium soap grease with EP additives
thru pressure fitting in end of sprocket pin to lubricate bearing
in chain sprocket.
d. On 3 ton model lubricate sprocket in hanger bracket with a
few drops of Bar and Chain Oil in hole provided in center of
sprocket hub.
4-5. LUBRICATE LIMIT LEVER CONTROL SHAFT AND
GEARS.
Apply a few drops of Bar and Chain Oil on limit lever shaft at
bearing points.
WARNING
Before performing any internal work on hoist, be
certain power is shut off. Lock main service switch
in the open position.
SECTION V - MAINTENANCE
5-1. GENERAL. Preventive maintenance services required on
Yale Electric Hoists are for the most part, simple periodic
inspection procedures to determine condition of hoist
components. Below are suggested inspection procedures,
based on daily average hoist usage.
5-2. THIRTY-DAY INSPECTION. Hoist may be left suspended.
a. Inspect Load Chain.
10077L
Figure 4-1. Location of Oil Filter and Plugs
Page 8
(1) Operate hoist under load and observe operation of chain
over sprocket in both directions of chain travel. Chain should
feed smoothly into and away from the sprocket. If chain binds,
jumps or is noisy, first see that it is clean and properly lubricated.
If trouble persists, inspect chain as outlined below, depending
on type of chain.
WARNING
To avoid serious personal injury from a dropped load
caused by possible chain breakage, when replacing
link load chain, use only factory approved chain
conforming to Yale hoist specifications for material,
hardness, strength and link dimensions. Chain not
conforming to factory Specifications may be dangerous
as it will not fit in the load sprocket and chain guide
correctly, causing serious internal damage to hoist and
it will wear prematurely, deform and eventually break.
Figure 5-1. Check Chain Wear at Bearing
Surfaces Between Links
(3) Removing and Replacing Link Load Chain.
(2) Link Type Load Chain. Clean chain for inspection.
Examine visually for gouges, nicks, weld spatter, corrosion or
distorted links. Slacken chain and check bearing surfaces
between links for wear, fig. 5-1. Greatest wear will often occur
at sprocket at high or low point of lift, particularly when hoist is
subjected to repetitive lifting cycles. Case hardness of chain is
about. 015" deep. Chain must be replaced before the case is
worn thru. Also check chain for elongation using a vernier
caliper (fig. 5-2). Select an unworn, unstretched section of chain
(usually at slack or tail end) and measure and record the
length over the number of chain links (pitches) indicated in
figure 5-2. Measure and record the same length of a worn
section in the load side of the chain. Obtain the amount of
wear by subtracting the measurement of the unworn section
from the measurement of the worn section. If the result (amount
of wear) is greater than the amount specified in the
“ALLOWABLE CHAIN WEAR” table, the chain has elongated
beyond the maximum allowable length and must be replaced.
Chain with excessively pitted, corroded, nicked, gouged, twisted
or worn links should be replaced using only factory approved
chain. Never weld or attempt to repair link chain.
(a) Replacement link load chain is installed by attaching it
to tail end of old chain, after disconnecting old chain from side
of hoist frame and removing limit actuator. New chain is then
run into hoist as old chain is run out. Use open “C” links,
figures 5-3 and 5-4, for attaching chains. Links must be identical
in size to hoist chain - 1/4" wire size with .745" pitch length for
1/4 thru 1/2 ton models, 5/16" wire size with .858" pitch for 1
thru 3 ton models. Be certain that all welds on links of
replacement chain face away from center of load sprocket.
Figure 5-3. Open "C" Link for Removing and
Installing Link Load Chain
Figure 5-2. Check Coil Chain Using Verni er Caliper
ALLOWABLE CHAIN WEAR - ELONGATION
Hoist
Rated Load
(tons)
Chain Size
(wire dia.)
No. of
Pitches
to Measure
1/4 & 1/2
1/4"
13
.145"
1 thru 3
5/16"
11
.142"
Maximum
Wear Limit
CAUTION
Do not assume that load chain is safe because it measures
below replacement points given herein. Other factors, such
as those mentioned in visual checks above, may render
chain unsafe or ready for replacement long before
elongation replacement is necessary.
10307
Figure 5-4. Installing Coil Load Chain Using Two
"C" Links (1/4, 1/2 & 1 ton hoists)
Page 9
(b) Remove lower block assembly and actuator from old
chain and attach them to replacement chain at end which was
just run thru hoist. Install limit actuator (as noted below) on
other end of chain and anchor chain to side of hoist frame.
CAUTION
Two "C" links must be used on 1/4, 1/2 and 1 ton capacity
hoists (fig. 5-4) in order to correctly position end link on
tail end of chain to fit tail end anchor at side of hoist
frame; only one "C" link is required on 2 thru 3 ton capacity
hoists.
NOTE: Install limit actuator on the 8th link from the end
and secure with grooved pin.
On 2 ton double reeved models, also connect opposite end of
chain (from lower block) to load chain anchor inside of frame.
On 3 ton triple reeved models, the opposite end of the chain is
attached to the lower block connecting link.
NOTE: In the event the old chain is to be removed from
hoist and reinstalled, a short length of chain (about 18"
long) must be run into hoist when the old chain is removed.
This short length can then be used in the same manner
as shown in paragraph 5-2. a.(3). Be sure to use the
proper number of open “C” links in order to correctly
position end link on tail end of chain to fit anchor at side
of hoist frame.
CAUTION
To avoid serious internal damage to hoist, when installing
link load chain do not attempt to hand feed chain into hoist,
or use a piece of wire in place of the method described
herein. To do so may result in serious internal damage to
hoist, as link chain links must be properly seated in chain
sprocket before chain is run into hoist. Install chain only as
described in this manual.
CAUTION
Do not assume that load chain is safe because it measures
below replacement points given herein. Other factors, such
as those mentioned in visual checks, may render chain
unsafe or ready for replacement long before elongation
replacement is necessary. Do not attempt to splice the
chain to replace worn or damaged sections unless you
have the required equipment to properly spin rivet
heads. It is suggested that you have this done by an
authorized Yale Repair Station that is equipped with the
necessary special tools.
WARNING
When replacing roller type load chain, use only factory
approved chain conforming to factory specifications
for material, hardness, tensile strength, size and
construction. Yale Hoist Roller chain is specially
designed for hoisting service and is the only type roller
chain that can safely be used with Yale electric hoists.
Chain not conforming to Yale Roller Chain specifications
may be dangerous as it will not withstand heavy impact
loads and does not have adequate tensile strength.
(5) Check anchor end of chain at side of hoist frame for
damage to last link, also connecting link on roller chain hoists.
Replace damaged parts.
(6) Check connection of chain to lower block on 1/4 thru 1, 3,
and 5 ton hoists. Replace parts showing evidence of damage,
twisting or elongation.
(7) Check connection of chain to anchor inside hoist frame
on double-reeved, 2-ton hoists. Replace parts showing evidence
of damage, twisting or elongation. (Also see Sec. VII, par. 7-2.
a. (2)).
(8) Lubricate load chain before using hoist. See paragraph 43, Section IV.
b. Inspect Lower Block.
WARNING
Keep fingers clear of chain sprocket when replacing
link load chain.
(4) Roller Type Load Chain. Visually check for possible twists,
broken links, wear or elongation. Any links that do not flex
easily, even when lubricated, may be damaged and should be
replaced. Check roller chains for elongation from wear by pulling
chain taut and measuring as follows: On RC-625, 625 or H-5
size chain (5/8" pitch), measure distance over a length of 20
pitches (center-to-center distance, between 21 rivets) - it must
not exceed 12-3/4 inches. On RC-750, H-6 or HF size chain
(3/4" pitch) measure length of 16 pitches (center-to-center
distance between 17 rivets) - it must not exceed 12-1 /4 inches.
If chain exceeds the limit, replace damaged section or install
new load chain assembly. Check chain for twist. If twist in any
5 foot extension exceeds 15 degrees, replace chain. Check
chain for camber. If any section has side bow exceeding 1 /4
inch in five feet, replace chain.
Page 10
(1) Check for bent or distorted hook. If hook is opened beyond
the dimension given in figure 5-5, it must be replaced. Also
check to see that hook swivels and is free to pivot. Lubricate
these points if necessary.
Figure 5-5. Lower Hook Opening
(Shown with latch removed for clarity.)
Hook Throad Opening
Hoist
Rated Load
(tons)
Normal
Opening
1/4 & 1/2
1-1/8
1-1/4
1
1-1/4
1-7/16
2
1-3/8
1-9/16
3
1-1/2
1-11/16
Replace Hook if Opening
is Greater Than
(2) On 2 thru 3 ton hoists, check sprockets and bearings in
lower block for freedom of movement and signs of damage.
Lubricate if necessary. Replace damaged parts.
(3) Check hook latches. Replace damaged or bent latches or
broken springs.
c. Inspect Upper Suspension.
(1) On hook suspended models, check for bent or distorted
hook. If hook is opened beyond the dimension given in figure
5-6, it must be replaced. Also check to see that hook pivots.
Lubricate if necessary.
(2) On lug suspended models, check condition of suspension
lug. Replace lug if damaged or cracked. Check to see that lock
plate is in place on lug and screw holding it is tight.
(3) On 2-ton hoists, check to see that upper lock plate securing
hook or lug bushing is in place and screws holding it are tight.
Lubricate hook shank.
(4) Check hook latch. Replace damaged or broken parts.
d. Inspect Motor, Frame and Electrical Compartment Cover.
CAUTION
Hooks, upper or lower, damaged from chemicals,
deformation or cracks or having more than 15 percent in
excess of normal throat opening or more that 10 degrees
twist from the plane of the unbent hook, or opened, allowing
the hook latch to bypass hook tip must be replaced.
Any hook that is twisted or has excessive throat opening
indicates abuse or overloading of the hoist. Other load
bearing components of the hoist should be inspected for
damage. (See Section V. Par. 5-2. d. (2) below).
(1) Check to see that bolts securing motor to frame are tight.
Also check for any visible damage to motor, such as a cracked
end bell or dented stator housing. Replace damaged parts.
(2) Check hoist frame for signs of visible damage. If frame
shows evidence of fracture, the hoist should be disassembled
and inspected for further signs of damage from possible
overloading. Replace damaged parts. Also check condition of
limit lever.
(3) Check for possible damage to electrical compartment
cover. Be sure screws holding cover are tight.
e. Check Oil Level. Remove oil level plug (fig. 4-1). If oil level
is not even with bottom of tapped hole, add Automatic
Transmission Fluid, DEXRON Type, to bring to proper level.
5-3. SIX-MONTH INSPECTION OR 500-750 HOURS OF
OPERATION. Hoist may be left suspended.
a. Inspect Electrical Controls. Shut off power supply to hoist
and remove electrical compartment cover from hoist. Use
caution as some covers contain counterweights. Two speed
hoists with a 2-1 /4 horsepower motor have an externally
mounted counterweight at the electrical compartment cover.
(1) Check all wiring and terminals. Insulation should be sound
and terminals securely crimped to wires. Terminal screws should
be tight and plug-type terminals completely mated. Replace
terminals or wires as necessary.
(2) Check control circuit transformer for evidence of
overheating. Replace if necessary.
Hook Throad Opening
Hoist
Rated Load
(tons)
Normal
Opening
1/4 & 1/2
1-1/8
1-1/4
1
1-1/4
1-7/16
2
1-3/8
1-9/16
3
1-1/2
1-11/16
Replace Hook if Opening
is Greater Than
Figure 5-6. Upper Hook Opening
(Shown with latch removed for clarity.)
(3) Check control shaft centering spring by operating limit
lever. If limit lever does not return to neutral position after it is
tripped, the spring is probably broken or control shaft is bent.
Replace broken or damaged parts.
(4) Check limit switch to see that wires are securely soldered
and mounting screws are tight.
(5) Check contactor solenoid coils and replace coils if they
show evidence of overheating.
(6) Check control cable wire strain reliever to see that it is in
good condition and securely attached to gear case cover.
Replace rubber strain reliever grommets if damaged.
b. Change Gear Case Oil. See Section IV, paragraph 4-2.
c. Relubricate Load Chain. See Section IV, paragraph 4-3.
Page 11
d. Lubricate Upper Hook and Lower Block. See Section IV,
paragraph 4-4.
e. Lubricate Limit Lever Control Shaft. See Section IV,
paragraph 4-5.
5-4. INSPECTION: 5000 HOURS “ON” TIME OR 5 YEARS
ELAPSED TIME. Hoist must be removed from overhead
suspension.
a. Disassemble Hoist into Subassemblies. Follow procedure
outlined in Section VII, paragraph 7-2.
b. Motor shaft oil seal, sprocket shaft bearing and seal, guide
pin “0” rings and all gaskets should be replaced.
c. Inspect Load Brake and Overload Clutch. Disassemble
load brake and clutch assembly as outlined in paragraph 7-4.
Friction discs should be discarded and replaced with new discs.
Check load brake friction surfaces on flange, ratchet assembly
and gear clutch cone. Replace parts if badly scored or worn.
Check condition of pawl and ratchet assembly. If pawl, ratchet
teeth or pawl spring are broken, damaged or badly worn,
replace complete assembly. Check contact faces of load brake
cam and gear clutch cone. Brake gear and pinion teeth should
be inspected for wear or broken teeth. Clean parts thoroughly
with an oil solvent before reassembly.
NOTE: The overload clutch assembly should not be
disassembled as it is preset at the factory to provide
proper clutch pressure for a specific hoist capacity range.
If there is evidence of the clutch slipping or wear or
damage to the clutch components, the complete clutch
assembly should be replaced or sent to an authorized
Yale Hoist Repair Station to be rebuilt and properly
adjusted to factory specifications.
d. Inspect Sprocket and Intermediate Gears.
(1) On 1 thru 5 ton hoists, check condition of gear teeth on
intermediate gear and pinion shaft assembly. Replace worn or
damaged parts.
(2) Check condition of teeth or pockets on chain sprocket (all
capacities). Replace worn or damaged parts.
e. Inspect Motor Brake. For access to motor brake parts,
except for two speed, remove motor assembly as outlined in
paragraph 7-2. d. Then, remove brake par ts following
instructions given for the specific type brake, depending upon
model of hoist. Check braking surfaces for wear and scoring.
Replace badly worn or scored parts. Check to see that plate
support pins inside frame are tight. Check large compression
spring and spring plunger. Replace parts that are worn or
damaged.
For two speed hoist, remove brake housing screws, housing,
support plate screws, support plate assembly, friction disc and
stationary discs. Check braking surfaces for wear and scoring.
Replace badly worn or scored parts.
f. Reassemble and Test Hoist. Reassemble hoist from
subassemblies following procedure outlined in paragraph 7-11.
After assembly is complete, test hoist as outlined in paragraphs
7-12 and 7-13.
Page 12
SECTION Vl - TROUBLE SHOOTING
Trouble
6-1. Hoist Will Not Operate.
6-2. Hook Moves in Wrong Direction.
6-3. Hook Will Raise But Not Lower.
Probable Cause
Remedy
a. No power to hoist.
a. Check switches, circuit breakers and
connections in power supply lines. Check
power collectors.
b. Wrong voltage.
b. Check voltage required on motor data plate
against power supply.
c. No control voltage.
c. Check transformer fuse. If blown, check
for grounding and/or short in the pushbutton
station. Check the transformer coil for signs of
overheating. Replace transformer if burned
out. Verify the transformer secondary is the
same voltage as the coils to which it is
connected.
d. Loose or broken wire
connections in hoist electrical
system.
d. Shut off power supply, remove electrical
cover from hoist and check wiring connections
Also check connections in push button
station and limit switches.
e. Contactor assembly not
functioning.
e. Check for burned out solenoid coil. See that
the necessary jumper wires are properly
installed.
f. Starting switch burned out
(single phase motor).
f. Replace burned out parts.
g. Motor burned out.
g. Replace motor. On single-phase motors the
starting switch may be burned out.
a. Reverse phasing on threephase hoists.
a. Interchange any two of the three power
supply line leads. Do not change green ground
lead. Refer to Section II, par. 2-4.
b. Hoist wired wrong.
b. Check wiring connections with appropriate
wiring diagram.
c. Starting switch not working
correctly (single phase motor).
c. Check for correct starting switch part
number and function. Replace if necessary.
a. "DOWN" electrical circuit
open.
a. Check for loose connections. See that
necessary jumper wires are properly installed
on contactor. Check limit switch condition and
electrical connections.
b. Contactor assembly not
functioning.
b. See that necessary jumper wires are
properly installed. Verify that the contactor
armatures are free to move. If binding occurs
replace contactor. Check for burned out
contactor coils.
c. Push Button Inoperative.
c. Check push button contacts and wires.
d. Load Brake locked up and
overload clutch slipping.
d. Consult Authorized Yale Hoist Repair Station.
Page 13
SECTION Vl - TROUBLE SHOOTING (Continued)
Trouble
6-4. Hook Will Lower But Not Raise
6-5. Hoist Will Not Lift Rated Load.
6-6. Excessive Drift When Stopping.
6-7. Hoist motor overheats.
Probable Cause
a. Excessive load, causing
overload clutch to slip.
a. Reduce loading to rated load of hoist, as
shown on nameplate.
b. Overload clutch out of
adjustment.
b. Test hoist and replace clutch if hoist will not
lift rated load.
c. "UP" electrical circuit open.
c. Check for loose connections. See that
necessary jumper wires are properly installed
on contactor. Check limit switch condition
and electrical connections.
d. Contactor assembly not
functioning.
d. See that necessary jumper wires are
properly installed. Verify that the contactor
armatures are free to move. If binding occurs
replace contactor. Check for burned out
contactor coils.
e. Push button inoperative.
e. Check push button contacts and wires.
a. Low voltage
a. See that power supply is same voltage
listed on motor data plate. Check size of
power supply lines. Refer to fig. 2-1.
b. Overload clutch out of
adjustment.
b. Remove and replace clutch assembly. Refer
to Section IV, par. 7-2 and 7-4.
c. Motor brake not releasing.
c. Check brake components. Refer to Section
VII, par 7-2.d, 7-2.e and 7-2.f.
a. Excessive load.
a. Reduce loading to rated load, shown on
nameplate.
b. Motor brake not holding.
b. Check brake components. Refer to Section
VII, par. 7-2.d.
c. Motor brake not setting due
to insufficient plunger air gap.
c. Adjust air gap. Refer to Section VII, par.
7-11.c.
d. Load brake not holding.
d. Remove load brake and inspect parts. Refer
to Section V, par. 5-4.
a. Excessive load.
a. Reduce loading to rated load of hoist,
shown on nameplate
b. Excessive duty-cycle.
b. Reduce frequency of lift.
c. Excessive "jogging."
c. Reduce frequency of jogs.
d. Wrong voltage.
d. Check voltage rating on motor data plate
against power supply.
e. Starting switch on singlephase motors not opening
starting winding.
e. Refer to Section VII, par. 7-9.b. (3) (b).
Inspect Switch.
f. Damaged motor or worn
bearings in motor or hoist frame.
f. Disassemble hoist and inspect for worn or
damaged parts.
g. Motor brake not releasing.
g. Check brake components. Refer to Section
VII, par. 7-2.d.
SECTION VII - DISASSEMBLY AND
REASSEMBLY
7-1. GENERAL.
a. The following disassembly and reassembly instructions apply
to all models in the line of Yale Electric Hoists with 4 digit
catalog numbers and equipped with overload clutch. Where
needed, variations to instructions are provided to cover
differences between models (suspensions, load chains, rated
Page 14
Remedy
load sizes and motor voltage ratings), with applicable models
specifically noted.
b. A complete teardown procedure is given, however, if only
certain parts require repair or replacement, a partial teardown
may be performed using the applicable portions of the
instructions.
c. For easier handling during disassembly, the following
disassembly steps may, where conditions permit, be completed
before hoist is removed from its overhead suspension or
disconnected from its power supply: Remove chain container,
if hoist is so equipped; remove lower block and load chain
assembly, following procedure outlined in paragraph 7-2. a.
Drain and discard gear case oil, by removing plug at bottom of
frame.
d. These hoists contain precision machined parts and should
be handled with care at disassembly and at reassembly. When
removing or installing parts with press fits, be careful to apply
pressure evenly. On ball bearings, apply pressure to face of
inner or outer race, whichever is adjacent to mating part. This
will avoid damage to bearing races from brinelling by pressing
thru bearing balls. Apply a thin film of sealant to parts having a
press fit when they are installed.
NOTE: If hoist is inoperative it will be necessary to wait
until after load brake is removed (par. c., below), then the
chain can be pulled thru the hoist by hand.
(3) On triple-reeved 3 ton link chain hoists, remove retaining
ring and connecting link pin as shown in figures 7-30 and 7-31.
Remove connecting link with chain from lower block.
7-2. DISASSEMBLY OF HOIST INTO SUBASSEMBLIES.
a. Removal of Lower Block and Load Chain Subassembly.
(1) On models with single-reeved load chains (1/4 thru 1 ton
rated loads) disconnect tail end of load chain from anchor at
side of frame. Remove spring clip and connecting link attaching
chain to anchor on roller chain models (fig. 7-1). Remove fillister
head screw holding end link to frame on link chain models.
Remove grooved pin from the limit actuator and pull it off end
of chain. With hoist connected to power supply, run chain out
of hoist by operating in “lowering” direction. (See note following
paragraph (2) below and note in Sec. V, par. 5-2. a. (3) for
inserting short length of chain.)
Figure 7-2. Ton Hanger Bracket Connection Pin Removed
Figure 7-3. Removing 3 Ton Hanger Bracket from Hoist Frame
10308
Figure 7-1. Removing Spring Clip from Connecting Link
at Tail End of Load Chain (Roller Chain Models)
(2) On models with double-reeved load chains (2 ton hoists)
disconnect tail end of load chain from anchor at side of hoist
frame and remove limit actuator as in (1) above, run chain out
of hoist by operating it in “lowering” direction, and disconnect
opposite end of load chain from anchor inside hoist frame. To
disconnect this end of chain, remove cotter pin from end of
anchor pin, press pin from anchor and withdraw chain. On
roller chain models the anchor in hoist frame must be rotated
about 90' to permit removal of anchor pin. The drive pin securing
threaded end of anchor in upper block assembly (at top of
frame) must be removed in order to rotate the anchor.
To remove connecting link from chain, take out cotter key and
push anchor pin from connecting link. Chain can now be pulled
thru hanger bracket and lower block. Unfasten tail chain from
hoist frame, remove limit actuator, and if power is available,
operate hoist in lowering direction to remove chain. (See note
in Sec. V, par. 5-2. a. (3) for inserting short length of chain). If
hoist is inoperative see note below but be sure to install short
length of chain into hoist before removing load chain.
NOTE: If hoist is inoperative it will be necessary to remove
load brake (par. c, below) so chain can be pulled thru the
hoist by hand.
(4) To remove 3 ton hanger bracket from hoist, remove
retaining ring and connecting rod pin (see fig. 7-2). Rotate
hoist approximately 45° (see fig. 7-3) and hanger will slip free
from hoist frame.
Page 15
b. Removal of Electrical Compartment Cover, Electrical
Controls and Gear Case Subassembly.
(1) Disconnect hoist from power source. Remove three cover
retaining screws and lift off cover (fig. 9-1). Cover screws have
retaining rings which hold them in cover. Use caution as some
covers contain counterweights. Two speed hoists with a 2-1 /4
horsepower motor have an externally mounted counterweight
at the electrical compartment cover.
(2) Disconnect push button conductor cable leads at plug-in
type connectors that can be pulled apart. Remove screw and
washer securing strain reliever (fig. 9-8) and pull the cable and
grommet from its slot in gear case cover.
(3) Disconnect power supply flexible cable leads from
terminals of contactor. Remove screw attaching ground leads
to gear case cover and pull flexible cable and grommet from
slot in cover.
(4) Disconnect motor leads from electrical control units.
Number of leads depends on type of motor. (See wiring
diagrams in Section VIII).
10312
Figure 7-5. Removing Limit Lever Key from Control Shaft
(5) Remove eight hex socket head screws and lockwashers
securing gear case cover to hoist frame. Pry gear case cover
partially off hoist frame using screw driver at special notches
provided at opposite corners of cover (fig. 7-4) to provide access
for removing limit lever key from control shaft. Tilt Woodruff key
in shaft slot using drift punch (fig. 7-5) and pull out using pliers.
Gear case cover with electrical controls attached can now be
lifted from frame (fig. 7-6). Limit lever will drop free of frame as
shaft is removed with cover. Discard gear case cover gasket.
10313
Figure 7-6. Gear Case Cover with Electrical
Controls Removed from Frame
c. Removal of Load Brake and Clutch Assembly and
Intermediate Gear Subassembly.
(1) On 1 /4 thru 1 /2 ton hoists, pull load brake and overload
clutch assembly and the brake shaft washers from inside hoist
frame (fig. 7-7). Caution: Grease-retained bearing has 36 rollers
(all capacities) and may be reinstalled unless rollers are broken
or missing or cup is damaged.
10311
Figure 7-4. Prying Gear Case Cover from Hoist Frame
10314
Figure 7-7. Removing Load Brake and Clutch Assembly
(1/4 & 1/2 Ton Hoists)
Page 16
(2) On 1 thru 3 ton hoists, pull load brake and clutch assembly
and intermediate gear assembly, including the thrust washers
for each unit, from hoist frame (fig. 7-8).
7-3. REBUILD OF HOIST FRAME, SPROCKET GEAR,
SPROCKET SHAFT AND CHAIN GUIDE.
a. Disassembly of Sprocket Gear, Shaft and Chain Guide.
(1) Remove retaining ring from end of sprocket shaft and pull
off sprocket gear using a common puller (fig. 7-10). Remove
Woodruff key from shaft.
10322
10315A
Figure 7-8. Removing Load Brake and Clutch and
Intermediate Gear Subassemblies (1 thru 3 Ton Hoists)
d. Removal of Motor Brake.
(1) Remove acorn nuts holding brake cover and remove brake
cover (fig. 9-16).
(2) Disconnect wire nuts on brake rectifier leads.
(3) Remove brake mounting plate screws (fig. 9-16) and lift
brake assembly off to gain access to the motor mounting bolts.
Figure 7-10. Pulling Sprocket Gear from Sprocket
Shaft using Common Puller
e. Removal of Motor Assembly.
(1) Place hoist frame on wood blocks to protect intergral gear
on motor shaft. Loosen four motor mounting bolts and lift motor
assembly from frame (fig. 7-9). Guide motor leads through wire
passage to avoid damage.
(2) Unscrew four fillister head machine screws securing
sprocket bearing retaining plate and remove plate (fig. 7-11).
Remove and discard ring gasket from groove around bearing
or remove seal disc (fig. 7-12).
10323
10316A
Figure 7-9. Removing Motor Assembly
Figure 7-11. View of Sprocket Bearing Retaining Plate
Page 17
10326
10324
Figure 7-12. Removing Sprocket Bearing Ring Gasket.
(On later model hoists ring gasket is replaced by
a seal disk with oil seals)
(3) Using suitable pry bar (fig. 7-13) partially raise two chain
guide support pins from their bores in frame. Pull them the rest
of the way out using pliers with jaws protected to avoid
damaging pins. Remove and discard two “0” ring gaskets from
grooves on each support pin.
Figure 7-14. Removing Sprocket Shaft and Front Bearing
NOTE: Do not remove oil seal, ball bearings, and needle
bearings from their bores in the frame unless they show
evidence of wear or damage and require replacement.
When replacing rear sprocket ball bearing pack bearing
1/2 full with NLGI No. 2 grease.
10325
10327
Figure 7-13. Removing Chain Guide Support
Pins using Pry Bar
(4) Remove sprocket shaft and front ball bearings assembly
from frame by lifting up on end of shaft while prying up on
sprocket as illustrated in figure 7-14. The chain guide will need
to be repositioned in frame as sprocket shaft is raised to allow
the sprocket to pass thru hole of guide (fig. 7-15). On roller
chain model hoists, the chain stripper must be partly removed
from guide by prying it out using screw driver or other suitable
tool. See figures 7-16 and 7-17.
Page 18
Figure 7-15. Chain Guide Being Removed from Frame
as Sprocket Shaft is Lifted Out (Link Chain Models)
10328
Figure 7-16. Chain Stripper being partially removed from
Chain Guide (Roller Chain Model)
Figure 7-18. Removing Upper Hook and Hook Nut
from Hoist Frame (1/4 thru 1 Ton Models)
(2) On 2 ton models, unscrew two hex socket head screws
holding suspension bushing lock assembly to upper block (fig.
7-19) and remove lock. Unscrew suspension bushing from block
to remove hook. To disassemble block from frame remove drive
pin from nut inside frame and unscrew nut from stud holding
body to frame. Remove drive pin securing threaded end of
chain anchor in block and unscrew anchor. Block can then be
lifted off.
10329
Figure 7-17. Chain Guide and Stripper being removed from
Frame as Sprocket Shaft is lifted out (Roller Chain Model)
b. Disassembly of Upper Hook. (Hook Suspension Models)
(1) On 1 /4 thru 1 ton models, drive pin from hook nut using
drift punch and unscrew upper hook. Nut is reached thru access
hole in side of hoist frame. See figure 7-18.
10331
Figure 7-19. View of Upper Hook Assembled
to Hoist Frame (2 Ton Models)
NOTE: Hook and bushing assembly is not to be further
disassembled as nut securing bushing to hook shank is
welded in place at the factory. Only the assembly is
available for replacement.
Page 19
(3) On 3 ton models, remove retaining ring from connecting
rod pin and push connecting rod pin through bracket and
connecting rod, releasing hanger (see fig. 7-2). Raise hanger
above hoist frame to provide access to hook nut. Rotate hook
until grooved pin in nut is visible from end of hanger frame.
Using a drift punch, drive grooved pin thru hook nut until it hits
hanger pocket. Remove drift far enough to hold nut from turning
and unscrew hook from nut. Thrust washer will fall free.
(4) To remove connecting rod (fig. 7-2) on 3 ton hoist, drive
pin from rod nut using drift punch and unscrew connecting rod.
Nut is reached thru access hole in side of hoist frame. (See fig.
7-18).
(2) Reassemble suspension hook or lug, chain guide, sprocket
shaft and sprocket gear to frame following a reverse procedure
of the disassembly steps listed in paragraphs (a.) thru (c.),
above. If ball bearing is to be reinstalled on sprocket be certain
to position it so that the seal side of bearing faces out, away
from sprocket. To help prevent oil seepage, apply sealant on
O.D. of sprocket bearing and in seat for the ring gasket.
7-4. REBUILD OF LOAD BRAKE AND OVERLOAD CLUTCH
ASSEMBLY.
a. Disassembly.
(1) Place load brake and clutch assembly, flange up, in a
vise equipped with brass or copper jaw plates to protect pinion
gear teeth. Remove snap ring of load brake shaft (fig. 7-21).
10333
11761
Figure 7-20. Removing Suspension Lug
(1/4 thru 1 Ton Models)
c. Disassembly of Suspension Lug (Lug Suspension Models).
Figure 7-21. Removing Snap Ring from Load Brake Shaft
(1) On 1 /4 thru 1 ton models drive grooved pin from the
round nut inside the hoist frame. Hold round nut from rotating
with drift punch thru access hole in side of hoist frame. Unscrew
suspension stud assembly by wrenching hex on top of
suspension lug (see fig. 7-20).
(2) On 2 ton models, remove three hex socket head screws
securing the two lock plates to block at top of frame and pull
out locks. Remove suspension lug, using an extra thin 1-1 /4"
open end wrench to unscrew suspension bushing from block.
Instructions for removing block from frame are given in
paragraph b. (2).
NOTE: The suspension lug is not to be fur ther
disassembled, as nut securing suspension bolt and
bushing to lug is permanently secured in place at the
factory. Only the suspension lug assembly is available for
replacement.
10334
(3) On 3 ton models lug bolt is removed in same manner as
hook. See paragraph 7-3. b. (3).
d. Reassembly.
(1) Before assembly, all parts should be thoroughly cleaned
and inspected to determine their serviceability. Replace parts
that are excessively worn or damaged.
Page 20
Figure 7-22. View Showing Load Brake Flange Removed
(2) Using a puller tool, remove brake flange from shaft. A
groove is provided around outer diameter for this purpose.
See figure 7-22. Remove key from shaft and lift off 2 friction
discs, and the pawl and ratchet assembly (fig. 7-23).
(4) The load brake pawl and ratchet is a riveted assembly
and is not to be disassembled.
b. Reassembly.
(1) Before assembly, all parts should be cleaned and inspected
to determine their serviceability. Replace parts that are
excessively worn or damaged.
(2) Reassemble load brake parts following a reverse procedure
of the disassembly steps listed above, observing the assembly
steps (3) thru (6) below.
10335
(3) Before installing spring in its recess in center of clutch
cone (fig. 7-24) apply a good grade of ball bearing grease to
inside of recess. Spring must be positioned exactly as illustrated,
abutted against pin.
(4) When installing pawl and ratchet assembly on load brake
shaft, be certain that teeth on ratchet face are in the same
direction as shown in fig. 7-23. The ratchet assembly should
rotate freely when turned counterclockwise and the pawl should
engage ratchet teeth when unit is turned clockwise.
(5) When installing brake flange position it with chamfer facing
friction disc, figure 7-22.
Figure 7-23. Removing Pawl and Ratchet Assembly
from Load Brake Shaft
(3) Remove load brake gear and overload clutch assembly
from output pinion shaft. Pull the spring from its recess in
clutch cone (fig. 7-24) but do not further disassemble gear and
clutch assembly. See “NOTE” below.
NOTE: Disassembly of the load brake gear and overload
clutch assembly (fig. 7-24) is not recommended. Clutch
pressure is preset by the factory at assembly to provide
the correct torque to allow the clutch to refuse loads
within a specified range (110% of rated load to 180%
rated load). It is suggested whenever there is a need to
repair or readjust the gear and clutch assembly that it be
sent to an authorized Yale Hoist Repair Station where
adequate tools, fixtures and appropriate test equipment
is available.
(6) The brake spring must be pre-loaded at assembly to a
torque of from 6 to 10 lb. ft. when used with yellow (color code)
spring and a torque of 10 to 14 lb. ft. when used with plain (no
color code) spring. (See Section IX for proper spring). This is
accomplished using a plumber’s strap wrench to wind (rotate)
load brake gear to set up spring (fig. 7-25) while pressing
brake flange into place using an arbor press. Clamp pinion end
of shaft into a portable vice to keep brake from rotating in
press. Use brass or copper jaw plates on vise to protect pinion
gear teeth. Wind gear counterclockwise (viewing brake from
flange end) with strap wrench and press down on flange until
snap ring groove in shaft is exposed allowing snap ring to be
installed. Use extreme care not to over wind spring as yield will
result and final spring torque will be reduced. Do not wind gear
beyond point necessary to install snap ring in groove.
10610
11927
Figure 7-24. Load Brake Gear and Overload Clutch
Assembly Removed from Load Brake Shaft
Showing Brake Spring Installed in Clutch Cone
Figure 7-25. Winding Load Brake Gear
Using a Strap Wrench to Set Up Load Brake Spring
Page 21
7-5. REBUILD OF LOWER BLOCK AND LOAD CHAIN
ASSEMBLY.
a. Disassembly (1/4 through 1-ton, single reeved models).
(1) Separate load chain (link or roller type) from lower block
assembly. Drive out small roll pin securing lower block pin in
lower block yoke and push lower block pin from yoke to release
chain. On roller chain models, an adapter is used to attach
chain to lower block. This adapter is removed from end of
chain by first driving out small roll pin and then pushing out
adapter pin.
10336A
(2) Drive grooved pin from limit actuator and pull actuator
from end of chain.
(3) Lower blocks are of a pinned construction, permitting
replacement of body, thrust bearing, or hook and nut assembly.
To disassemble, drive spring pin from hook nut (fig. 7-26). With
pin removed, hold hook nut from turning with drift punch and
rotate hook to unscrew it from nut.
Figure 7-27. Removing Chain Center Guide from
2 thru 5 Ton Lower Block Assembly (Link Chain Model)
11868
10337A
Figure 7-28. Removing Sprocket Pin Lock on
2 thru 5 Ton Lower Block Assembly (Link Chain Model)
Figure 7-26. Removing Roll Pin Securing Hook Nut
to Hook Shank
Separate hook, bearing shield, needle bearings and two thrust
washers from body. Hook and nut are drilled at assembly and
are replaced only as an assembly.
b. Disassembly (2-ton, double reeved models).
10338A
(1) On 2-ton roller chain models, remove retaining ring from
one end of sprocket pin and press pin from lower block body.
Grasp chain and pull out sprocket and two spring washers
from body. Do not remove needle bearing from sprocket or
pressure lube fitting from sprocket pin unless replacement is
necessary.
(2) On 2-ton link chain models, remove fillister head screw
securing center guide in top of lower block body and lift out
guide (fig. 7-27) and sprocket pin lock (fig. 7-28). Press sprocket
pin from body and pull out chain, sprocket and washer (fig. 729). Do not remove bushing type bearing from sprocket or
pressure lube fitting from sprocket pin unless replacement is
necessary.
Figure 7-29. Removing Coil Chain and Sprocket on
2 thru 5 Ton Lower Block Assembly (Link Chain Model)
(3) To disassemble hook and nut, drive groove pin from hook
nut with drift punch. With pin removed, hole hook nut from
turning with drift punch and rotate hook to unscrew it from nut.
Separate hook, nut, bearing shield, needle bearing and two
thrust washers from body. Hook and nut are drilled at assembly
and are replaced only as an assembly.
c. Disassembly (3-ton, triple reeved models).
(1) Remove chain sprocket from lower block following
procedure for 2-ton link chain models described in paragraph
7-5. b. (2) above.
Page 22
(2) To disconnect end of chain anchored to lower block,
remove retaining ring from pin bore (fig. 7-30). Push connecting
link pin from bore by pressing through hole provided in opposite
side of block (fig. 7-31). Chain connecting link is now free and
can be further disassembled for inspection.
(2) Lubricate and reassemble following a reverse procedure
of the disassembly steps above.
7-6. REBUILD OF ELECTRICAL CONTROLS AND GEAR
CASE COVER SUBASSEMBLY.
a. Disassembly.
(1) Disconnect two limit switch leads from contactor. Also, if
hoist has a transformer, disconnect transformer leads at the
contactor or terminal board.
(2) Remove reconnectable terminal board if so equipped.
(3) Remove two screws and lift transformer from gear case
cover if hoist is so equipped.
(4) Remove two screws attaching contactor assembly to cover
and lift off contactor. Refer to paragraph 7-8 for instructions for
rebuild of contactor assembly.
11752A
(5) Remove two hex socket head screws and lockwashers
securing limit switch assembly to gear case cover and pull limit
switch assembly and control shaft from cover.
(6) Loosen two nuts and screws holding limit switches to
retainer bracket and remove.
(7) Remove self-locking nut from end of control shaft and pull
off washer, switch activator, centering lever, spring, spacer tube,
retainer bracket and washer.
Figure 7-30. Removing Retaining Ring from Bore of
Connecting Link Pin - 3 Ton Lower Block Assembly
NOTE: Do not remove needle bearings from gear case
cover unless they show evidence of wear or damage and
require replacement.
b. Reassembly.
(1) Before assembly, all parts should be thoroughly cleaned
and inspected to determine their serviceability. Replace parts
that are worn or damaged.
(2) Reassemble parts to gear case cover in reverse of the
disassembly steps above. Ends of centering spring must
straddle centering levers. Lubricate contact segments of limit
switch with small amount of graphite grease.
7-7. REBUILD OF PUSH BUTTON STATION AND
CONDUCTOR CABLE ASSEMBLY.
a. Disassembly.
11752B
Figure 7-31. Removing Connecting Link Pin from 3 Ton
Lower Block Assembly
(3) To remove hook from lower block body, first drive grooved pin
from hook nut. Then hold nut from turning using drift punch and rotate
hook to unscrew it from nut. Separate hook, shroud and thrust washer
from body. Note that bearing surface of washer faces nut.
(4) To remove chain sprocket from upper suspension hanger,
first remove hanger as outlined in paragraph 7-2. a. (4). With
hanger removed, push sprocket pin from hanger and sprocket.
NOTE: Sprocket pin must be removed toward side having small
anti-rotation pin slot in hanger.
d. Reassembly of Lower Blocks.
(1) Remove seven pan head machine screws and
lockwashers from back of push button station and lift off rear
cover.
(2) Loosen three terminal screws and remove strain cable
screw, lockwasher and plain washer.
(3) Remove two pan head machine screws and lockwashers
from housing cap and remove cap, grommet and cable
assembly.
(4) Remove two pan head screws, contact assembly and
button assembly.
b. Reassembly.
(1) Before assembly, all parts should be thoroughly cleaned
and inspected to determine their serviceability. Replace all parts
that are worn or damaged.
(1) Clean, inspect and replace worn or damaged parts.
Page 23
(2) Reassemble push button station and conductor cable
following a reverse procedure of the disassembly steps listed
above.
NOTE: Do not attempt to shorten or lengthen push button
conductor cable. Odd length conductor cable assemblies
for other than standard 10 ft. lift hoists can be procured
from the factory.
(3) Remove internal retaining ring from bearing bore in end
bell and press out bearing assembly.
b. Reassembly.
(1) Before assembly, all parts should be cleaned and
inspected to determine their serviceability. Replace all parts
that are worn or damaged.
7-8. REBUILD OF CONTACTOR ASSEMBLY.
(2) Reassemble motor following a reverse procedure of the
disassembly steps listed above.
a. General. Wear or damage to contractor parts requires
replacement of complete contactor assembly.
7-11. REASSEMBLY OF HOIST FROM SUBASSEMBLIES.
7-9. REBUILD OF SINGLE PHASE MOTOR ASSEMBLY.
a. Disassembly.
(1) To inspect capacitor, remove two cover mounting screws
and lift off capacitor cover. Do not disconnect wires at capacitor
unless capacitor must be replaced.
(2) Remove external retaining ring from end of shaft and
press shaft out of bearing in end bell.
(3) Remove motor end bell from stator assembly. If necessary
loosen it by tapping with soft mallet.
(4) Remove internal retaining ring from bearing bore in end
bell and press out bearing assembly.
b. Reassembly.
(1) Before assembly, all parts should be cleaned and
inspected to determine their serviceability. Replace all parts
that are worn or damaged.
(2) Reassemble motor following a reverse procedure of the
disassembly steps listed above.
(3) After reinstalling hoist motor, connect hoist to power supply
and carefully complete both checks (a) and (b) below:
(a) To check direction of rotation, briefly operate ““ button. If
hook lowers, interchange motor lead ‘T1" with “T4” at the
contactor or controller. Hook must raise when the ““ push
button is operated.
(b) To check the starting winding switch, connect ammeter
(minimum 10 ampere) to motor lead “T5”. Amperes must drop
to zero in approximately one second when operating hoist in
both ““ and ““ directions. If ampere reading does not drop to
zero, interchange motor leads “T7” and “T8”. If, after above
checks were made with motor having been run in both
directions, the ammeter reading still does not return to zero,
the motor switch is not functioning properly and should be
replaced.
a. General. The procedure to be followed to reassemble the
hoist from subassemblies is in reverse order of the disassembly
steps outlined in paragraph 7-2. Listed below are special
assembly precautions which should be observed to assure
proper assembly.
NOTE: Grease retained bearings (see Section VII, par. 72. c. (1) and fig. 7-7) have loose rollers. When reassembling
hoist, make certain the correct number of rollers are held
in roller cup with grease before assembling load brake
shaft to hoist.
b. Assembly of Load Brake Thrust Washers. When reinstalling
load brake assembly be certain thrust washers are properly
installed at both ends of load brake shaft, as noted below.
(1) A bronze thrust washer with a lug on one side belongs on
pinion end of shaft and must be installed so that its lug engages
the special slot located on spotface surrounding bearing bore
inside hoist frame or gearcase cover. Use heavy grease to
hold washer in proper position in frame or cover (depending
upon hoist capacity) during assembly.
(2) On hoists with Catalog Number prefix letters “A,” “C,” “D,”
“L” an 11/16" I.D. plain steel thrust washer must be used
between end of pinion gear and the bronze thrust washer (fig.
7-7).
(3) A 5/8" I.D. steel thrust washer is to be installed on the
brake flange end (end opposite pinion) of load brake assembly.
c. Motor Brake. Instructions for adjusting the brake are inside
the brake cover and are repeated below. Check brake
adjustment after first 30 days of service and regularly thereafter
during the six-month inspection procedure.
12759D
WARNING
Do not change circuit wiring. Severe damage and
malfunction of hoist may result.
7-10. REBUILD OF THREE PHASE MOTOR ASSEMBLY.
a. Disassembly.
(1) Pull four motor mounting bolts from motor and separate
stator assembly from the end bell and rotor shaft assembly.
(2) Remove external retaining ring from end of motor shaft
and press shaft from bearing in end bell.
Page 24
Figure 7-32. Hoist Motor Brake
(1) Examine position of indication tang located below the
solenoid coil (see figure 7-32).
(2) If the tang is below the line by more than 1/8", the brake
should be adjusted to bring the top of the tang back up
alongside the line on the adjust label.
(3) Removing the hex key (1/8" size) from the holster on the
cover mounting stud and carefully turn the ADJUSTING SCREW
(located above the solenoid coil) clockwise. The indicating tang
will move a large distance for a small turn of the adjusting
screw, therefore turn the screw no more than one-quarter turn
before checking adjustment.
(4) After adjustment operate the brake by hand to assure
brake disc running clearance. The outboard brake pad should
separate from the brake disc by approximately .010".
(5) Air gap adjustment.
counterclockwise as chain is fed into opening. When sufficient
chain has been run into hoist to reach anchor position, plus a
slack loop, install limit actuator on anchor end of load chain
(see (3) below) and attach end of chain to frame with special
fillister head screw. Be certain chain is not twisted.
(2) On roller chain models, the chain may be installed after
step (e) below is accomplished, allowing chain to be run into
hoist under power. Caution must be exercised so that fingers
or hands are not caught in chain while it is being fed into hoist.
NOTE: The spring clip connecting link must be attached
to anchor end of roller load chain before chain is run into
hoist. Failure to do so may result in damage to chain or
hoist.
(3) When installing limit actuator on anchor end of load chain
attach it at link shown below using a grooved pin. See Figure
3-2.
(a) Loosen jam nut using 7/16" wrench while holding set
screw with 1/8" hex key.
(b) Pull brake release lever as far as possible away from
motor, and hold.
(c) Turn in set screw until it contacts plunger (when
movement is felt in release lever), then turn in 1/4 to 1/2
additional turn.
(d) Tighten jam nut, making sure set screw does not turn.
Type Chain
Size Chain
Number of
Chain Links
From End Link
Link
1/4" Wire Dia.
8 Links
Link
5/16" Wire Dia.
8 Links
Roller
5/8" Pitch
8 Links
Roller
3/4" Pitch
7 Links
(e) Test operation of brake.
(6) Replace hex key in holster.
e. Wiring Hook-Up. Before installing hoist, connect wiring to
electrical controls in accordance with applicable wiring diagram.
Wires are coded and/or numbered to agree with wiring
diagrams.
(7) Replace brake cover.
f. Lubricate Hoist. Lubricate hoist as outlined in Section IV.
(f) Readjust as necessary, 1/4 to 1/2 turn at a time, until
brake sets properly.
(1) Brake Adjustment. Adjust brake if clearance between
pressure pad and brake disc is more than. 040" (see fig. 7-32)
or if brake is drifting.
(2) Tools Required.
(a) Feeler gage (.020" to .040") or equivalent.
(b) Hex key (1/8" size).
(3) To Adjust Brake.
(a) Minimum clearance between pressure pad and brake
disc is .020" to .025" (see fig. 7-32). Set feeler gage between
.020" and .025" and place between pressure pad and brake
disc. Use 1/8" hex key on adjusting screw (located above
solenoid coil). Stop turning adjusting screw when contact is
made with the pressure pad. Remove feeler gage.
(b) After adjustment operate brake by hand to assure brake
disc running clearance. The outboard pressure pad should
separate from the brake disc by approximately .010" to .013".
(4) Replace brake cover.
d. Assembly of Load Chain.
NOTE: Link chain must be installed so welds on vertical
links face away from the load sprocket.
(1) On link chain and roller chain models install load chain
over sprocket before load brake assembly is installed. Insert
anchor end of chain (end opposite lower block on single reeved
models) into chain guide opening on far side of hoist (viewing
frame from anchor screw side). Rotate sprocket gear by hand
7-12. TESTING HOIST.
a. General. After completion of reassembly and before placing
hoist in service, hoist should be tested to insure safe operation.
To test: suspend hoist from an overhead supporting member of
sufficient strength to carry rated load; connect to a power supply
of the specified voltage (see data plate attached to motor); and
perform the following checks and adjustments.
b. Check For Correct Control Operation. Refer to Section II,
par. 2-4. d, under “Warning.”
c. Check Upper and Lower Limit Stop Operation. To
determine if upper and lower limit stop functions properly, make
the following checks while operating hoist with push button
control and actuating the limit lever by hand:
(1) Depress ““ push button and with chain running in raise
direction, pull down on end of limit lever at tail chain side of
hoist (left side facing cover end). The “UP” limit switch should
cut off power, causing the hoist to stop.
(2) Depress ““ push button and with chain running in lowering
direction, push up on same end of limit lever. The “DOWN” limit
switch should cut off power, causing the hoist to stop.
(3) If hoist does not stop in both travel directions, check for
improper wiring. Refer to par. 6-2 and appropriate wiring
diagram. If wiring is correct, check to see that limit switch is
correctly installed.
(4) As a final check, operate hoist (no load) in the lowering
direction and allow tail chain limit actuator to trip limit lever.
Page 25
Hook should stop. Repeat check in hoisting direction and allow
lower block to trip limit lever. Hook should stop.
(3) Test shall be made only by a qualified operator thoroughly
familiar with the hoist and the purpose of the test.
d. Check Hoist With Rated Load. Attach rated load to lower
hook and check hoist operation. If hoist does not lift rated load,
refer to par. 7-13.
(4) Provide adequate and proper rigging to insure test loads
are securely attached, properly balanced, and will lift level.
(1) Operate hoist to raise load. When control is released,
load hoist should instantaneously stop and hold load at that
level.
(2) Operate hoist to lower load a short distance, then release
control. Hoist should stop instantaneously and hold load at
that level.
(3) If hoist does not stop or hold load refer to Section VI.
7-13. TEST PROCEDURE FOR CHECKING OPERATION OF
OVERLOAD CLUTCH.
a. General. The overload clutch must be tested using known
weights. The following prerequisites (par. (1) thru (4)) must be
strictly observed in performing this test.
(1) A qualified person shall determine before testing, that all
structures supporting the hoist are adequately strong to with
stand the test load of 200 percent of rated hoist load, whether
hoist is tested in installed position or moved to a designated
test facility.
b. Test Procedure. With the above prerequisites satisfied and
hoist properly connected to electrical power, proceed with the
test as follows:
(1) Using a known load equal to rated load of hoist, operate
hoist to lift load. Raise load high enough to be certain the
entire load is freely suspended. Clutch should not slip at
rated load. If hoist does not lift rated load, clutch requires
adjustment. Refer to Section V, par. 5-4. c.
(2) Increase load to 200 percent rated load and operate hoist
to lift the load. Clutch must slip, causing the hoist to refuse to
lift the load. If hoist lifts this overload, the overload clutch is
out-of-adjustment and must be readjusted. Refer to Section V,
par. 5-4. c.
(3) If clutch slips as required in step (2) above, continue to
run hoist (clutch slipping-hoist refusing to lift load) for five (5)
cycles of one (1) second each.
(4) Remove excess weight to return the load to rated hoist
load. Lift rated load one final time to be certain-ai i that the
clutch does not slip and that the hoist lifts the rated load.
(2) Loads used for testing must be accurately known.
WARNING
DO NOT LIFT MORE THAN RATED LOAD EXCEPT FOR TEST PURPOSES
NOTICE
THIS EQUIPMENT MUST BE EFFECTIVELY GROUNDED ACCORDING TO THE NATIONAL ELECTRIC
CODE, ARTICLES 250-57, 250-59, OR 610-61 OR OTHER APPLICABLE CODES. IF THE GROUNDING
METHOD USED IS THROUGH THE TROLLEY WHEELS, THEN EACH SECTION OF THE TRACK MUST BE
GROUNDED BY METAL-TO-METAL CONNECTION TO THE BUILDING GROUND OR ELECTRICAL
SYSTEM GROUND.
Page 26
SECTION IX - REPLACEMENT PARTS
This section contains complete replacement parts information
for your new Yale Electric Hoist. The parts are grouped and
illustrated in exploded view photos to permit easy identification.
Each part in an illustration is keyed by reference number to a
corresponding parts table. In the table will be found the BH
part number, description and quantity required.
authorized testing equipment; and stock a complete inventory
of genuine replacement parts.
NOTICE: Information herein is subject to change without
notice. Parts must be ordered from an Authorized Yale
Repair Station or from a Yale Hoist Distributor.
When ordering replacement parts it will be necessary that you
include, with your order, the BH part number of parts required,
plus, hoist catalog number and model number, which will be
found on the hoist nameplate attached to motor. For motors
complete motor nameplate data is required. Complete
inspection, maintenance and overhaul service is available for
Yale Electric Hoists at any of the Authorized Repair Stations.
All are staffed by qualified factory-trained servicemen; have
The numbers assigned to the parts of our various
assemblies in our parts lists are not the part numbers
used in manufacturing the part. They are identification
numbers, that when given with the hoist serial number,
permit us to identify, select or manufacture, and ship
the correct part needed for any hoist.
INDEX OF EXPLODED VIEW PARTS ILLUSTRATIONS
Figure No.
Title
Page
9-1
Frame and External Parts ......................................................................................................................... 29-32
9-2
Upper Suspension, Load Chain and Lower Block Parts (2 ton Hoists) .................................................. 33-34
9-3
Upper Suspension, Load Chain and Lower Block Parts (3 ton Hoists) .................................................. 35-36
9-4
2 and 3 Ton Lower Block Assembly (Link Chain Hoists) .............................................................................. 37
9-5
2 Ton Lower Block Assembly (Roller Chain Hoists) ...................................................................................... 38
9-6
Gearing and Load Brake Parts (1/4 and 1/2 Ton Hoists) ......................................................................... 39-40
9-7
Gearing and Load Brake Parts (1 thru 3 Ton Hoists) ............................................................................... 41-42
9-8A
Electrical Control Units (Three Phase Single Speed Hoists - Later Version) ......................................... 43-44
9-8
Electrical Control Units (Three Phase Single Speed Hoists - Early Version) ......................................... 45-46
9-9A
Electrical Control Units (Two Speed Hoists Only - Later Version) ........................................................... 47-48
9-9
Electrical Control Units (Two Speed Hoists Only - Early Version) ........................................................... 49-50
9-10A
Electrical Control Units (Single Phase Hoists - Later Version) ................................................................ 51-52
9-10
Electrical Control Units (Single Phase Hoists - Early Version) ..................................................................... 53
9-11
Limit Lever and Switch Parts .......................................................................................................................... 54
9-12
Push Button Station and Conductor Cable Assembly (Single Speed Hoists) ............................................. 55
9-13A
Push Button Station and Conductor Cable Assembly (Two Speed Hoists Only - Later Version) .......... 57-58
9-13
Push Button Station and Conductor Cable Assembly (Two Speed Hoists Only - Early Version) .......... 59-60
9-14A
Single Phase Motor Assembly - later Version ............................................................................................... 61
9-14
Single Phase Motor Assembly - Early Version .............................................................................................. 62
9-15
Three Phase Motor Assembly ................................................................................................................... 63-64
9-16A
Hoist Motor Brake ...................................................................................................................................... 65-66
Page 27
NOTES
Page 28
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
Figure 9-1. FRAME AND EXTERNAL PARTS
Standard and Plating Service Hoists
(Except 2 thru 3 Ton Model Upper Suspension, Load Chain and Lower Block)
Ref.
No.
Part
Number
1
BH-1001
BH1001A
BH-1167
BH-1003
3
BH-1004
BH-1 081
BH-1094
4
5
6
7
BH-1005
BH-1006
BH-1007
BH-1008
Description
Hook Assembly-Upper with Latch (Includes Items 21, 22, 23 & 51) (for 1/4 & 1/2 ton)
Hook Assembly-Upper with Latch (Includes Items 21, 22, 23 & 51) (for 1 ton)
Spacer Washer Under Hook - Not Shown
Frame Assembly (For Hoists with Cat. No. prefix letters A, C, G, H & J. Includes 2
bushings, 1 needle bearing, 1 cup, 1 oil seal, 1 oil filter, 2 pipe plugs, and 2 dowel
pins.)
Frame Assembly (For Hoists with Cat. No. prefix letters D, K, L, P, M, S, T, W, & V.
Includes 2 bushings, 2 needle bearings, 1 oil seal, 1 oil filler, 2 pipe plugs and 2
dowel pins.)
Frame Assembly (For 1/4 & 1/2 ton special sealed frame hoists with suffix -4, -5).
Includes sealed frame, 2 bushings, 1 needle bearing, 2 oil seals, 1 oil filler, 2 pipe
plugs, and 2 dowel pins.
Frame Assembly (For 1 & 2 ton special sealed frame hoists with suffix -4, -5).
Includes sealed frame, 2 bushings, 2 needle bearings, 2 oil seals, 1 oil filler, 2 pipe
plugs, and 2 dowel pins.
Pin-Support, chain guide
Gasket “O” Ring
Gasket-Gearcase
Cover Assembly-Gearcase (For Hoists with Cat. No. prefix letters
A, C, G, H & J. Includes 1 needle bearing, 1 cup and 2 grooved pins).
Qty.
Req’d
1*
1
1
1
1
1
2
4
1
1
(Continued on following page)
Page 29
Figure 9-1. FRAME AND EXTERNAL PARTS - Continued
Ref.
No.
Part
Number
BH-1009
BH-1082
BH-1095
8
BH-1157
BH-1010
9
BH-1096
10
11
BH-1014
BH-1168
BH-1169
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
YH-1190
YH-1191
YH-1192
YH-1193
YH-1194
BH-1020
BH-1021
BH-1022
BH-1023
BH-1024
BH-1025
BH-1026
BH-1027
BH-1028
BH-1029
BH-1030
**
BH-1031
BH-1032
***
BH-1033
BH-1034
BH-1080
BH-1086
***
BH-1039
BH-1040
BH-1075
BH-1076
BH-1171
BH-1172
BH-1173
BH-1043
BH-1044
30
BH-1035
BH-1035A
BH-1036
Description
Cover Assembly -Gearcase (For Hoists with Cat. No. prefix letters D, K, L, P, M, S, T,
W, & V. Includes 2 needle bearings and 2 grooved pins).
Cover Assembly-Gearcase (For 1/4 & 1/2 ton special sealed frame Hoists with
suffix -4, -5). Sealed and includes 1 needle bearing, 1 cup and 2 grooved pins.)
Cover Assembly-Gearcase (For 1 & 2 ton special sealed frame Hoists with suffix
-4, -5). Sealed and includes 2 needle bearings and 2 grooved pins.)
Cover Assembly-Gearcase (For Two Speed Hoists with 2-1/4 Horsepower Motor Only.)
Cable Assembly-Flexible, 5' (Incl. Items 9 & 10)
115 volt, 1 phase, 60 hertz hoists
230 volt, 1 phase, 60 hertz hoists
200/230/460/575 volt, 3 phase, 60 hertz hoists
Grommet-Flexible Cable-3 phase
Grommet-Flexible Cable-1 phase
Clamp-Flexible Cable
Cover-Electrical Compartment
Without internal counterweight
With internal counterweight
Capacity Label (Not Shown)
1/4 Ton
1/2 Ton
1 Ton
2 Ton
3 Ton
Screw-Fillister Head Machine
Hi-Collar Helical Spring Lock Washer (1/4)
Ring-Retaining
Regular Helical Spring Lock Washer (#10 Pltd.)
Hex Socket Head Cap Screw (#10-24 x 3/4)
Grooved Pin (Type D 1/8 x 1/2 Pltd.)
Grommet-(Motor Driven Trolley Models)-Not Shown
Dowel Pin (3/8 x 3/4)
Hex Socket Pipe Plug (1/8)
Washer-Thrust, upper hook
Grooved Pin (Type F 3/16 x 1-1/4 Pltd.)
Nut-Upper Hook
Guide Assembly-Link Load Chain
1/4 & 1/2 ton Hoists
1 thru 3 ton Hoists
Chain Assembly-Link, load
1/4" Dia.-1/4 & 1/2 ton Hoists
5/16" Dia.-1 ton Hoists
1/4" Dia.-1/4 & 1/2 ton Hoists - Zinc Plated
5/16" Dia.-1 ton Hoists - Zinc Plated
Chain Assembly-Roller, load
5/8" Pitch-For 1/4, and 1/2 ton Hoists
3/4" Pitch-For 1 ton Hoists
Repair Link-5/8" Pitch Roller Chain (not shown)
Repair Link-3/4" Pitch Roller Chain (not shown)
Slotted Spring Pin (3/32 x 5/8 Pltd.)
Adapter Kit-Roller Load Chain (Incl. Items 27, 28, 29, 40 and 41)
5/8" Pitch-For 1/4, and 1/2 ton hoists
3/4" Pitch-For 1 ton hoists
Pin-Adapter, roller load chain (5/8" Pitch)
Pin-Adapter, roller load chain (3/4" Pitch)
Block Assembly-Lower, link and roller chain (Incl. items 32 thru 39)
For 1/4 ton Hoists
For 1/2 ton Hoists
For 1 ton Hoists
Note: Lower block assemblies do not include attaching pins or roller chain adaptor.
Order separately.
(Continued on following page)
Page 30
Qty.
Req’d
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
8
8
2
1
2
2
1
1
1
1
1*
1*
1
1
1
1
1
1*
1*
Figure 9-1. FRAME AND EXTERNAL PARTS - Continued
Ref.
No.
Part
Number
32
BH-1174
BH-1174A
BH-1175
33
BH-1176
BH-1177
34
35
36
37
38
39
40
41
42
BH-1182
BH-1183
BH-1178
BH-1179
BH-1180
BH-1181
**
BH-1037
BH-1038
BH-1045
BH-1046
BH-1047
43
BH-1048
BH-1049
44
45
46
47
48
49
50
51
52
53
54
55
58
59
BH-1050
BH-1 051
BH-1052
BH-1053
BH-1054
††
BH-1098
BH-1099
BH-1184
BH-1185
BH-1057
BH-1058
BH-1183
BH-1089*
BH-1088*
BH-1087*
BH-1092
BH-1186
BH-1158
BH-1159
BH-1160
Description
Body-Lower Block, link and roller chain
1/4 ton Hoists
1/2 ton Hoists
1 ton Hoists
Hook, Nut and Latch Assembly-Lower Block
1/4 and 1/2 ton Hoists
1 ton Hoists
Latch Kit-Hook, lower
1/4, and 1/2 ton Hoists
1 ton Hoists
Washer-Thrust, needle bearing
Bearing Assembly-Needle, thrust
Shield-Bearing
Grooved Pin (Type F 5/32 x 1-1/8 Pltd.)
Nut-Hook
Pin-Connecting, lower block
1/4 and 1/2 ton Hoists
1 ton Hoists
Slotted Spring Pin (3/32 x 3/4 Pltd.)
Stripper-Roller Chain
1/4 and 1/2 ton Hoists
1 & 2 ton Hoists
Guide Assembly-Roller Chain
1/4 and 1/2 ton Hoists
1 & 2 ton Hoists
Link Assembly-Roller Chain (For connecting tail end of chain only - Must not be used
to join chain.)
1/4 & 1/2 ton Hoists
1 & 2 ton Hoists
Fillister Head, Self Locking Machine Screw (5/16-18 x 3/4 Pltd.)
Anchor-Link, roller load chain
1/4 & 1/2 ton Hoists
1 & 2 ton Hoists
Actuator-Limit Lever
For 1/4" Dia. Link Chain and 5/8" Pitch Roller Chain
For 5/16" Dia. Link Chain and 3/4" Pitch Roller Chain
Grooved Pin (For Actuator BH-1098) (Type F 7/32 x 2 Pltd.)
Grooved Pin (For Actuator BH-1099) (Type F 1/4 x 2 Pltd.)
Bushing-Control Shaft
Filler Assembly-Oil
Latch Kit-Hook (upper) 1/4 thru 1 ton
Slotted Spring Pin (1/4 x 11/16 Pltd.)
Stud-Suspension, nut and pin (Includes item 55.)
Bracket-Suspension
Washer (.0747 Thk.)
Washer (.0478 Thk.)
The following items are for two speed hoists with 2-1/4 horsepower motor only:
Insert-Coil
Support Stud
Top
Bottom
Qty.
Req’d
1*
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
1
1
2
1
1*
1
As Req’d.
3
2
1
(Continued on following page)
Page 31
Figure 9-1. FRAME AND EXTERNAL PARTS - Continued
Ref.
No.
Part
Number
60
61
62
63
BH-1161
BH-1162
BH-1163
YH-1164
YH-1165
YH-1166
Qty.
Req’d
Description
Counterweight
Plain Washer (Type W 1/4 Pltd.)
Heavy Hex Self-Locking Nut (1/4 - 20)
Capacity Label
1 Ton
2 Ton
3 Ton
1
3
3
1
* Refer to Figure 9-2 for 2 Ton Model Upper Suspension, Load Chain and Lower Block Parts.
Refer to Figure 9-3 for 3 Ton Model Upper Suspension, Load Chain and Lower Block Parts.
Later model hoists also have a set screw (BH-1199) to lock rotation.
** Hook and suspension bolt nuts are not serviced separately. They are available only with hook or bolt as assemblies.
** Load Chain Assemblies listed are for hoists with standard
10 ft. lifts. Bulk chain is available in 1 ft. increments and 50 ft.
lengths as follows:
†† A urethane Bumper (BH-1063) is used over the top of the
steel limit level actuator at lower block on all high speed 64
fpm hoists, 32 fpm 1 Ton (2½ hp) hoists, and single phase
32 fpm hoists.
Page 32
Â
Type Chain
Roller (5/8" Pitch)
Roller (3/4" Pitch)
Link (1/4" Dia.)
Link (5/16" Dia.)
Link (1/4" Dia. Zinc Plate)
Link (5/16" Dia. Zinc Plate)
50' Lengths
Bulk
BH-1064
BH-1067
Not Available
Not Available
Not Available
Not Available
BH-1065
BH-1068
BH-1066
BH-1069
BH-1083
BH-1093
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
10251B
Figure 9-2. UPPER SUSPENSION, LOAD CHAIN AND LOWER BLOCK PARTS
(2 Ton Hoists)
Page 33
Figure 9-2. UPPER SUSPENSION, LOAD CHAIN AND LOWER BLOCK PARTS - Continued
Ref.
No.
Part
Number
1
905422
2
3
4
BH-1102
BH-1030
5
6
7
8
9
10
11
12
13
14
15**
16
17
18**
19
20
21
22
23
BH-1104
BH-1105
BH-1106
BH-1107
BH-1108
BH-1109
BH-1061
BH-1110
BH-1111
BH-1112
BH-1076
BH-1113
(See Fig. 9-4)
(See Fig. 9-5)
BH-1114
BH-1115
*
BH-2213
BH-1029
BH-1099
BH-1185
Description
Bracket Assembly Kit- Lug Suspension
(Link Chain Model Only. Includes Items 6, 8 and 9).
Hook Assembly-Upper (Includes Items 5, 6, 7 and 20).
Grooved Pin (Type F 3/16 x 1-1/4 Pltd.)
Block Assembly-Upper
Link Chain Models, Includes Items 3, 10, 11, 14, 16, 19 and 21
Roller Chain Models, Includes Items 3, 10, 12, 13, 14, 19 and 21
Lock Assembly-Suspension Bushing
Regular Helical Spring Lock Washer (#10 Pltd.)
Hex, Socket Head Cap Screw (#10-24 x 1/2)
Hex, Socket Head Cap Screw (#10-24 x 3/8)
Plate - Lock (Link Chain Lug Suspension Models Only)
Stud - Upper Block
Anchor - Link Load Chain
Anchor - Roller Load Chain
Pin - Roller Chain Anchor
Cotter Pin (3/32 x 3/4)
Chain Assembly-Roller Load (3/4" Pitch)
Repair Link-3/4" Pitch Roller Chain (Not Shown)
Pin-Link Chain Anchor
Block Assembly-Lower (Link Chain Models)
Block Assembly-Lower (Roller Chain Models)
Chain Assembly-Link Load
Chain Assembly-Link Load (Zinc Plated)
Nut-Upper Block Stud
Latch Kit-Hook
Washer-Thrust
Actuator-Limit Lever
Grooved Pin (Type F 1/4 x 2 Pltd.)
Qty.
Req’d
1
1
3
1
1
3
2
1
1
1
1
1
1
1
1
As Req’d.
1
1
1
1
1
1
1
1
1
1
* Not available as individual parts. Order upper block assembly, Item 4.
** Load Chain Assemblies listed are for hoists with standard 10 ft. lists. Bulk chain is available in 1 ft. increments and 50 ft.
lengths as follows:
Type Chain
Roller (3/4" Pitch)
Link (5/16" Dia.)
Link (5/16" Dia. Zinc Plate)
Page 34
50' Lengths
Bulk
BH-1067
Not Available
Not Available
BH-1068
BH-1069
BH-1093
To enable us to expedite your
parts order, always give Model
and Catalog Number and Electric
Current of Hoist. (See nameplate.)
11757B
Figure 9-3. UPPER SUSPENSION, LOAD CHAIN AND LOWER BLOCK PARTS
(3 Ton Hoists)
Page 35
Figure 9-3. UPPER SUSPENSION, LOAD CHAIN AND LOWER BLOCK PARTS - Continued
Ref.
No.
Part
Number
1
2
3
BH-1131
BH-1132
905424
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
BH-1134
BH-1135
BH-2214
BH-2217
BH-1138
BH-1139
BH-1029
BH-1030
BH-1142
BH-1143
BH-1144
BH-1145
BH-1146
BH-1147
BH-1148
BH-1149
BH-1150
BH-1151
BH-1152
BH-1153
See Fig. 9-4
BH-2210
BH-1154
BH-1099
BH-1185
Description
Suspension Pin and Nut Assembly
Spherical Washer
Suspension Lug Kit
(Includes Items 1, 2, 4 and 26)
Pin - Grooved (Type A 3/16 x 2 Pltd.)
Hook/Latch and Nut (Includes Item 6)
Latch Kit, Hook
Washer, Thrust
Hanger
Connecting Rod Assembly
Washer, Thrust
Grooved Pin (Type F 3/16 x 1-1 /4 Pltd.)
Pin, Connection
Ring, Retaining
Sprocket & Bushing Assembly (Includes Item 15)
Bushing
Pin, Sprocket
Grooved Pin (Type A 3/16 x 3/8 Pltd.)
Chain Assembly, Coil Load
Link, Connecting
Pin, Anchor
Cotter Pin (3/32 x 3/4)
Dowel Pin (1/2 x 2-1/4)
Ring, Retaining
Block Assembly, Lower, Coil Chain
Washer, Thrust
Washer
Actuator - Limit Lever
Grooved Pin (Type F 1/4 x 2 Pltd.)
Qty.
Req’d
1
1 Pr.
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
2
1
1
1
NOTICE
Always insist on factory approved Yale Hoist replacement parts when servicing this equipment. Parts are
available from your local Authorized Repair Station.
NOTES
Page 36
To enable us to expedite your
parts order, always give Model and
Catalog Number and Electric
Current of Hoist. (See nameplate.)
12444A
Figure 9-4. 2 and 3 TON LOWER BLOCK ASSEMBLIES (Link Chain Hoists)
Ref.
No.
1
2
3
4
5
6
7
9
10
11
12
13
14
15
16
17
18
19
20
21
Part
Number
BH-2219
BH-2218
BH-2202
BH-2203
BH-2204
BH-2205
BH-2206
BH-2207
BH-2208
BH-2210
BH-2211
BH-2212
BH-2213
BH-2214
BH-2215
BH-2216
BH-2217
BH-2220
BH-2221
BH-2222
BH-2223
BH-2224
BH-2225
Description
Block Assembly-Lower Complete
Block Assembly-Lower Complete
Guide-Center
Lock-Sprocket Pin
Sprocket-Coil Chain
Bushing-Sprocket
Screw-Fillister Head, Self locking
Pin-Sprocket
Fitting-Hydraulic Drive
Washer, Thrust
Body Assembly-Lower Block
Hook/Latch and Nut (Includes Items 12, 13 and 15)
Latch Kit, Hook
Latch Kit, Hook
Pin, Grooved
Shroud
Washer, Thrust
Hook/Latch and Nut (Includes Items 12 and 17)
Pin, Grooved
Shield, Bearing
Bearing Assembly-Needle, Thrust
Washer, Thrust
Body-Lower Block
Quantity Required
2 Ton
3 Ton
1
—
1
1
1
1
1
1
1
1
—
—
1
—
—
—
—
1
1
1
1
2
1
—
1
1
1
1
1
1
1
1
1
1
1
—
1
1
1
1
—
—
—
—
—
—
Page 37
To enable us to expedite your
parts order, always give Model and
Catalog Number and Electric
Current of Hoist. (See nameplate.)
10263B
Figure 9-5. 2 TON LOWER BLOCK ASSEMBLY (Roller Chain Hoists)
Ref.
No.
Part
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
BH-2301
BH-2302
BH-2303
BH-2304
BH-2305
BH-2208
BH-2307
BH-2308
BH-2311
BH-2312
BH-2313
BH-2315
BH-2308
BH-2213
Description
Block Assembly-Lower, Complete
Washer-Spring Thrust
Sprocket-Chain
Bearing Assembly-Needle
Ring-Retaining, External
Fitting-Hydraulic Drive
Pin-Sprocket
Hook and Nut Assembly-Lower Block (Includes Item 12 below)
Pin-Grooved
Shroud
Washer-Thrust
Body Assembly
Hook and Nut Assembly
Latch Kit-Hook
NOTICE
Always insist on factory approved Yale Hoist replacement parts when servicing this equipment. Parts are
available from your local Authorized Repair Station.
Page 38
Qty.
Req’d
1
2
1
1
2
1
1
1
1
1
1
1
1
1
To enable us to expedite your
parts order, always give Model and
Catalog Number and Electric
Current of Hoist. (See nameplate.)
11898
Figure 9-6. GEARING AND LOAD BRAKE PARTS (1/4 and 1/2 Ton Hoists)
Ref.
No.
Part
Number
1
2
3
4
5
6
BH-1201
BH-1202
BH-1203
BH-1237
BH-1205
BH-1206
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
BH-1207
BH-1208
BH-1209
BH-1210
BH-1239
BH-1212
BH-1213
BH-1214
BH-1216
BH-1240
BH-1241
BH-1242
BH-1218
BH-1238
BH-1219
BH-1220
BH-1221
BH-1222
BH-1223
BH-1224
BH-1225
BH-1226
BH-1227
Description
Seal-Oil, motor shaft
Bearing Assembly-Ball, motor shaft
Ring-Retaining, Internal
Bearing Assembly-Needle, 11/16" I.D. (36 rollers, grease retained)
Bearing-Thrust, bronze
Washer-Thrust, 11/16" I. D. (Used with 14 tooth Pinion Load Brake
Shaft-13H-1207 below)
Shaft & Integral Pinion-load brake,
14 teeth
23 teeth
36 teeth
Key-Woodruff
Retainer-Spring, load brake
Spring-load brake (Plain-no color code)
Spring-load brake (Yellow color code)
Pin-Grooved
Cam-load brake
Gear & Clutch Assembly-load brake
For use with 1/4 H.P. Motor
For use with 1 /2 H.P. Motor
For use with 1 H.P. Motor
Disc-Friction, load brake
Bushing—Ratchet
Flange—load brake
Bearing Assembly-Needle, 5/8" I.D.
Washer-Thrust, 5/8" I.D.
Ring-Snap, brake flange
Pawl & Ratchet Assembly-load brake (includes item 15)
Ring-Snap, sprocket gear
Gear-Sprocket
74 teeth
65 teeth
52 teeth
Qty.
Req’d
1
1
1
1
1
1
1
2
1
1
1
2
1
1
2
2
1
1
1
1
1
1
1
(Continued on following page)
Page 39
Figure 9-6. GEARING AND LOAD BRAKE PARTS - Continued
Ref.
No.
23
24
25
26**
27
28**
29**
30
31
32**
33**
34**
Part
Number
BH-1228
BH-1229
BH-1230
BH-1231
BH-1232
BH-1318
BH-1233
BH-1234
BH-1235
BH-1236
BH-1315
BH-1316
BH-1317
Description
Screw - Fillister Head Machine
Lockwasher- Spring Type
Plate - Retainer, Sprocket Bearing
Gasket - Ring, Sprocket Bearing
Bearing Assembly- Ball, Sprocket
Ball Bearing On Later Model Hoists
Sprocket-Coil Chain (1/4" Dia. Wire)
Sprocket - Roller Chain (5/8" Pitch)
Bearing Assembly - Ball, Sprocket
Key - Woodruff
O-Ring
Seal Disk
Seal - Oil
Qty.
Req’d
4
4
1
1
1
1
1
1
1
1
1
1
1
* This gear and clutch assembly should not be field disassembled. Replace assembly only as clutch pressure is preset at factory based on
hoist capacity and motor H.P.
** On later model hoists; Ref. No. 26 is replaced by Ref. Nos. 32, 33 and 34 and BH-1233 and BH-1234 are replaced by BH-1311 and BH-1313.
NOTES
Page 40
To enable us to expedite your
parts order, always give Model and
Catalog Number and Electric
Current of Hoist. (See nameplate.)
11899
Figure 9-7. GEARING AND LOAD BRAKE PARTS (1 thru 3 Ton Hoists)
Ref.
No.
Part
Number
1
2
3
4
5
6
7
8
9
10
11
BH-1201
BH-1202
BH-1203
BH-1220
BH-1221
BH-1222
BH-1219
BH-1218
BH-1223
BH-1238
12
13
14
15
16
17***
18
19
20
21
22
23
24
25
26
27
28**
29
BH-1241
BH-1242
BH-1212
BH-1216
BH-1239
BH-1210
BH-1207
BH-1208
BH-1206
BH-1205
BH-1204
BH-1214
BH-1224
BH-1225
BH-1226
BH-1236
BH-1304
BH-1237
BH-1305
BH-1306
BH-1307
BH-1228
Description
Seal-Oil, motor shaft
Bearing Assembly-Ball, motor shaft
Ring-Retaining, Internal
Bearing Assembly-Needle, 5/8" I.D.
Washer-Thrust, 5/8" I.D.
Ring-Snap, brake flange
Flange-Load Brake
Disc-Friction, load brake
Pawl and Ratchet Assembly-Load Brake (includes item 15)
Bushing-Ratchet
Gear and Clutch Assembly-Load Brake
For use with 1 /2 H.P. Motor
For use with 1 and 2-1/2 H.P. Motors
Spring-Load Brake (Plain-no color code)
Cam-Load Brake
Retainer-Spring, Load Brake
Key-Woodruff
Shaft and Integral Pinion-Load Brake
14 teeth
23 teeth
Washer-Thrust, 11/16" I.D.
Bearing-Thrust, bronze
Bearing Assembly-Needle, 11 /16" I.D.
Pin-Grooved
Ring-Snap, intermediate gear
Gear-Intermediate
74 teeth
65 teeth
Key-Woodruff
Shaft and Integral Pinion-Intermediate
Bearing Assembly-Needle, 11/16" I.D.
Ring-Snap, sprocket gear
Gear-Sprocket
Spacer-Sprocket Gear
Screw-Fillister Head Machine
Qty.
Req’d
1
1
1
2
2
1
1
2
1
1
1
1
1
1
2
1
2
1
1
2
1
1
1
1
1
1
1
1
4
(Continued on following page)
Page 41
Figure 9-7. GEARING AND LOAD BRAKE PARTS - Continued
Ref.
No.
Part
Number
30
31
32**
33
BH-1229
BH-1230
BH-1231
BH-1232
BH-1318
BH-1308
BH-1309
BH-1311
34
35**
36**
37
38**
39**
40**
BH-1312
BH-1310
BH-1313
BH-1314
BH-1235
BH-1315
BH-1316
BH-1317
Description
Lockwasher - Spring Type
Plate - Retainer, Sprocket Bearing
Gasket - Ring, Sprocket Bearing
Bearing Assembly - Ball, Sprocket
Ball Bearing On Later Model Hoists
Key -Woodruff, Sprocket
Sprocket - Coil Chain
Later Model Hoists:
1/4" Dia. Wire
5/16" Dia. Wire
Sprocket - Roller Chain
Later Model Hoists:
5/8" Pitch
3/4" Pitch
Bearing Assembly - Ball, Sprocket
O-Ring
Seal Disk
Seal - Oil
Qty.
Req’d
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
* This gear and clutch assembly should not be field disassembled. Replace assembly only as clutch pressure is preset at factory based on
hoist capacity and motor H.P.
** On later model hoists; Ref. No. 28 is not used, Ref. No. 32 is replaced by Ref. Nos. 38, 39 and 40 and BH-1309 and BH-1310 are replaced
by BH-1311 thru BH-1314 as shown above.
*** Ref. No. 17 occurs next to Ref. No. 16 for 14 tooth pinion load brake shaft only.
Later model hoists are hoists starting with model number 116887
NOTES
Page 42
To enable us to expedite your
parts order, always give Model and
Catalog Number and Electric
Current of Hoist. (See nameplate.)
11900J
Figure 9-8A. ELECTRICAL CONTROL UNITS (Three phase Single Speed Hoists - Later Version)
Ref.
No.
1
2
3
4
5
6
7
8
Part
Number
BH-3800
BH-3801
BH-3802
BH-2155
BH-3803
BH-3804
BH-2189
BH-2161
BH-2162
See Fig. 9-11
BH-2166
BH-3805
BH-2168
BH-2169
BH-3806
BH-2172
Description
Contactor and Mounting Plate Assembly (Includes Ref. Nos. 1, 3 and 4)
Three Phase 24V Control
Three Phase 115V Control
Mounting Plate - Contactor
Sems Round Head Machine Screw with External Lock Washer (#10-24 x 3/8)
Contactor Assembly
Three Phase 24V Control
Three Phase 115V Control
Pan Head Self Tapping Screw (#8-32 x 1/2)
Hex Socket Head Cap Screw (#10-24 x 3/8 Pltd.)
Regular Helical Spring Lock Washer (#10 Pltd.)
Limit Switch and Shaft Assembly
Transformer
Three Phase 208V/24V
Three Phase 230V/460V/24V
Three Phase 575V/24V
Three Phase 208V/115V
Three Phase 230V/460V/115V
Three Phase 575V/115V
Qty.
Req’d
1
1
5
1
2
2
2
1
1
(Continued on following page)
Page 43
Figure 9-8A. ELECTRICAL CONTROL UNITS - Continued
Ref.
No.
9
10
11
12
13
Part
Number
BH-2173
BH-2174
BH-2175
See Fig. 9-12
BH-2176
BH-2177
14
15
16
17
18
BH-2178
BH-2179
BH-3807
BH-2181
BH-2182
BH-3808
BH-1422
Description
Sems Round Head Machine Screw with External Lock Washer (1/4-20 x 5/8)
Plain Washer (Type N 1/4)
Grommet
Push Button Station and Conductor Cable Assembly
Fuse, Fuse Holder and Wire Assembly
3A/250V
1/2A/250V
Fuse Only
3A/250V Rating
1/2A/250V Rating
Block-Terminal
Spacer-Terminal Block
Regular Helical Spring Lock Washer (#8 Pltd.)
Round Head Machine Screw (#8-32 x 1 Pltd.)
Flanged Sleeve Bearing
Note: Replacement fuses are standard automotive type and may be purchased locally.
NOTES
Page 44
Qty.
Req’d
1
2
1
1
1
1
1
1
2
2
2
1
To enable us to expedite your
parts order, always give Model and
Catalog Number and Electric
Current of Hoist. (See nameplate.)
11900F
Figure 9-8. ELECTRICAL CONTROL UNITS (Three phase Single Speed Hoists - Earlier Version)
Ref.
No.
1
2
3
4
5
6
7
8
Part
Number
BH-2150
BH-2151
BH-2154
BH-2155
BH-2156
BH-2157
BH-2160
BH-2161
BH-2162
See Fig. 9-11
BH-2166
BH-2164
BH-2167
BH-2168
BH-2169
BH-2170
BH-2171
BH-2172
Description
Contactor and Mounting Plate Assembly (Includes Ref. Nos. 1, 3 and 4)
Three Phase 24V Control
Three Phase 115V Control
Mounting Plate-Contactor
Sems Round Head Machine Screw with External Lock Washer (#10-24 x 3/8)
Contactor Assembly
Three Phase 24V Control
Three Phase 115V Control
Round Head Machine Screw (#8-32 x 1/2)
Hex Socket Head Cap Screw (#10-24 x 3/8 Pltd.)
Regular Helical Spring Lock Washer (#10 Pltd.)
Limit Switch and Shaft Assembly
Transformer
Three Phase 200V/24V
Three Phase 230V/24V
Three Phase 460V/24V
Three Phase 575V/24V
Three Phase 200V/115V
Three Phase 230V/115V
Three Phase 460V/115V
Three Phase 575V/115V
Qty.
Req’d
1
1
4
1
2
2
2
1
1
(Continued on following page)
Page 45
Figure 9-8. ELECTRICAL CONTROL UNITS - Continued
Ref.
No.
9
10
11
12
13
Part
Number
BH-2173
BH-2174
BH-2175
See Fig. 9-12
BH-2176
BH-2177
14
15
16
17
18
BH-2178
BH-2179
BH-2180
BH-2181
BH-2182
BH-2183
BH-1422
Description
Sems Round Head Machine Screw with External Lock Washer (1 /4-20 x 5/8)
Plain Washer (Type N 1/4)
Grommet
Push Button Station and Conductor Cable Assembly
Fuse, Fuse Holder and Wire Assembly
3A/24V
1/2A/115V
Fuse Only
3A/250V Rating
1/2A/250V Rating
Block-Terminal
Spacer-Terminal Block
Regular Helical Spring Lock Washer (#8 Pltd.)
Round Head Machine Screw (#8-32 x 1 Pltd.)
Flanged Sleeve Bearing
Note: Replacement fuses are standard automotive type and may be purchased locally.
NOTES
Page 46
Qty.
Req’d
1
1
1
1
1
1
1
2
2
2
1
To enable us to expedite your
parts order, always give Model and
Catalog Number and Electric
Current of Hoist. (See nameplate.)
11900K
Figure 9-9A. ELECTRICAL CONTROL UNITS (Two Speed Hoists Only - Later Version)
Ref.
No.
1
2
Part
Number
BH-3800
BH-3801
BH-3802
BH-2155
3
4
5
6
7
8
BH-3803
BH-3804
BH-2189
BH-2161
BH-2162
See Fig. 9-11
9
BH-2166
BH-2164
BH-2167
BH-2168
BH-2169
BH-2170
BH-2171
BH-2172
BH-2173
10
11
BH-2174
See Fig. 9-13
Description
Contractor and Mounting Plate Assembly (Includes Ref. Nos. 1, 3 and 4)
Three Phase 24V Control
Three Phase 115V Control
Mounting Plate - Contactor
Sems Round Head Machine Screw with External Lock
Washer (#10-24 x 3/8)
Contactor Assembly
Three Phase 24V Control
Three Phase 115V Control
Pan Head Self Tapping Screw (#8-32 x 1/2)
Hex Socket Head Cap Screw (#10-24 x 3/8 Pltd.)
Regular Helical Spring Lock Washer (#10 Pltd.)
Limit Switch and Shaft Assembly
Transformer
Three Phase 208V/24V
Three Phase 230V/24V
Three Phase 460V/24V
Three Phase 575V/24V
Three Phase 208/115V
Three Phase 230V/115V
Three Phase 460V/115V
Three Phase 575V/115V
Sems Round Head Machine Screw with External Lock
Washer (1/4-20 x 5/8)
Plain Washer (Type N 1/4)
Push Button Station and Conductor Cable Assembly
Qty.
Req’d
1
1
5
1
2
2
2
1
1
1
2
1
(Continued on following page)
Page 47
Figure 9-9A. ELECTRICAL CONTROL UNITS - Continued
Ref.
No.
Part
Number
12
BH-2176
BH-2177
BH-2178
BH-2179
13
14
BH-3809
BH-3810
BH-3811
BH-2193
15
16
17
BH-3812
BH-3813
BH-2199
BH-1422
Description
Fuse, Fuse Holder and Wire Assembly
3A/250V
1/2A/250V
Fuse Only
3A/250V Rating
1/2A/250V Rating
Contactor and Mounting Plate Assembly (Includes
Ref. Nos. 13, 15 and 16)
Three Phase 24V Control
Three Phase 115V Control
Mounting Plate - Contactor
Sems Round Head Machine Screw with External Lock
Washer (#8-32 x 1/2)
Contactor Assembly
Three Phase 24V Control
Three Phase 115V Control
Pan Head Self Tapping Screw (#8-32 x 3/8)
Flanged Sleeve Bearing
Note: Replacement fuses are standard automotive type and may be purchased locally.
NOTES
Page 48
Qty.
Req’d
1
1
1
1
2
1
2
1
To enable us to expedite your
parts order, always give Model and
Catalog Number and Electric
Current of Hoist. (See nameplate.)
11900G
Figure 9-9. ELECTRICAL CONTROL UNITS (Two Speed Hoists Only - Earlier Version)
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
Part
Number
BH-2150
BH-2151
BH-2154
BH-2155
BH-2156
BH-2157
BH-2160
BH-2161
BH-2162
See Fig. 9-11
BH-2166
BH-2164
BH-2167
BH-2168
BH-2169
BH-2170
BH-2171
BH-2172
BH-2173
BH-2174
See Fig. 9-13
Description
Contactor and Mounting Plate Assembly (Includes Ref. Nos. 1, 3 and 4)
Three Phase 24V Control
Three Phase 115V Control
Mounting Plate - Contactor
Sems Round Head Machine Screw with External Lock Washer (#10-24 x 3/8)
Contactor Assembly
Three Phase 24V Control
Three Phase 115V Control
Round Head Machine Screw (#8-32 x 1/2)
Hex Socket Head Cap Screw (#10-24 x 3/8 Pltd.)
Regular Helical Spring Lock Washer (#10 Pltd.)
Limit Switch and Shaft Assembly
Transformer
Three Phase 200V/24V
Three Phase 230V/24V
Three Phase 460V/24V
Three Phase 575V/24V
Three Phase 200V/115V
Three Phase 230V/115V
Three Phase 460V/115V
Three Phase 575V/115V
Sems Round Head Machine Screw with External Lock Washer (1 /4-20 x 5/8)
Plain Washer (Type N 1/4)
Push Button Station and Conductor Cable Assembly
Qty.
Req’d
1
1
4
1
2
2
2
1
1
1
1
1
(Continued on following page)
Page 49
Figure 9-9. ELECTRICAL CONTROL UNITS - Continued
Ref.
No.
Part
Number
12
BH-2176
BH-2177
BH-2178
BH-2179
13
14
15
16
17
BH-2190
BH-2191
BH-2192
BH-2193
BH-2194
BH-2195
BH-2196
BH-1422
Description
Fuse, Fuse Holder and Wire Assembly
3A/24V
1/2A/115V
Fuse Only
3A/250V Rating
1/2A/250V Rating
Contactor and Mounting Plate
Assembly (Includes Ref. Nos. 13, 15 and 16)
Three Phase 24V Control
Three Phase 115V Control
Mounting Plate-Contactor
Sems Round Head Machine Screw with External Lock Washer (#8-32 x 1/2)
Contactor Assembly
Three Phase 24V Control
Three Phase 115V Control
Pan Head Self Tapping Screw (#8-32 x 1/2 Pltd.)
Flanged Sleeve Bearing
Note: Replacement fuses are standard automotive type and may be purchased locally.
NOTES
Page 50
Qty.
Req’d
1
1
1
1
2
1
2
1
To enable us to expedite your
parts order, always give Model and
Catalog Number and Electric
Current of Hoist. (See nameplate.)
11900J
Figure 9-10A. ELECTRICAL CONTROL UNITS (Single Phase Hoists - Later Version)
Ref.
No.
Part
Number
BH-3800
BH-3801
BH-3814
1
2
BH-3815
BH-3802
BH-2155
3
BH-3803
BH-3804
BH-3816
4
5
6
7
8
9
BH-3817
BH-2189
BH-2161
BH-2162
See Fig. 9-11
BH-3818
BH-3819
BH-2173
Description
Contractor and Mounting Plate Assembly (Includes Ref. Nos. 1, 3 and 4)
1/4, 1/2 & 1 HP
Single Phase 24V Control
Single Phase 115V Control
2-1/4 HP Only
Single Phase 24V Control
Single Phase 115V Control
Mounting Plate - Contactor
Sems Round Head Machine Screw with External Lock
Washer (#10-24 x 3/8)
Contactor Assembly
1/4, 1/2 & 1 HP
Single Phase 24V Control
Single Phase 115V Control
2-1/4 HP Only
Single Phase 24V Control
Single Phase 115V Control
Pan Head Self Tapping Screw (#8-32 x 1/2)
Hex Socket Head Cap screw (#10-24 x 3/8 Pltd.)
Regular Helical Spring Lock Washer (#10 Pltd.)
Limit Switch and Shaft Assembly
Transformer
Single Phase 115V/230V/24V
Single Phase 115V/230V/115V
Sems Round Head Machine Screw with External Lock
Washer (1/4-20 x 5/8)
Qty.
Req’d
1
1
4
1
2
2
2
1
1
1
(Continued on following page)
Page 51
Figure 9-10. ELECTRICAL CONTROL UNITS - Continued
Ref.
No.
10
11
12
13
Part
Number
BH-2174
BH-2175
See Fig. 9-12
BH-2176
BH-2177
14
15
16
17
18
BH-2178
BH-2179
BH-3807
BH-2181
BH-2182
BH-3820
BH-1422
Description
Plain Washer (Type N 1/4)
Grommet
Push Button Station and Conductor Cable Assembly
Fuse, Fuse Holder and Wire Assembly
3A/250V
1/2A/250V
Fuse Only
3A/250V Rating
1/2A/250V Rating
Block-Terminal
Spacer-Terminal Block
Regular Helical Spring Lock Washer (#8 Pltd.)
Pan Head Self Tapping Screw (#8-32 x 5/8 Pltd.)
Flanged Sleeve Bearing
Note: Replacement fuses are standard automotive type and may be purchased locally.
NOTES
Page 52
Qty.
Req’d
2
1
1
1
1
1
2
2
2
1
To enable us to expedite your
parts order, always give Model and
Catalog Number and Electric
Current of Hoist. (See nameplate.)
11900H
Figure 9-10. ELECTRICAL CONTROL UNITS (Single Phase Hoists - Earlier Version)
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Part
Number
BH-3101
BH-2154
BH-2155
BH-3102
BH-3103
BH-2161
BH-2162
See Fig. 9-11
BH-2173
BH-2174
BH-2175
See Fig. 9-12
BH-3104
BH-3105
BH-3106
BH-3107
BH-3108
BH-3109
BH-3110
BH-3111
BH-3112
BH-3113
BH-3114
BH-3115
BH-1422
Description
Contactor and Mounting Plate Assembly (Includes Ref. Nos. 1, 3 and 4)
Mounting Plate-Contactor
Sems Round Head Machine Screw with External Lock Washer (#10-24 x 3/8)
Contactor Assembly
Pan Head Self Tapping Screw (#8-32 x 1/2 Pltd.)
Hex Socket Head Cap Screw (#10-24 x 3/8 Pltd.)
Regular Helical Lock Washer (#10 Pltd.)
Limit Switch and Shaft Assembly
Sems Round Head Machine Screw with External Lock Washer (1/4-20 x 5/8)
Plain Washer (Type N 1/4)
Grommet
Push Button Station and Conductor Cable Assembly
Mounting Plate-Terminal Board
Pan Head Self Tapping Screw (#10-24 x 3/8 Pltd.)
Terminal Block
Pan Head Self Tapping Screw (8-32 x 1/2 Pltd.)
Mounting Bracket-Starting Switch
Pan Head Self Tapping Screw (#6-32 x 3/8 Pltd.)
Starting Switch
1/4 Horsepower
1/2 Horsepower
1 Horsepower
Round Head Machine Screw (#6-32 x 5/16 Pltd.)
Fuse, Fuse Holder and Wire Assembly (1/2A/250V)
Fuse Only (1/2A/250V Rating)
Flanged Sleeve Bearing
Qty.
Req’d
1
1
4
1
2
2
2
1
1
1
1
1
1
2
1
2
1
2
1
1
1
1
1
Note: Replacement fuses are standard automotive type and may be purchased locally.
Page 53
To enable us to expedite your
parts order, always give Model and
Catalog Number and Electric
Current of Hoist. (See nameplate.)
11901A
Figure 9-11. LIMIT LEVER AND SWITCH PARTS
Ref.
No.
Part
Number
BH-1850
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Page 54
BH-1851
BH-1852
BH-1853
BH-1854
BH-1855
BH-1856
BH-1857
BH-1858
BH-1859
BH-1860
BH-1861
BH-1862
BH-1863
BH-1864
BH-1865
BH-1866
BH-1867
BH-1868
BH-1869
BH-1870
Description
Limit Switch and Shaft Assembly (Includes
Ref. Nos. 1 thru 14 and 17 and 18)
Light Hex Self-locking Nut (#4-40 Pltd.)
Retainer
Insulation
Limit Switch-Upper
Limit Switch-Lower
Insulation
Plate-Cover
Round Head Machine Screw (#40-40 x 1-1/8 Pltd.)
Light Thin Hex Self-locking Nut (#10-24 Pltd.)
Plain Washer (#10 Pltd.)
Switch Actuator
Centering Lever
Spring-Control
Spacer
Hex Socket Head Cap Screw (#10-24 x 3/8 Pltd.)
Regular Helical Spring Lock Washer (#10 Pltd.)
Plain Washer (Type N 5/16 Pltd.)
Control Shaft
Key-Woodruff
Limit Lever
Qty.
Req’d
1
2
1
2
1
1
1
1
2
1
1
1
1
1
1
2
2
1
1
1
1
To enable us to expedite your
parts order, always give Model and
Catalog Number and Electric
Current of Hoist. (See nameplate.)
12763
Figure 9-12. PUSH BUTTON STATION AND CONDUCTOR CABLE ASSEMBLY (Single Speed Hoists)
Ref.
No.
Part
Number
BH-3401
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
BH-3402
*
*
*
BH-3403
*
BH-3404
BH-3405
*
*
*
*
*
*
BH-3406
*
BH-3407
BH-3408
Description
Push Button Station and Conductor Cable Assembly
(Includes Ref. Nos. 1 thru 17)
Push Button Station (Includes Ref. Nos. 1 thru 15)
Type 1 Pan Head Machine Screw (M3.5 x 0.6 x 12 Pltd.)
Lockwasher (M 3.5 Pltd.)
Rear Cover
Gasket
Type l Pan Head Thread Cutting Screw (M 4 x 15 Pltd.)
Contact Assembly
Button Assembly
Type 1 Pan Head Machine Screw (M 6 x 1 x 12 Pltd.)
Lockwasher (M 6 Pltd.)
Plain Washer (M 6 Pltd.)
Type 1 Pan Head Machine Screw (M 3.5 x 1 x 14 Pltd.)
Lockwasher (M 3.5 Pltd.)
Housing Cap
Grommet
Housing
Conductor Cable Assembly
Plastic Warning Tag
Qty.
Req’d
1
1
7
7
1
1
2
1
1
1
1
1
2
2
1
1
1
1
1
* Not available separately. Order Push Button Station.
Page 55
NOTES
Page 56
To enable us to expedite your
parts order, always give Model and
Catalog Number and Electric
Current of Hoist. (See nameplate.)
12721A
Figure 9-13A. PUSH BUTTON STATION AND CONDUCTOR CABLE ASSEMBLY
(Two Speed Hoists Only - Later Version)
Ref.
No.
Part
Number
BH-1980
1
7
11
12
13
14
15
16
17
18
19
20
BH-1981
BH-1982
BH-1971
BH-1972
BH-1973
*
*
*
*
*
*
*
*
Description
Push Button Station and Conductor Cable Assembly
(Includes Ref. Nos. 1 thru 30)
Grommet
Conductor Cable
Operator Warning Label
Push Button Station (Includes Ref. Nos. 12 thru 30)
Sleeve - Conductor
Support - Strain Cable
Screw - Slotted Head
Lockwasher
Enclosure - Rear
Gasket
Screw - Slotted Head
Screw - Slotted Head
Clamp - Conductor
Qty.
Req’d
1
1
1
1
1
1
1
4
4
1
1
2
2
1
(Continued on following page)
Page 57
Figure 9-13A. PUSH BUTTON STATION AND CONDUCTOR CABLE ASSEMBLY - Continued
Ref.
No.
21
22
23
24
25
26
27
28
29
30
Part
Number
*
BH-1974
BH-1975
*
BH-1976
BH-1977
**
*
**
**
**
**
**
**
Description
Contact Block Assembly
Contact Block
Contact Block
Interlock - Mechanical
Up Push Button Assembly (Includes 1 Each of Ref. Nos. 23 and 25 thru 29)
Down Push Button Assembly (Includes 1 Each of Ref. Nos. 23, 25 thru 28 and 30)
Ring - Retaining
Enclosure - Front
Seat - Spring
Spring
Seal
Plate - Push Button
Push Button - Up
Push Button - Down
* Not available separately. Order Push Button Station.
** Not available separately. Order Push Button Assembly.
NOTES
Page 58
Qty.
Req’d
1
2
2
1
1
1
2
1
2
2
2
2
1
1
To enable us to expedite your
parts order, always give Model and
Catalog Number and Electric
Current of Hoist. (See nameplate.)
12721
Figure 9-13. PUSH BUTTON STATION AND CONDUCTOR CABLE ASSEMBLY
(Two Speed Hoists Only - Earlier Version)
Ref.
No.
Part
Number
BH-1960
1
2
3
4
5
6
7
8
9
10
11
BH-1961
BH-1962
BH-1963
BH-1964
BH-1965
BH-1966
BH-1967
BH-1968
BH-1969
BH-1970
BH-1971
BH-1972
Description
Push Button Station and Conductor Cable
Assembly (Includes Ref. Nos. 1 thru 30)
Anchor Bracket-Strain Cable
Grip Assembly-Conductor
Connector-Strain Cable
Thimble-Strain Cable
Connector-Conductor to Strain Cable
Clamp-Conductor
Conductor Cable
Strain Cable
Sleeve-Pressure
Tie-Conductor
Operator Warning Label
Push Button Station (Includes Ref. Nos. 12 thru 30)
Qty.
Req’d
1
1
1
1
2
1
1
1
1
1
As Req’d.
1
1
(Continued on following page)
Page 59
Figure 9-13. PUSH BUTTON STATION AND CONDUCTOR CABLE ASSEMBLY - Continued
Ref.
No.
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Part
Number
BH-1973
*
*
*
*
*
*
*
*
*
BH-1974
BH-1975
*
BH-1976
BH-1977
**
**
**
**
**
**
**
**
Description
Sleeve-Conductor
Support-Strain Cable
Screw-Slotted Head
Lockwasher
Enclosure-Rear
Gasket
Screw-Slotted Head
Screw-Slotted Head
Clamp-Conductor
Contact Block Assembly
Contact Block (ZB2-BE101)
Contact Block (ZB2-BE201)
Interlock-Mechanical
Up Push Button Assembly (Includes 1 Each of Ref. Nos. 23 and 25 thru 29)
Down Push Button Assembly (Includes 1 Each of Ref. Nos. 23, 25 thru 28 and 30)
Ring-Retaining
Enclosure-Front
Seat-Spring
Spring
Seal
Plate-Push Button
Push Button-Up
Push Button-Down
* Not available separately. Order Push Button Station.
** Not available separately. Order Push Button Assembly.
NOTES
Page 60
Qty.
Req’d
1
1
4
4
1
1
2
2
1
1
2
2
1
1
1
2
1
2
2
2
2
1
1
To enable us to expedite your
parts order, always give Model and
Catalog Number and Electric
Current of Hoist. (See nameplate.)
12724B
Figure 9-14A. SINGLE PHASE MOTOR ASSEMBLY - Later Version
Ref.
No.
1
2
3
4
5
6
7
8
Part
Number
BH-3900
BH-3901
BH-3902
BH-3903
BH-3904
BH-3905
BH-3906
BH-3907
BH-3908
*
*
BH-3909
BH-3910
BH-3911
BH-3912
9
BH-3913
BH-3914
BH-3915
BH-3916
10
11
12
BH-3917
BH-3918
BH-3919
BH-3919
BH-3919
BH-3920
BH-3921
BH-3922
Description
Motor Assembly (Includes Ref. Nos. 1 thru 12)
1/4 Horsepower
1/2 Horsepower
1 Horsepower
2-1/4 Horsepower
Bell - End
Ring - Retaining
Bearing - Ball
Ring - Retaining
Key - Brake
Rotor and Shaft Assembly
Stator Assembly
Bolt - Motor Mounting
1/4 Horsepower
1/2 Horsepower
1 Horsepower
2-1/4 Horsepower
Capacitor Assembly
1/4 Horsepower
1/2 Horsepower
1 Horsepower
2-1/4 Horsepower
Cover
For Ref. No. 9
1/4 Horsepower
1/2 Horsepower
1 Horsepower
2-1/4 Horsepower
For Ref. No. 12
Slotted Hex Head Self Tapping Screw (#8-32 x 5/16)
Solid State Switch Assembly
1/4, 1/2 & 1 Horsepower
2-1/4 Horsepower
Qty.
Req’d
1
1
1
1
1
1
1
1
4
1
1
2
1
* Furnished only as part of motor assembly.
Page 61
To enable us to expedite your
parts order, always give Model and
Catalog Number and Electric
Current of Hoist. (See nameplate.)
1122255101
1122105101
1122245101
12724A
Figure 9-14. SINGLE PHASE MOTOR ASSEMBLY - (Earlier Version)
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
Part
Number
BH-3001
BH-3002
BH-3003
BH-3004
BH-3005
BH-3006
BH-3007
BH-3008
*
*
BH-3015
BH-3016
BH-3017
BH-3018
BH-3019
BH-3020
Description
Motor Assembly (Includes Ref. Nos. 1 thru 11)
1/4 Horsepower
1/2 Horsepower
1 Horsepower
Bell-End
Ring-Retaining
Bearing-Ball
Ring-Retaining
Key-Brake
Rotor and Shaft Assembly
Stator Assembly
Bolt-Motor Mounting
1/4 Horsepower
1/2 Horsepower
1 Horsepower
Capacitor Assembly
Capacitor Cover
Screw
* Furnished only as part of motor assembly.
NOTES
Page 62
Qty.
Req’d
1
1
1
1
1
1
1
1
4
1
1
2
To enable us to expedite your
parts order, always give Model and
Catalog Number and Electric
Current of Hoist. (See nameplate.)
12724
Figure 9-15. THREE PHASE MOTOR ASSEMBLY
Ref.
No.
Part
Number
BH-3301
BH-3302
BH-3303
BH-3304
BH-3305
BH-3306
BH-3307
BH-3308
BH-3309
BH-2945
BH-2946
BH-2947
BH-2901
BH-2902
BH-2903
BH-2904
BH-2905
BH-2906
BH-2907
BH-2908
BH-2909
BH-2910
BH-2911
BH-2912
1
BH-3310
BH-2913
BH-2913
Description
Motor Assembly (Includes Ref. Nos. 1 thru 8)
1/4 Horsepower (1 Speed)
200 Volt
230/460 Volt
575 Volt
1/2 Horsepower (1 Speed)
200 Volt
230/460 Volt
575 Volt
1 Horsepower (1 Speed)
200 Volt
230/460 Volt
575 Volt
2-1/2 Horsepower (1 Speed)
200 Volt
230/460 Volt
575 Volt
1/2-1/6 Horsepower (2 Speed)
200 Volt
230 Volt
460 Volt
575 Volt
1-1/3 Horsepower (2 Speed)
200 Volt
230 Volt
460 Volt
575 Volt
2-1/4 - 3/4 Horsepower (2 Speed)
200 Volt
230 Volt
460 Volt
575 Volt
Bell - End
1 Speed - 1/4, 1/2 and 1 HP
1 Speed - 2-1/2 HP
2 Speed
Qty.
Req’d
1
1
(Continued on following page)
Page 63
Figure 9-15. THREE PHASE MOTOR ASSEMBLY - Continued
Ref.
No.
Part
Number
2
BH-3311
BH-2914
BH-2914
3
BH-3312
BH-2915
BH-2915
4
BH-3313
BH-2916
BH-2916
5
6
7
8
BH-3314
BH-2917
BH-2917
*
*
BH-3315
BH-2954
BH-2942
Description
Ring - Retaining
1 Speed- 1/4, 1/2 and 1 HP
1 Speed - 2-1/2 HP
2 Speed
Bearing - Ball
1 Speed - 1/4, 1/2 and 1 HP
1 Speed - 2-1/2 HP
2 Speed
Ring - Retaining
1 Speed - 1/4, 1/2 and 1 HP
1 Speed - 2-1/2 HP
2 Speed
Key - Brake
1 Speed - 1/4,1/2 and 1 HP
1 Speed - 2-1/2 HP
2 Speed
Rotor and Shaft Assembly
Stator Assembly
Bolt - Motor Mounting
1 Speed - 1/4, 1/2 and 1 HP
1 Speed - 2-1/2 HP
2 Speed
1
1
1
1
1
1
4
* Furnished only as part of motor assembly.
NOTES
Page 64
Qty.
Req’d
12756G
Figure 9-16A. HOIST MOTOR BRAKE
Ref.
No.
Part
Number
Description
Qty.
Req’d
Motor Brake Assembly (Includes Ref. Nos. 1 thru 31)
BH-3701
BH-3702
BH-3703
1
2
3
BH-3704
BH-3705
*
BH-3706
*
5
6
7
8
*
*
*
*
Hoist Speeds
Motor HP
Voltage
1
1/4, 1/2 & 1
115/230
1
2-1/2
200
2
1 / 1/3
200 & 230
2
2-1/4 / 3/4
200 & 230
1
1/4 & 1/2
200 & 230/460
1
1
200, 230/460 & 575
1
2-1/2
575
2
1/2 / 1/6
200 & 230
2
1 / 1/3
460
2
2-1/4 / 3/4
230/460 & 575
1
1/4 & 1/2
575
2
1/2 / 1/6
460 & 575
2
1 / 1/3
575
1
2-1/2
115/230
1
2-1/2
230/460
Acorn Nut - Plated (#10-32)
Brake Cover Assembly (Includes Brake Cover and Label Inside Cover)
Cover Stud
Phillips Pan Head Self Tapping Screw- Plated (#10-32 x 1-3/4)
Solenoid Frame Cover Assembly
Hex Key (1/8 - 3/4 x 2)
Solenoid Coil Assembly
For BH-3701
For BH-3702
For BH-3703
For BH-3704
For BH-3705
1
2
1
2
1
4
1
1
1
(Continued on following page)
Page 65
Figure 9-16A. HOIST MOTOR BRAKE - Continued
Ref.
No.
9
10
11
12
13
14
15
16
17
18
19**
20**
21
22
23
24
25
26
27
28
29
30
31
Part
Number
*
*
*
*
*
*
BH-3707
*
*
*
*
*
*
*
*
*
*
*
BH-3708
*
*
*
*
Description
Tubing
Hex Nut - Plated (#10-32)
Solenoid Frame
Hex Washer Head Thread Forming Screw - Plated (#10-32 x 3/4)
Rectifier Assembly
Hex Head Self Locking Nut - Plated (#10-32)
Solenoid Support
Hex Washer Head Thread Forming Screw - Plated (#10-32 x 3/4)
Solenoid Plunger
Hex Socket Head set Screw- Oval Point (1/4-28 x 1)
Hex Socket Shoulder Screw (#10-24 x 1)
Hex Self Locking Nut - Plated (#10-24)
Brake Spring
Brake Lever Assembly
Pressure Pad
Brake Disc (Non-asbestos)
Brake Support Stud
Separating Spring
Brake Mounting Plate
Hex Socket Head Self Locking Set Screw - Cup Point (1/4-20 x 3/8
Brake Hub
Hex Socket Head Screw (3/8-16 x 3/4)
Lock Washer (3/8)
Wire Nuts - Not Shown (No. 22 thru 14 AWG)
Qty.
Req’d
3
2
1
1
1
2
1
2
1
1
1
1
1
1
2
1
2
2
1
2
1
2
2
4
* Not available as individual parts. See replacement kits listed below. Kits include quantities shown above.
** On later model hoists Ref. No. 19 is a hex socket head screw (1/4-20 x 1-1/2) and Ref. No. 20 is a hex self locking nut - plated (1/4-20).
Kit Description
Part
Number
Brake Disc
BH-3709
23, 24, 26
Brake Lever
BH-3710
6, 15, 17, 18, 19, 20, 21 (Zinc Color), 22,
Adjusting Screw Label, Brake Adjust Label - Discard Red Spring
Rectifier
BH-3711
12, 13, 4 Wire Nuts
Hardware
BH-3712
1, 3, 4, 5, 7, 9, 10, 12, 16, 18, 20, 25, 28, 30, 31,
Instruction Label, Power Warning Label
Brake Hub
BH-3713
28, 29, Hub Drive Key (Shown Elsewhere)
Solenoid
BH-3714
8 (Order Same Part Number)
Page 66
Reference Numbers Included
NOTES
Page 67
Recommended Spare Parts for Your Yale Hoist
Certain parts of your hoist will, in time, require replacement under normal wear conditions.
It is suggested that the following parts be purchased for your hoist as spares for future use.
Set of Gaskets
Contactor
Set of Bearings
Transformer Fuse
Set of Oil Seals
Limit Lever
Lower Block Assembly
Limit Switch Assembly
Load Chain
Set of Brake Discs for Load Brake
Set of Brake Discs for Motor Brake
Push Button Station & Cable Assembly
Transformer
Note: When ordering parts always furnish Model and Catalog Number of Hoist and lift of hoist on chich the
parts are to be used.
Parts for your hoist are available from your local authorized Yale repair station.
For the location of your nearest repair station, write:
IN USA
YaleŸŸLift-Tech
P.O. Box 769
Muskegon, MI 49443-0769
Phone: 800 742-9269
Fax:
800 742-9270
WARRANTY
WARRANTY AND LIMITATION OF REMEDY AND LIABILITY
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
immediately upon discovery and in any event, within one (1) year from
shipment of the applicable item unless Seller specifically assumes
installation, construction or start-up responsibility. All claims for
defective products or parts when Seller specifically assumes
installation, construction or start-up responsibility and all claims for
defective work must be made in writing immediately upon discovery
and in any event, within one (1) year from completion of the applicable
work by Seller, provided; however, all claims for defective products
and parts made in writing no later than eighteen (18) months after
shipment. Defective items must be held for Seller’s inspection and
returned to the original f.o.b. point upon request. THE ‘FOREGOING
IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES
WHATSOEVER, EXPRESS, IMPLIED AND STATUTORY,
INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES
OF MERCHANTABILITY AND FITNESS.
B. Upon Buyer’s submission of a claim as provided above and its
substantiation, Seller shall at its option either (i) repair or replace its
product, part or work at either the original f.o.b. point of delivery or at
Seller’s authorized service station nearest Buyer or (ii) refund an
equitable portion of the purchase price.
C. This warranty is contingent upon Buyer’s proper maintenance and
care of Seller’s products, and does not extend to normal wear and
tear. Seller reserves the right to void warranty in event of Buyer’s use
of inappropriate materials in the course of repair or maintenance, or
if Seller’s products have been dismantled prior to submission to Seller
for warranty inspection.
D. The foregoing is Seller’s only obligation and Buyer’s exclusive
remedy for breach of warranty and is Buyer’s exclusive remedy
hereunder by way of breach of contract, tort, strict liability or otherwise.
In no event shall Buyer be entitled to or Seller liable for incidental or
consequential damages. Any action for breach of this agreement
must be commenced within one (1) year after the cause of action has
accrued.
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