Yale Y80 Wire Rope Electric Hoist Operation, Service & Parts Manual

OPERATION, SERVICE & PARTS MANUAL

SERIES Y80

YALE

®

WIRE ROPE ELECTRIC HOISTS

Before installing hoist, fill in the information below. Refer to the

Hoist and Motor data plates.

Model No. _________________

Serial No. _________________

Purchase Date _____________

Voltage ___________________

Rated Load _______________

INCLUDING

WEIGHT WATCHER OVERLOAD CLUTCH MODELS

RATED LOADS 1/2 THRU 5 TONS

May, 2003

Printed in U.S.A.

Copyright 2003, Yale•Lift-Tech, division of Columbus McKinnon Corporation Part No. 117404-10

Page 1

FOREWORD

This manual contains important information to help you install, operate, maintain and service your new YALE electric hoist. We recommend that you study its contents thoroughly before putting the hoist into use.

Read ANSI B30.16 safety code for hoists. Then, thru proper installation, application of correct operating procedures and by practicing the recommended maintenance suggestions you can expect maximum lifting service from the hoist.

provided on the front cover of this Manual for entering this information.

We recommend that you fill it out immediately so it is readily at hand when needed.

The contents of this manual are of necessity, general in nature and may cover features not incorporated on your hoist; therefore, the user must exercise care in applying instructions given in this manual. If specific information not in this manual is required, contact the factory at Muskegon, Michigan 49443.

It will likely be a long time before parts information found in Section IX is needed; therefore, after the hoist is installed and you have completely familiarized yourself with operation and preventive maintenance procedures, we suggest that this book be carefully filed for future reference.

When ordering replacement parts from this book, it will be necessary that you include, with your order, the Hoist Serial Number, Model

Number and Catalog Number which is found on the nameplate attached to the hoist electrical cover. For your convenience, a space has been

THE INFORMATION CONTAINED IN THIS MANUAL IS FOR

INFORMATIONAL PURPOSES ONLY AND YALE•LIFT-TECH DOES

NOT WARRANT OR OTHERWISE GUARANTEE (IMPLIEDLY OR

EXPRESSLY) ANYTHING OTHER THAN THE COMPONENTS THAT

YALE•LIFT-TECH MANUFACTURES AND ASSUMES NO LEGAL

RESPONSIBILITY (INCLUDING, BUT NOT LIMITED TO

CONSEQUENTIAL DAMAGES) FOR INFORMATION CONTAINED IN

THIS MANUAL.

NOTICE: Information contained in this book is subject to change without notice.

INDEX

SECTION I GENERAL DESCRIPTION Page

Paragraph 1-1 General ................................................................................................................................................................. 3

Paragraph 1-2 Basic Construction ............................................................................................................................................... 3

Paragraph 1-3 Differences Between Models ............................................................................................................................... 3

SECTION II INSTALLATION

Paragraph 2-1 General ................................................................................................................................................................. 3

Paragraph 2-2 Suspending Hoist ................................................................................................................................................. 3

Paragraph 2-3 Connecting Hoist to Electrical Service ................................................................................................................ 4

Paragraph 2-4 Pre-Operation Checks .......................................................................................................................................... 4

SECTION III OPERATION

Paragraph 3-1 General ................................................................................................................................................................. 6

Paragraph 3-2 Push Button Operation ......................................................................................................................................... 6

Paragraph 3-3 Overload Clutch Operation (Optional) ................................................................................................................. 6

Paragraph 3-4 Operating Precautions .......................................................................................................................................... 6

SECTION IV LUBRICATION

Paragraph 4-1 General ................................................................................................................................................................. 7

Paragraph 4-2 Change Gear Case Oil ......................................................................................................................................... 7

Paragraph 4-3 Lubricate Hoist Cable ........................................................................................................................................... 7

Paragraph 4-4 Lubricate Upper Sheave and Lower Block Assembly ......................................................................................... 7

Paragraph 4-5 Lubricate Limit Stop Lever .................................................................................................................................... 8

Paragraph 4-6 Lubricate Limit Switch .......................................................................................................................................... 8

SECTION V INSPECTION AND PREVENTIVE MAINTENANCE

Paragraph 5-1 General ................................................................................................................................................................. 8

Paragraph 5-2 Inspect Lower Block ............................................................................................................................................. 9

Paragraph 5-3 Inspect Upper Block and Hoist Suspension ........................................................................................................ 9

Paragraph 5-4 Inspect Electrical Controls .................................................................................................................................... 9

Paragraph 5-5 Inspect Motor Brake ........................................................................................................................................... 11

Paragraph 5-6 Inspect Mechanical Load Brake, Gearing and Overload Clutch (Optional) ..................................................... 11

Paragraph 5-7 Inspect Rope Drum and Shaft ............................................................................................................................ 13

Paragraph 5-8 Rope Inspection, Maintenance and Replacement ............................................................................................ 14

Paragraph 5-9 Rope Reeving ..................................................................................................................................................... 14

Paragraph 5-10 Testing Hoist and Overload Clutch (Optional) ................................................................................................... 17

SECTION Vl TROUBLE SHOOTING CHART ............................................................................................................................ 19-20

SECTION Vll ADJUSTMENTS

Paragraph 7-1 Mechanical Load Brake ...................................................................................................................................... 21

Paragraph 7-2 Motor Brake ......................................................................................................................................................... 21

Paragraph 7-3 Block Operated Limit Switch .............................................................................................................................. 21

Paragraph 7-4 Screw- Type Limit Switch .................................................................................................................................... 21

Paragraph 7-5 Overload Clutch Adjustment .............................................................................................................................. 22

SECTION VIII WIRING DIAGRAMS

SECTION IX PARTS LIST

Paragraph 9-1 General ............................................................................................................................................................... 22

Paragraph 9-2 List of Parts Illustrations ..................................................................................................................................... 22

No part of this document may be reproduced in any form, in an electronic retrieval system or otherwise, without prior written permission of the publisher.

Page 2

SECTION I — GENERAL DESCRIPTION

1-1. GENERAL. YALE electric hoists are precision built wire rope and drum type hoists which are made in five rated load sizes (1/2, 1, 2, 3 and 5 tons) with various lifts, lifting speeds and electrical service. Equipped with an integrally welded mounting lug, they are designed to be rigidly attached to an overhead structure or mounted on YALE rigid mount trolleys for operation on runway beams. On certain models optional base mounting or other supporting methods may be obtained.

For full information apply to factory at Muskegon, Michigan

49443.

NOTICE

YALE hoists are available with an optional built-in mechanical overload clutch. Hoists having this device are identified with words WEIGHT WATCHER on the hoist.

The WEIGHT WATCHER overload clutch permits operation of your hoist within its rated load and helps prevent lifting of excessive loads which could cause permanent deformation of a properly maintained hoist or trolley.

1-2. BASIC CONSTRUCTION. All models are of the same basic construction and consist of a rugged welded steel frame which houses a lifting drum and serves as the suspension for carrying the entire hoist load. A mounting lug, for attaching the hoist to a trolley or overhead support, is located on top of the frame. An aluminum alloy gearcase and cover, attached to one end of frame, houses a three-reduction gear train and a mechanical load brake. An electric driving motor with disctype motor brake is located beside the frame, face mounted on the back of the gearcase. Electrical system components, located on the end of the frame (opposite gearcase end) and enclosed by a steel cover, control operation and rotating direction of a driving motor. A hoisting rope and an enclosed lower block assembly are used for lifting loads. An upper limit stop is used to limit travel of the lower block in the raising direction, to protect hoist from damage. A push button control station, for operating the hoist, is suspended from the electrical compartment.

1-3. DIFFERENCES BETWEEN MODELS. The main differences between models are in rope reeving and frame size as described below.

a. Rope Reeving. There are four types of rope reeving used:

Two parts of rope single reeved, four parts of rope single reeved, six parts of rope single reeved and two parts of rope double reeved. Single reeved hoists have one end of the rope anchored to the drum, whereas, double reeved hoists have both ends anchored to the drum. On single reeved models, the lower block travels sideways as rope winds on drum, double reeved models offer true ver tical lift. For illustrations, refer to Section V, paragraph 5-9, “Rope Reeving” instructions.

b. Frame Size. Length of frame furnished is dependent on hoist capacity and lift. Four frame lengths are used; short frame, long frame, first and second extensions. Short frame hoists have a rope drum flange to flange distance of approximately 9-3/4", whereas this distance on a long frame hoist is approximately 16-3/4". First extension frame hoists have a flange to flange distance of 22-15/16" and second extensions have 35-3/8".

c. Motor Brake. Hoists are equipped with a disc brake mounted on the motor end bell and operated by a short stroke solenoid.

This brake requires periodic adjustment.

SECTION II — INSTALLATION

2-1. GENERAL. YALE electric hoists are lubricated and tested before being shipped from the factory. To place hoist in service, attach to a suitable suspension (paragraph 2-2), connect to electrical service (paragraph 2-3) and perform pre-operation tests and checks (paragraph 2-4).

WARNING

Before attempting installation of hoist or trolley, the main power switch must be locked in the open position

(off).

2-2. SUSPENDING HOIST. The hoist may be suspended in a fixed location servicing only the area directly below the hoist

(Lug Mounted) or the hoist may be attached to a moveable trolley or trolleys which in turn may be mounted on an l-beam attached to a building or crane, servicing a larger area (Trolley

Mounted).

WARNING

DO NOT use small holes for attaching this hoist unless rated load on lower block is 1 (one) ton (2000 Ibs.) or less.

a. Lug Mounted hoists attach to adequate supports welded or bolted to a building or other structure. The supporting structure must have sufficient strength with appropriate safety factor, to support the weight of the hoist and rated load as well as other loads to which the supporting structure may be subjected.

WARNING

Design and installation of hoist support shall be performed only by qualified persons.

Steel angles or plates used to suspend hoist should be spaced as close to the hoist suspension lug as possible. Mounting bolts or threaded studs, attaching hoist to mounting structure, shall have a diameter not less than recommended by manufacturer and material equivalent to ASTM A 325. Make certain that mounting bolts or studs are long enough so that the threads do not engage the mounting support and that mounting bolts or studs are secured with nuts and lockwashers, self-locking nuts or cross bolting, if unthreaded.

b. Trolley Mounted hoists are attached to moveable trolleys. If the hoist is mounted on an existing trolley, a qualified person shall determine that the trolley and its supporting structure are adequate to support the rated load and weight of the hoist. Hoist/trolley units may be shipped from the factory with trolley packaged separately. If the trolley can be installed directly over the end of the supporting beam, assemble trolley to hoist. Be certain that the spacing between wheel flanges, after assembly, is 1/4" greater than exact width of beam flange. (See Figure 2-1 below and instruction sheet furnished with trolley.) Using proper equipment, carefully lift trolley and hoist and install on end of beam.

Page 3

For trolleys which are to be mounted along the span of a beam not having open ends, measure exact width of beam flange and assemble trolley to hoist so that spacing between wheel flanges is 1/4" (see Figure 2-1) greater than beam width (3/8" if beam has curves). This is accomplished by rearranging the spacer washers on the bolts connecting trolley side plates to hoist mounting lug. If trolley is shipped separate from hoist, see instruction sheets furnished with trolley for orientation and installation.

When proper spacing has been determined, loosen mounting nuts (item 1, Figure 2-1) to allow trolley wheels to spread far enough to pass over edges of beam flange. (Some installations may require complete removal of one trolley side plate.) Using adequate equipment, carefully lift the hoist and trolley so the wheel treads will rest on the lower beam flange. Replace side plate and washers if removed for installation. Replace suspension stud nuts.

CAUTION

Recheck spacer washers to make certain that the number of washers between the side plate and hoist suspension lug are equal, and also the number on the outside of each side plate are equal. The suspension stud nuts should only be snugged up on the lockwashers until a load has been applied on the hook. A partial load (approx. 25% rated hoist load) placed on the hook will properly seat hoist in the trolley. Tighten suspension stud nuts only after hoist has been properly seated in the trolley.

WARNING

Be certain that electrical power supply is off and locked in the open position before attempting any electrical connections to the hoist. This equipment must be effectively grounded according to the National Electric

Code, or other applicable codes. If the grounding method used is through the trolley wheels, then each section of track must be grounded by metal-to-metal connection to the building ground. Cer tain environments may prevent proper grounding by this means. In this case a separate grounding conductor should be provided.

a. Follow National, State and Local Electrical Codes when providing electrical service to the hoist.

CAUTION

208/230/460V single speed motors are reconnectable at the motor. See motor nameplate. Transformer may be reconnected for 200/230/460/575V. See transformer. Check with wiring diagram to make certain that motor, transformer and brake leads are properly connected.

b. Make electrical connections using the appropriate wiring diagrams furnished with the hoist. All electrical connections, including connections to collectors or power cord, shall be made only by qualified journeymen electricians.

WARNING

Mounting of the hoist-trolley unit on the monorail and final pre-operation inspection shall be performed only by qualified persons properly supervised.

11207A

Figure 2-1. Sectional View of Trolley showing proper wheel and washer spacing.

2-3. CONNECTING HOIST TO ELECTRICAL SERVICE.

Electrical service to the hoist may be power cable or a guarded system having sliding shoe collectors.

WARNING

The green wire provided in the power supply cable

(when furnished) is a grounding wire and must be connected to a proper ground.

c. When trolley is shipped separate from hoist, see special instructions fur nished with trolley for or ientation and installation.

2-4. PRE-OPERATION CHECKS.

a. Check Oil Level and Grease Fittings. The gearcase has been filled with oil to the proper level and grease points for lower and upper sheaves have been lubricated at the factory.

However, this should be checked before operating hoist. Check oil level by removing oil level plug with hoist in a level position.

Oil level should be at the bottom edge of the plug hole. If not, add oil as specified in Section IV. Grease fittings in lower and upper sheave pins should show evidence of grease.

CAUTION

Overfilling of the gearcase may result in the excess fluid being expelled through the breather.

Page 4

b. Check Push Button Operation and Phasing.

WARNING

On three phase hoists it is possible to have “Reverse

Phasing” causing the lower block to lower when the

á button is depressed. When this condition exists, the automatic limit stop switch is inoperative and hoist operation will be dangerous.

To properly check the phase of the hoist, follow the steps below:

(1) With “POWER OFF” operate all the push buttons and determine that they do not bind or stick in any position

When floating rod is raised, stop switch is actuated first and then the reversing switch is actuated (Figure 2-3). Stop switch stops hoist. Reversing switch lowers hook block in case of floating rod over-travel. If limit switch does not function in this manner, refer to trouble shooting chart Section Vl for possible remedy.

WARNING

If any push button binds or sticks in any position —

DO NOT TURN POWER ON — determine the cause and correct the malfunction before operating.

(2) Temporarily connect hoist to power source.

(3) Operate á button briefly to determine direction of hook travel.

(4) If hook raises, phase is correct. Turn power off and make temporary connections permanent.

(5) If hook lowers, hoist is “Reverse Phased”. TURN

POWER OFF and correct by interchanging any two leads at power source connection. Do not change internal wiring of hoist.

c. Check Limit Switch Operation.

(1) A block operated upper limit stop (Figure 2-2) is furnished as standard equipment. This limit stop is factory set to stop lower block in its high position and guard against over-travel and possible damage to hoist. (Note mounting position of floating lever for 3 and 5 ton hoists.) No adjustment can be made. Limit switch operation should be tested when hoist is installed. Move hook to a low position by depressing push button marked â. Now depress button marked á to raise hook. While hook is traveling upward, manually (or with an extension pole) raise limit stop mechanism (Figure 2-2).

Figure 2-3. Electrical Compartment Cover Removed

Showing Limit Switch and Reversing Switch Arrangement.

WARNING

Do not attempt to make above test with hook in a high position near hoist.

(2) A screw-type upper and lower limit switch is provided optionally when both upper and lower limit stops are required

(Figure 7-2). This switch is adjustable and must be adjusted, at time hoist is installed, to desired high and low limits of lower block travel. Refer to Section Vll.

d. Check Lower Block and Hoisting Cable. Depress â push button and run lower block to its lowest position. No less than two wraps shall remain on the drum with the loaded hook in its lowest position, unless hoist is equipped with a lower limit switch in which case no less than one and one half wraps shall remain on the drum. Also check to see that lower block and rope does not twist excessively. If it does twist to the extent that two ropes rub against each other, disengage rope from the frame anchor and twist rope four or five turns in a direction opposite to that which the block turns. Reconnect rope to anchor (Figure 2-4), holding firmly to eliminate rope twisting back to its original position. Operate hoist up and down a few times. If lower block still rotates, repeat process until twisting is corrected.

e. Lubricate Hoisting Cable. For longer cable life, it is recommended that the cable be lubricated at time of installation by applying a Chain and Cable Fluid as outlined in Section IV, paragraph 4-3.

Figure 2-2. Limit Stop Mechanism

Being Tripped By Lower Block.

11403

Figure 2-4. Rope End Anchor.

Page 5

SECTION III — OPERATION

3-1. GENERAL. Operation of Series 800 YALE electric hoists is controlled by a convenient pendant push button station.

With it, the hoist can be controlled to give fast lifting and lowering; or controlled to lift or lower load in small increments, providing accurate spotting. The push button station has a built-in interlock to prevent depressing opposing buttons simultaneously.

When first using hoist, break-in by operating under lighter loads to full travel before applying maximum load.

3-2. PUSH BUTTON OPERATION.

a. Depress push button marked á to raise load.

b. Depress push button marked â to lower load.

c. Jogging the push button will give “hairline” load movement.

The quickness of the depressing motion will determine the amount of movement. Excessive use of this “Jogging” feature will cause premature burning of contact tips and motor overheating.

d. On two-speed hoists, partial depression of button operates the hoist at slow speed; depressing button completely operates the hoist at fast speed.

3-3.

OVERLOAD CLUTCH OPERATION (Optional). The overload clutch, when furnished with the hoist, is factory preset and tested so that the hoist will lift its full rated load but will refuse to lift overloads which could cause deformation or weakening of your hoist. If the load to be lifted exceeds the clutch setting, the hoist motor will continue to run when the á button is depressed and rotate the load brake gear without lifting the load. Whenever this slipping occurs, immediately release the á push button to prevent overheating of the clutch friction surfaces and the hoist motor.

NOTICE

Always know load to be lifted. Lift-Tech does not recommend lifting loads greater than the rated load of your hoist.

3-4.

OPERATING PRECAUTIONS.

WARNING

Equipment covered herein is not designed or suitable as a power source for lifting or lowering persons.

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.

b.

DO be familiar with hoist operating controls, procedures and warnings.

c.

DO make sure hook travel is in the same direction as shown on controls.

Page 6 d.

DO make sure hoist limit switches function properly.

e.

DO maintain firm footing when operating a 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, 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.

l.

DO warn personnel of an approaching load.

m. DO protect wire rope from weld splatter or other damaging contaminants.

n.

DO promptly repor t any malfunction, unusual performance, or damage of the hoist.

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.

r.

DO apply lubricant to wire rope as recommended.

s.

DO NOT lift more than rated load.

t.

DO NOT use a damaged hoist or a hoist that is not working correctly.

u.

DO NOT use the hoist with twisted, kinked, damaged or worn wire rope.

v.

DO NOT lift a load unless wire rope is properly seated in its drum groove(s).

w.

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

x.

DO NOT lift a load if any binding prevents equal loading on all supporting ropes.

y.

DO NOT apply the load to the tip of the hook.

z.

DO NOT operate unless load is centered under hoist.

aa. DO NOT allow your attention to be diverted from operating the hoist.

ab. DO NOT operate the hoist beyond limits of wire rope travel.

ac. DO NOT use limit switches as routine operating stops unless recommended. They are emergency devices only.

ad. DO NOT use hoist to lift, support or transport people.

ae. DO NOT lift loads over people.

af. DO NOT leave a suspended load unattended unless specific precautions have been taken.

ag. DO NOT allow sharp contact between two hoists or between hoist and obstructions.

ah. DO NOT allow the rope or hook to be used as a ground for welding.

ai.

DO NOT allow the rope or hook to be touched by a live welding electrode.

aj.

DO NOT remove or obscure the warnings on the hoist.

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

al.

DO NOT attempt to lengthen the wire rope or repair damaged wire rope.

am. DO NOT allow personnel not physically fit or properly qualified to operate hoist.

an. DO NOT operate hoist unless limit switch is operating properly.

ao. DO be sure there is no twist in wire rope.

ap. DO avoid operating hoist when hook is not centered under hoist. Avoid side pulls and swinging of load or load hook when traveling hoist.

WARNING

DO NOT operate hoist with the hoisting rope out of the drum groves. Such operation may result in the rope breaking and dropping the load which can cause damage to equipment and injury to operator and other personnel. Hoist rope will remain in the drum groves during operation under normal operating conditions, however, slack or kinked rope, excessive side pulls, swinging or jerking of load, or similar abuse, may cause the rope to leave the groves.

SECTION IV — LUBRICATION

4-1. GENERAL. T h e l u b r i c a t i o n s e r v i c e s o u t l i n e d i n paragraphs 4-2 thru 4-6 should be performed at regular intervals to maintain top hoist performance and ensure long life. Intervals of at least six (6) months, coinciding with spring and fall seasons, are recommended. The reason for this is, on hoists installed out-of-doors and in unheated areas, a

“cold test” lubricant is required in cold (below freezing) climates making seasonal changes necessary.

4-2. CHANGE GEARCASE OIL. (Figure 4-1) a.

Remove oil drain plug from bottom of gearcase and drain out oil. (Two drain plugs, one on front and one on back of gearcase.) b.

Flush out housing using petroleum solvent. Reinstall drain plug.

c.

Refill thru oil hole cover to proper level (bottom of oil level plug hole) using 10 pints of Automatic Transmission

Fluid, DEXRON III Type, suitable for all temperature ranges.

aq. DO operate hoist within recommended duty cycle and do not “jog’’ unnecessarily.

ar.

DO conduct regular visual inspections for signs of damage or wear.

as. DO NOT operate hoist with hooks that have opened up. See Figure 5-1.

at.

DO provide supporting structure or anchoring means that has a load rating at least equal to that of the hoist.

au. DO NOT use hoists in locations that will not allow operator movement to be free of the load.

av. DO, when starting to lift or pull, move the load a few inches at which time the hoist should be checked for proper load holding action. The operation shall be continued only after the operator is assured that the hoist is operating properly.

aw. DO NOT leave a loaded hoist unattended at the end of a work shift or for extended periods during the work shift. Where operations are such that this condition cannot be avoided the operator must be assured that the condition does not create a hazard to personnel or property.

ax. DO NOT use the hoist load limiting device to measure the load.

ay. DO NOT operate hoist unless hook moves in the same direction as indicated on the pushbutton. If opposite direction occurs, see pre-operation checks, Paragraph 2-

4.b.

az. Observe recommended inspection and maintenance procedures.

ba. DO use common sense and best judgement whenever operating a hoist. Observe American National Standard

Safety standard, ANSI B30.16, Iatest issue.

11413A

Figure 4-1. View Showing Location of

One Oil Drain Plug.

4-3. LUBRICATE HOISTING CABLE. Hoists are shipped from the factory without an exterior coating on hoisting cable. It is recommended, where conditions permit, that the cable be thoroughly coated at installation and kept well lubricated with

LUBRIPLATE Chain and Cable Fluid, or equal, suitable for all temperature ranges.

4-4.

LUBRICATE UPPER SHEAVE AND LOWER BLOCK

ASSEMBLY.

a.

All hoists have grease fittings located in ends of sheave pins. Apply (*) NLGI No. 2 grease for operating temperatures from +50°F to +125°F. For colder temperatures, (-20°F to

+50°F) use NLGI No. 1 grease.

b.

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

(*) National Lubricating Grease Institute.

4-5.

LUBRICATE LIMIT STOP LEVER.

a.

Apply a few drops of S.A.E. No. 50 oil to pivot points of limit rod.

b.

Apply a few drops of S.A.E. No. 50 oil to shaft bearing at rear of electrical compartment.

Page 7

4-6.

LUBRICATE LIMIT SWITCH. Provide a light film of

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

SECTION V

INSPECTION AND PREVENTIVE

MAINTENANCE

5-1.

GENERAL. YALE, Series 800, hoists are inspected and tested at the factory. Regular in service inspection and preventive maintenance programs not only help reduce overall maintenance costs but may also prevent serious shutdowns by forewarning of problems that could cause these shutdowns.

Regular inspections, periodic minor adjustments, regular cleaning and lubrication and replacement of worn parts can help preserve good performance and operation of your hoist.

Many factors influence the inspection and preventive maintenance program required for your hoist. Frequency and severity of service and material handled, local environmental conditions and various applicable codes are some of the factors that the user must consider to adjust inspection and maintenance program outlined in this section to meet his specific conditions.

The inspection and maintenance services outlined in this section are considered minimum. Recommended in the schedule are minimum inspection and maintenance intervals based on average daily use in a normal environment. Average daily use is based on 1000 operational hours per year maximum and intermittent operation of the hoist eight hours per day, five days per week with a maximum 40% “on” time and the average loading not exceeding 65% of rated load.

Environmental conditions in which the hoist operates are also important considerations for the user when adjusting hoist inspection and maintenance programs to local conditions.

Frequency of inspection and maintenance must be increased if hoist is subjected to severe atmospheric environmental conditions, such as corrosive vapors, extreme heat or cold, cement or dust and other airborne contaminants. The user should carefully consider all environmental conditions and adjust frequency and degree of maintenance for his local conditions. Consult Lift-Tech Field Service Department for advice for unusual environmental conditions.

Various codes also regulate inspection and maintenance programs. Attention must be given to applicable Federal

Standards, OSHA regulations, National Standards, state and local codes which may include mandatory rules relating to hoist inspection and maintenance. The user should become familiar with all applicable codes for his area and be guided accordingly.

Listed on the Recommended Inspection and Maintenance

Schedule are inspection frequencies and requirements.

Perfor m these inspections regularly as scheduled and additional inspections as may be required for activity, service and environment of your hoist. The hoist operator must be responsible for determining the operating conditions and severity of service.

Inspection Schedule and Maintenance Report Form.

Shown on page 10 of this manual is a recommended

Inspection Schedule and Maintenance Report form which lists various components of the hoist. The form also includes trolley components, runway components, and miscellaneous items. This form is suggested as a guide for written inspection

Page 8 reports. Inspections are recommended each month and should be performed thoroughly enough to inform the hoist user of deficiencies for any item listed. This form does not supersede the Inspection and Maintenance Schedule listed below but may be used to record scheduled inspection and maintenance services required.

The user should revise the inspection interval, add additional units or provide a similar form to suit particular conditions which may exist. However, written, dated and signed inspection reports should be maintained particularly on critical items, such as hoist hooks, hoisting ropes, sheaves, drums and brakes. Periodic review of old inspection reports can point out service life of hoist components, forecasting need for adjustment, repair or replacement of these components.

As a matter of expedience, appointed maintenance personnel inspecting the hoist can also take care of minor adjustments, repairs and cleaning, where required. Note the column on

Inspection Schedule and Maintenance Report form headed

Corrective Action and Notes. When corrective action is made during inspection, note condition of part or unit as inspected in appropriate Condition column with a check mark (

ü

). Note

“during inspection” corrective action taken and date in space provided. In this manner, items requiring further attention will be checked (

ü

) without showing corrective action. This will advise the designated person responsible for hoist operation and safety, who reviews the reports, that deficiencies exist.

The designated person will check all deficiencies as listed and reexamine or otherwise determine whether they constitute a safety

WARNING

Deficiencies may be hazardous to personnel and equipment. Do not operate a hoist having deficiencies unless a designated qualified person has determined that these deficiencies DO NOT constitute a safety hazard.

Written, dated and signed inspection reports for many items are mandatory under OSHA regulations, and many state safety codes. It is strongly recommended that the Inspection

Schedule and Maintenance Repor t, shown herein, be completed by a qualified person designated with the responsibility for hoist operation and safety or an inspector appointed by this person.

Inspection records can point out the service life of hoist components and help forecast the need for adjustments, repairs and ordering of replacement parts. File and review these reports after each inspection.

WARNING

Do not operate a hoist having unusual vibrations, sounds or other conditions. Danger may be present that the hoist operator cannot see. Determine and correct cause of unusual conditions and make certain the hoist can be operated safely. Be certain to disconnect power to the hoist whenever electrical cover is removed.

5-2. INSPECT LOWER BLOCK.

a.

Check lubrication of all parts. If the thrust bearing is not equipped with a grease fitting, lubricate with SAE No. 50 oil.

Also lubricate the shank of the hook which passes through the lower block body.

b.

Check each sheave to ensure rope groove is smooth and free from burrs, or other surface defects.

c.

Check each sheave for freedom of rotation; replace bearings if defective.

d.

Make certain that dowel pin, holding the hook nut to the hook, is securely in position.

e.

If hook is equipped with a safety latch or rotational lock, check to determine that they are in good operating condition.

f.

Check throat opening of hook. (Refer to Figure 5-1.) It is recommended that upon receipt of the hoist a measurement be made and recorded of the hook throat opening. OSHA

Standards require that the hook be replaced if the throat opening exceeds 15 percent of the original opening, or if the hook is twisted more than 10 degrees from the unbent plane.

A gage block, properly identified to the hoist, similar to the one shown in Figure 5-1, is suggested to be made for each hook for use in these measurements.

NOTE: Hooks and hook openings shown are based on hooks normally furnished with standard hoists. For dimensions of hooks having a special size, shape or material, consult the Muskegon, Michigan factory. For hooks with certain kinds of safety latches it may be necessary to remove latch to measure hook opening.

g.

Hooks showing signs of cracks must be replaced. Hooks should be inspected at least once per year using dye penetrants, magnetic particle or other suitable crack detecting methods.

c.

Make certain that rope guide pins are not bent, loose or otherwise distorted; guide pins must have close clearance to sheave flange to keep rope in sheave grooves.

d.

Check hoist suspension bolts on lug suspended hoists; make certain that bolts are secure, properly tightened and free from damage.

e.

Inspect suspension lug at top of hoist frame for damage, cracks, hole elongation or other signs of wear. On all hoists, the suspension lug is integral with hoist frame and the entire frame must be replaced when suspension lug is damaged and requires replacement.

WARNING

Do not operate a hoist having worn or damages suspension bolts.

f.

Reinstall all parts following procedure in reverse of disassembly.

5-4. INSPECT ELECTRICAL CONTROLS. Arrangement of electrical control equipment varies with the type of control, physical space and the optional control features ordered with the hoist.

a.

Disconnect electrical power to hoist, remove electrical compartment cover (Figure 9-1, Ref. No. 29) and inspect wiring and terminals. Terminals should be securely crimped to wires and electrical insulation should be sound. Terminal screws should be tight.

b.

Check condition of contactor assembly, transformer, and limit stop and reverse switches.

11202A

HOIST

RATED

LOAD

(IN TONS)

1/2

1

2

3

5

HOOK

SIZE

(STANDARD)

CORRECT "L"

DIMENSION

(NEW HOOK)

G

G

1-1/8"

1-1/8"

H

I

J

1-1/4"

1-1/2"

1-3/4"

Figure 5-1. Proper Hook Opening.

(Shown with latch removed for clarity.) h.

Check wear of the hook, especially at the saddle and replace if badly worn.

5-3.

INSPECT UPPER BLOCK AND HOIST SUSPENSION.

a.

Check upper block sheaves (when hoist is so equipped) for wear, damage and freedom of rotation. If sheaves do not rotate freely, disassemble block and inspect bearings. Replace worn or damaged bearings, washers, pins or sheaves.

b.

Make certain that all sheaves, bearings and hanger pins are free of foreign material and properly lubricated. Bearings without grease fittings are lubricated for the life of the bearing and require no further lubrication. After inspection, lubricate all upper block lubrication fittings.

Page 9

INSPECTION SCHEDULE AND MAINTENANCE REPORT

HOIST SERIAL NO. (MFGRS) _______________________ CUSTOMER CRANE IDENTITY NO. _______________________

RATED LOAD _________________

TYPE ________________________

VOLTAGE _____________________

LOCATION IN PLANT __________________________________

THIS INSPECTION IS MONTHLY o

SEMI-ANNUAL o

ANNUAL o

INSPECTED BY: ________________ DATE _____________

COMPONENT, UNIT OR PART and location

*

mended

CONDITION

(Check column best indicating condition when

Inspection part or unit is inspected. Use note column to

Interval the right if condition is not listed below.)

CORRECTIVE ACTION

NOTES

COMPONENT,

UNIT OR

PART

(Indicate corrective action taken during inspection and note date. For corrective action to be done after inspection, a designated person must determine that the existing deficiency does not constitute a safety hazard before allowing unit to operate. When corrective action is completed, describe and note date in this column.)

DATE

Motor

Motor Brake

Mechanical Load Brake

Overload Clutch

Couplings

Gears, Shafts & Bearings

Upper Block

Lower Block

Hook & Throat Opening

Hoist Rope

Rope Drum

Guards

Limit Switch

X Record Hook Throat Opening

Pushbutton

Wiring

Motor

Brake (when so equipped)

Couplings

Gears, Shafts & Bearings

Frame

Wheels

Bumpers

Guards

Conductors

Collectors

Hoist

Trolley

Monorail Joints

Monorail

Main Conductors

Main Collectors

General Condition

Load Attachment Chains

Rope Slings & Connections

Change Gearcase Lub.

Grounding Faults

* See text for DAILY & WEEKLY REQUIREMENTS.

INSPECTION INTERVAL.

SIGNED & DATED REPORT REQUIRED – OSHA.

X MAGNETIC PARTICLE OR EQUIVALENT EXAMINATION REQUIRED.

Typical Inspection Schedule and Maintenance Report form.

User must adjust inspection interval and components to suit his individual conditions and usage.

Page 10

12375B

TIME INTERVAL

Daily or start of each shift

(\/isual)

1 Month

1 - 3 Months

6 Months

INSPECTION OR MAINTENANCE

Check operation of all functional mechanisms including limit switch operation, brakes and control. Check hoist cable for kinks, abrasions, corrosion or broken wires or evidence of improper spooling on drum. Inspect hooks, upper and lower blocks, and all load bearing components for damage.

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

* ELECTRICAL CONTROLS — Inspect per paragraph 5-4.

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

* LOWER BLOCK — Inspect per paragraph 5-2.

UPPER BLOCK — Inspect per paragraph 5-3.

Annually

6 Months or

500 - 750 hours

“on” time

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

* Inspect hooks with suitable crack detecting procedures per paragraph 5-2.

Drain and refill hoist gearcase per paragraph 4-2.

Inspect electrical controls per paragraph 5-4. Change hoist gearcase oil — Fill with oil per paragraph 4-2. Lubricate hoist cable per paragraph 4-3. Lubricate

* upper and lower hook block per paragraph 4-4. Lubricate limit stop lever per paragraph 4-5. If a screw type limit switch is furnished, add a light film of

NLGI No. 2 grease to bevel gear.

5 Years elapsed time or 5000 hours “on” time

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

* that your YALE Repair Station be contacted for this service.

*Perform services described by paragraph indicated.

Figure 5-2. Inspection and Maintenance Schedule.

5-5. INSPECT MOTOR BRAKE. See Figure 9-4.

a.

Remove acorn nuts holding brake cover and remove brake cover.

b.

Remove brake mounting plate screws and lift brake assembly off.

c.

Check braking surfaces for wear and scoring. Replace badly worn or scored parts.

d.

Reinstall parts in reverse of disassembly.

e.

Adjust brake as explained in Section Vll.

5-6. INSPECT MECHANICAL LOAD BRAKE, GEARING AND

OVERLOAD CLUTCH (Optional).

a.

The mechanical load brake and gearing may be inspected and serviced with hoist suspended. To do so, remove lower block and wire rope, drain oil from gearcase, remove 12 hex head bolts and lockwashers holding gearcase cover, and pull cover from gearcase (Figure 5-3).

11404A

Figure 5-3. View of Gearcase – Cover Removed.

b.

To inspect gearing, pull out intermediate gear and pinion assembly and roller thrust bearings (Figure 5-4), and load brake assembly (Figure 5-5). Do not remove drum gear unless visual inspection indicates replacement is necessary.

c.

Inspect gears and pinions for signs of tooth wear and damage. If replacement of any parts appears necessary, disassemble drum gear, intermediate gear and pinion assembly, and load brake assembly as directed on following page.

Page 11

(2) Using a puller tool, remove brake flange from shaft.

A groove is provided around outer diameter for this purpose.

See Figure 5-7. Remove key from shaft and lift off 2 friction discs, and the pawl and ratchet assembly (Figure 5-8).

11421

Figure 5-4. Removing Intermediate Gear and

Pinion Assembly.

11422

Figure 5-5. Removed Load Brake Assembly.

d.

To disassemble drum gear, remove external snap ring from splined shaft, using heavy-duty snap ring pliers, and pull off gear.

e.

To disassemble intermediate gear and pinion, press pinion shaft from gear using an arbor press.

f.

It is recommended that load brake assembly be returned to an Authorized Repair Station for inspection and repair. If it is necessary that you make your own inspection and repair, instructions below must be followed:

(1) Place load brake assembly, flange up, in a vise equipped with brass or copper jaw plates to protect pinion gear teeth. Remove snap ring from end of load brake shaft

(Figure 5-6).

10334

Figure 5-7. View Showing Load Brake

Flange Removed.

(3) Remove load brake gear. If replacement of spring, spring retainer or cam is necessary, press off shaft (Figure

5-9).

(4) The load brake pawl and ratchet is a riveted assembly and is not to be disassembled.

(5) Clean all parts thoroughly and inspect for wear and damage. Replace all par ts that are excessively worn or damaged. Hard surface or glazed friction discs should be replaced.

10333

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

Page 12

10335A

Figure 5-8. Removing Pawl and Ratchet Assembly

From Load Brake Shaft.

g.

Reassemble gearing and load brake par ts following reverse procedure of disassembly. In assembling load brake, observe assembly steps (1) through (4) below:

(1) Before installing spring in its retainer (Figure 5-9), apply a good grade of ball bearing grease to inside of retainer.

Spring must be positioned exactly as illustrated, butted against pin at side of cam.

LOAD BRAKE — OVERLOAD CLUTCH

LOAD BRAKE — STANDARD

Figure 5-9. Load Brake Gear Removed From

Load Brake Showing Load Brake Spring.

(2) When installing pawl and ratchet assembly on load brake shaft, be certain that teeth on ratchet face are in the same direction as shown in Figure 5-8. The ratchet assembly should rotate freely when turned counterclockwise and the pawl should engage ratchet teeth when unit is turned clockwise.

(3) When installing brake flange, position it with chamfer facing friction disc (Figure 5-7).

(4) The brake spring must be pre-loaded at assembly to a torque of from 10 to 14 lb.-ft. This is accomplished using a plumber’s strap wrench to wind (rotate) load brake gear to set up spring (Figure 5-10) while pressing brake flange into place using an arbor press. Clamp pinion end of shaft into a portable vise to keep brake from rotating in press. Use brass or copper jaw plates on vise to protect pinion gear teeth.

Wind gear counterclockwise (viewing brake from flange end) with strap wrench and press down on flange until snap ring groove in shaft is exposed allowing snap ring to be installed.

Use extreme care not to over wind spring as yield will result and final spring torque will be reduced. Do not wind gear beyond point necessary to install snap ring in groove.

h. Install gearing and load brake assembly in gearcase in reverse order of disassembly. Be certain roller thrust bearings are installed at both ends of intermediate gear shaft as shown in Figure 5-4 and that thrust washers are properly installed at both ends of load brake shaft as noted below:

(1) A steel thrust washer with 5/8" I.D. must be installed on the brake flange end (end opposite pinion) of load brake as shown in Figure 5-5.

(2) A bronze thrust washer with a lug on one side goes on pinion end of load brake shaft and it must be installed so that its lug engages the special slot located on the spot face surrounding the load brake bearing bore inside gearcase cover. Use heavy grease to hold it in place on cover as cover is installed.

On hoists with 18 or 20 tooth load brake pinion, an 11/

16" I.D. steel thrust washer is installed between pinion and bronze thrust washer.

j.

At completion of reassembly of gearing and load brake in gearcase, refill gearcase to proper level using correct grade of oil, as outlined in Section IV — LUBRICATION.

k. For hoists equipped with an overload clutch (optional) which has been functioning properly, visually inspect clutch adjusting nut and spring washer for signs of damage or looseness. With a small hex allen wrench, make certain two set screws in adjusting nut are tight. DO NOT TURN

ADJUSTING NUT OR DISASSEMBLE CLUTCH. If spring washer, adjusting nut or gear is loose or damaged, or the clutch did not function properly before disassembly of hoist for inspection, consult the nearest YALE Authorized Repair

Station for repair or adjustment.

5-7.

INSPECT ROPE DRUM AND SHAFT.

a.

To r e m ove d r u m , r e m ove w i r e r o p e, e l e c t r i c a l compartment cover and electrical panel assembly (Figure

9-1) and gearing and load brake assembly (paragraph 5-6).

b.

Remove four hex socket head bolts securing gearcase to cover. Three bolts are accessible from inside frame (Figure

2-2, Section II) and the fourth is accessible from electrical end of frame thru special access hole using a socket hex key wrench with an extension (Figure 5-11). With bolts removed, pry assembled gearcase and motor from frame. Exercise caution so that gearcase and motor assembly does not fall as it comes free of frame. This disassembly operation is not recommended with hoist suspended. Drum will remain in frame and can be lifted from drum shaft. To remove shaft, remove internal retaining ring from bearing bore in frame.

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

Wrench to Set Up Load Brake Spring.

Page 13

b.

Maintenance. Keep rope well lubricated to help reduce internal friction and prevent corrosion. Lubricant, as described in paragraph 4-3, should be applied as a part of the regular maintenance program. Special attention is required to lubricate sections of rope over equalizing sheaves and other hidden areas.

Avoid dragging ropes in dirt or around sharp objects which will scrape, nick, crush or induce sharp bends in the rope.

c.

Replacement. When recommended by an authorized inspector, the rope should be replaced. Replacement rope assemblies are shipped from the factory carefully coiled to prevent damage by kinking. Care must be taken to avoid twisting or kinking when uncoiling and handling during reeving.

Before replacing rope, check condition of grooves in sheaves and drums to determine if they are excessively worn.

Figure 5-11. Removing Bolt

Securing Gearcase to Frame.

c.

Check parts for wear and damage. Replace drum if there are any signs of cracks or other damage.

5-8.

RO P E I N S P E C T I O N , M A I N T E N A N C E A N D

REPLACEMENT.

WARNING

Use only factory approved rope with swagged wire rope sockets.

WARNING

Wire rope improperly handled or abused can create a

SAFETY HAZARD. Read and comply with inspection, maintenance and replacement information given herein.

a.

Inspection. Wire rope on your hoist is one of the most impor tant components requiring frequent inspection and maintenance. All wire ropes will eventually deteriorate to a point where they are not safe and will require replacement.

WIRE ROPE SHOULD BE THOROUGHLY INSPECTED AT

REGULAR MONTHLY INTERVALS BY AN AUTHORIZED

PERSON AND A DETERMINATION MADE WHEN FURTHER

USE OF THE ROPE WOULD CONSTITUTE A SAFETY

HAZARD. Each inspection should include a written, dated and signed report of rope condition. Reports should be filed and reviewed each month and any rope deterioration carefully noted. Inspections revealing but not limited to the following conditions should cause the inspector to question remaining strength of rope and consider replacement:

(1) Twelve randomly distributed broken wires in one rope lay or four broken wires in one strand.

(2) Wear of one-third of the original diameter of outside individual wires.

(3) Kinking, crushing or bird caging.

(4) Heat damage from any cause.

(5) Reductions from nominal diameter of more than

1/64" for 3/16", 1/4", and 5/16" diameter rope.

(6) Rope corrosion, internal or external.

(7) Effects from improper lubrication.

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

Special attention should be exercised when inspecting rope normally hidden during inspecting procedures.

When first using the hoist after rope replacement, break-in rope by operating under lighter loads to full travel before applying maximum load.

5-9. ROPE REEVING.

a.

General. Before unreeling rope from a coil or reel, be sure floor is clean. Dirt picked up by the rope can cause excessive wear and abrasion. Uncoil the rope by rolling the coil or reel along the floor; or, place reel on a stand with a shaft thru the center of reel so rope can be pulled straight out with the reel rotating.

CAUTION

It is imperative that the rope reel or coil rotates as rope unwinds. If coil or reel does not rotate, the wire will be twisted as it is uncoiled and kinking will result. A kinked rope may be damaged and unsafe.

Before removing the old rope, refer to reeving diagrams,

(Figures 5-12, 5-14, 5-15 and 5-17). Face the rope drum on your hoist from the side which the rope comes off drum. To assist with rereeving your hoist, select the reeving diagram for your hoist. Note the description (such as 2 part double reeved, Figure 5-17) and refer to the paragraph below with the same description which describes rereeving procedure.

b.

Removing old rope — for all reevings.

(1) Lower the bottom block to a scaffold located 6 to 7 feet below hoist to relieve tension on wire rope. (Bottom block may be lowered to floor if desired; however, to handle less weight and for ease of rereeving adequate scaffold below the hoist is recommended.)

(2) Remove bottom block sheave guard.

(3) Remove key plates from both sides of sheave pin and slide sheave pin from bottom block.

(4) Lift out sheaves from the top of the bottom block and remove wire rope.

Page 14

(5) Remove key plates or snap rings from upper block sheave(s) and slide out upper block sheave pins, releasing upper block sheaves. Remove wire rope from sheaves.

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

â

to completely unwind all wire rope from drum. Stop hoist so drum anchor slot(s) is accessible. Remove live rope and socket(s) from drum.

(7) TURN OFF POWER TO HOIST.

(8) Remove the bolt and lockwasher in the end of the rope anchor fitting. Remove rope from slot in top of anchor.

c. Installing new rope.

WARNING

Winding rope on rope drums with power can be hazardous. Keep hands safe distance from drum, wear gloves and use extreme care when handling rope.

With new rope installed on the drum as described in paragraph

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

(1) Pass other end of rope thru bottom opening of hoist, between floating limit rod and motor, and attach rope to cast dead end anchor fitting. A slot is located at top of fitting to accept cable. Reinstall bolt and lockwasher in end of anchor fitting to lock rope compression fitting in place.

(2) Grasp loop, formed after installing end anchor, and place bottom block sheave in loop. Lower sheave into bottom block and insert sheave pin. Replace key plates and bolts holding sheave pin in place.

(3) Replace sheave guard. Make certain rope is not twisted. Should the two parts of rope tend to wind around each other, remove cable from anchor slot and untwist cable.

Reattach the cable anchor.

(4) Lubricate cable per paragraph 4-3.

SINGLE REEVED HOISTS

Stretch new cable on floor in one continuous length. Make certain there is no twist in rope.

(1) Place one end of rope in rope drum anchor slot. Be sure end fitting is properly seated.

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

POWER.

(3) Operate hoist á , guiding new rope into drum grooves with gloved hand, until the following lengths remain unwound:

(a) 2 part single reeved — about 14'-0".

(b) 4 part single reeved — about 28'-0".

(c) 6 part single reeved — about 42'-0".

(4) Proceed with reeving as described in appropriate paragraph below and the reeving diagram for your hoist.

DOUBLE REEVED HOISTS

Stretch new cable on floor in one continuous length. Make certain there are no twists in rope.

(1) Pull far end of rope toward end of rope nearest hoist, until both ends are even and a loop is formed. Place fittings on both ends of rope in anchor slots on rope drum. Be sure end fittings are properly seated.

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

POWER.

(3) Operate hoist á guiding rope into grooves at both ends of drum, until the distance from the drum to the loop is

— about 28' for 2 part double reeved.

(4) Proceed with reeving as described in appropriate paragraph below and the reeving diagram for your hoist.

d.

Reeving — 2 part single.

See Figure 5-12 for diagram.

See Figure 9-11 for block parts.

12203A

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

e.

Reeving — 4 part single.

See Figure 5-14 for diagram.

See Figure 9-13 for block parts.

With new rope installed on the drum as described in paragraph 5-9c single reeved above, proceed with rereeving following steps below:

(1) Grasp the cable near the middle (about 14'-0") of the unwound end and form a loop. Place upper sheave in this loop. Slide upper sheave with cable into sheave pocket.

(2) Insert sheave pin into sheave. Replace key plates and bolts to hold sheave pin in place.

Page 15

(1) Grasp cable at a point one-third (approx. 14’0") the distance hanging below the rope drum and form a loop. Place one upper sheave in this loop. Slide upper sheave with cable into sheave pocket; partially insert sheave pin to hold sheave in place.

(2) Repeat (1) above and install second upper sheave with rope. Insert sheave pin and install key plates and bolts to secure sheave pin.

Figure 5-13. Upper Sheave Installed.

(Typical 3 and 5 Ton)

(3) Pass free end of rope thru bottom opening of hoist between floating limit rod and motor, and insert rope in anchor fitting at hoist frame. Be certain power is off before attempting to place rope in anchor fitting. With end fitting properly seated in anchor, replace bolt and lockwasher in end of socket. Two loops have now been formed for bottom block sheaves.

12204A

Figure 5-14. Hoist Reeving — Four Part Single.

(4) Place one sheave in each loop. Install one sheave with cable in bottom block, partially insert sheave pin to hold sheave in place. NOTE: Some blocks have spacer washers between sheaves. Be certain that washers are installed between sheaves, when shown on parts illustration. Install second sheave with cable into bottom block. Slide sheave pin through sheave. Replace key plates and bolts securing sheave pin.

(5) Replace sheave guard.

(6) Lubricate cable per paragraph 4-3.

f.

Reeving — 6 part single.

See Figure 5-15 for diagram.

See Figure 9-13 for block parts.

With new rope installed on the drum as described in paragraph

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

Page 16

12205A

Figure 5-15. Hoist Reeving — Six Part Single.

(3) Pass free end of rope thru bottom opening of hoist between floating limit rod and motor and insert in rope anchor fitting at hoist frame. Be certain power is off before attempting to place rope in anchor fitting. With end fitting properly seated in anchor, replace bolt and lockwasher in end of socket.

Three loops have now been formed for bottom block sheaves.

(4) Place sheave in each loop. Install one sheave with cable in bottom block; partially insert sheave pin to hold sheave in place. NOTE: Be certain that washers are installed between sheaves, as shown on parts illustration.

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

Install sheave pin through sheaves. Replace key plates and bolts securing sheave pin.

(6) Replace sheave guard.

(7) Lubricate cable per paragraph 4-3.

g. Reeving — 2 part double.

See Figure 5-17 for diagram.

See Figure 9-12 for block parts.

With new rope installed on the drum as described in paragraph

5-9c double reeved above, proceed with rereeving following steps below:

(1) Form loops in the two ropes coming from rope drum.

Place these loops into bottom block pockets and slide pipe or rod through sheave pin holes. Note position of ropes passing limit stop bar.

(2) Partially insert upper block sheave pin in opening and install one spacer washer. Raise remaining rope up to hoist, form a loop and place upper sheave in this loop.

Figure 5-16. Upper Sheave Installed (Typical).

(3) Place sheave with rope into upper sheave pocket and slide pin partially thru sheave. Install remaining washer and push pin thru side plates. Install snap ring on each end of pin to secure pin in place.

12206A

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

(4) Insert lower sheave pin into bottom block removing pipe as sheave pin is inserted. Be certain washers are replaced as shown on parts illustration. With sheave pin installed, replace key plates and bolts to secure sheave pin.

(5) Replace sheave guard.

(6) Lubricate rope per paragraph 4-3.

h. Checking for and removal of rope twisting.

Although rereeving of hoist may have been done carefully, sometimes after new rope has been installed twisting may occur. With new rope installed, the hoist block should be raised and lowered several times with gradually increasing loads, through full lift. If the block still rotates excessively at no load, the rope may have twists which should be removed.

(1) To remove rope twist in single reeved hoists.

(a) Observe direction block tends to rotate.

(b) Lower the block to a low position and turn off power.

(c) Rotate rope near the anchor end several turns in a direction tending to correct block rotation. This rotates rope end fitting in the anchor.

(d) Tur n on power ; raise and lower the block several times to feed the correcting twist in the rope through the reeving.

(e) If block still tends to twist, repeat the above procedure until block rotation is corrected.

(2) To remove rope twist in double reeved hoists.

(a) Observe direction block tends to rotate.

(b) Lower the bottom block unspooling rope from rope drum until only one quarter (1/4) turn remains to rope end anchors in drum.

(c) Rotate rope near ends entering drum in a direction tending to correct block rotation. This rotates rope end fittings in the drum.

(d) Turn on power; raise and lower the block several times to feed the correcting twist in the rope through the reeving.

(e) If block still tends to twist, repeat the above procedure until block rotation is corrected.

5-10. T E S T I N G H O I S T A N D OV E R L OA D C L U T C H

(Optional).

a.

General. Before placing hoist in service or after disassembly and reassembly, hoist should be tested. To test suspend hoist from an overhead supporting member of sufficient strength to support the weight of the hoist and the rated load.

Hoists having overload clutches, require an overhead supporting structure capable of supporting with appropriate safety factor, a load equal to 200 percent rated load and the weight of the hoist. Connect hoist to power supply as shown on hoist nameplate and perform the checks listed in b and c below.

b.

Check hoist as outlined in PRE-OPERATION CHECKS,

Section II, paragraph 2-4.

c.

Check hoist with capacity load.

(1) Attach rated load to lower hook.

(2) Depress á push button and raise load. When push button is released, hoist should immediately stop and hold load at that level.

(3) Depress â push button, lower load a short distance and release button. Hoist should stop immediately and hold load at that level.

NOTE: If load drifts downward slowly in step 2 or

3 above, motor brake requires adjustment — see

MOTOR BRAKE ADJUSTMENT — Section Vll — paragraph 7-2.

d.

Overload Clutch. The overload clutch (optional) must be tested for proper operation before placing hoist in service or after disassembly and reassembly of hoist. For test procedure follow instructions listed below.

Page 17

WARNING

BEFORE ATTEMPTING TO TEST THE OVERLOAD

CLUTCH, MAKE CERTAIN THE FOLLOWING

PREREQUISITES ARE STRICTLY OBSERVED: a.

An appointed person must determine, before starting, that all structures supporting the hoist are adequately strong to withstand the test load of 200% of the rated load, plus the weight of the hoist, whether hoist is tested in installed position or moved to a designated test facility.

b. Loads used for testing must be accurately known.

c.

Test must be made ONLY by a qualified operator, thoroughly familiar with the hoist and the purpose of the test.

d. Adequate and proper rigging must be provided to ensure that test loads are securely attached, properly balanced, and lifted level. Failure to provide adequate support could cause injury to personnel and/or damage to equipment.

(1) Using a known load, equal to the hoist rated load, energize hoist to lift the load. Raise this load just high enough to be certain hoist is lifting the entire load. Clutch should not

slip with the rated load. Lower load to rest position. If clutch slips with rated load, adjustment is required. (See paragraph

7-5. — “OVERLOAD CLUTCH ADJUSTMENT”.) If hoist will lift rated load, proceed to step (2).

(2) Increase load in steps from rated load, TO A MAXIMUM

OF 200% of the rated load, attempting to lift load with each increase in weight. Hoist Overload Clutch should slip and refuse to lift load before 200% of the rated load is reached. Should hoist lift 200% of the rated load — STOP TEST — A CLUTCH

ADJUSTMENT IS REQUIRED. (See paragraph 7-5 —

“OVERLOAD CLUTCH ADJUSTMENT”.)

(3) Run hoist with load causing clutch to slip (hoist refusing load) five cycles of approximately 1 second each.

CAUTION

To prevent overheating, release the hoist control button at once when the hoist refuses to lift the load.

(4) Remove weights added in step (2) and return to hoist rated load. Lift rated load one final time. Clutch should not slip.

WARNING

Do not lift more than rated load except for test purposes.

NOTICE

ALWAYS KNOW LOAD TO BE LIFTED, LIFT-TECH

DOES NOT RECOMMEND LIFTING LOADS GREATER

THAN THE RATED LOAD OF YOUR HOIST.

Page 18

Trouble

6-1. Hoist Will Not Operate.

SECTION Vl - TROUBLE SHOOTING

Probable Cause

a. No power to hoist.

Remedy

a. Check switches, circuit breakers or fuses and connections in power supply lines. Check power collectors.

b. Wrong voltage.

b. Check voltage required on motor data plate against power supply.

c. L o o s e o r b r o ke n w i r e connections in hoist electrical system.

c. Shut off power supply, remove electrical cover on hoist and check wiring connections. Also check connections in push button station and limit switches.

d. C o n t a c t o r a s s e m bl y n o t 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.

6-2. Hook Moves in Wrong

Direction.

e. No control voltage.

f. Motor burned out.

e. Check transformer fuse. If blown, check for grounding and/or shorts in the push button station.

C h e ck t h e t r a n s fo r m e r c o i l fo r s i g n s o f overheating. Replace transformer if burned out.

Verify the transformer secondary is the same voltage as the coils to which it is connected.

f. Replace motor. Check input power supply. Check hoist motor connections.

a. Reverse phasing on threephase hoists.

a. Interchange any two power supply line leads.

Refer to Section II, paragraph 2-4 b.

b. Hoist wired wrong.

b. Check wiring connections with appropriate wiring diagram.

6-3. Hook Will Raise But

Not Lower.

a. Lower electrical circuit open.

a. Check for loose connections. See that necessary jumper wires are properly installed on contactor.

b. C o n t a c t o r a s s e m bl y n o t 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. Down, push button inoperative.

c. Check push button contacts and wires.

6-4. Hook Will Lower But

Not Raise.

a. Excessive load.

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

b. Hoist electrical circuit open.

d. Up, push button inoperative.

b. Check for loose connections. See that necessary jumper wires are properly installed on contactor.

Check limit switch mounting and connections.

c. C o n t a c t o r a s s e m bl y n o t functioning.

c. See that necessary jumper wires are properly installed. Verify that the contactor armatures are free to move. If binding occurs, replace contactor.

Check for burned out contactor coils.

d. Check push button contacts and wires.

Page 19

Trouble

6-5. Hoist Will Not Lift Rated

Load.

SECTION Vl - TROUBLE SHOOTING (Continued)

Probable Cause Remedy

a. Low voltage a. See that power supply current is same voltage

Iisted on motor data plate. Check hoist motor connections. Check size of power supply lines.

b. Overload Clutch not properly adjusted.

b. See Section VII, paragraph 7-5.

6-6. Hoist Motor Overheats.

a. Excessive load.

a. Reduce loading to rated load of hoist, shown on nameplate.

b. Excessive duty-cycle.

b. Reduce frequency of lifts or amount of jogging.

c. Wrong voltage or frequency.

c. Check current rating on motor data plate against power supply. Check hoist motor connections.

d. Defective motor or worn bearings in hoist frame.

d. Disassemble hoist and inspect for defective, worn or damaged parts.

e. Overload Clutch slipping without lifting load.

e. See Section VII, paragraph 7-5.

6-7. Load Drifts Excessively

When Hoist Is Stopped.

6-8. Hoist Operates

Intermittently a. Excessive load.

b. Motor brake not holding.

c. Load brake not holding.

a. Reduce loading to rated load, as shown on nameplate.

b. With No Load, check hoist for drift. If drifting is excessive, inspect motor brake (Section V, paragraph 5-5) and adjust as outlined in Section

VII, paragraph 7-2.

c. (1) After determining that the motor brake is working properly, attach rated load to hook and operate hoist. If the load accelerates during lowering, the load brake is not functioning properly. See Section

V, paragraph 5-6 for replacing worn or damaged parts.

(2) If load brake checks O.K., magnetic motor brake needs adjustment (see b. above).

a. Collectors make poor contact.

b. Loose connections.

a. Check collectors for free movement of spring arm, weak spring or electrical connections.

b. Check all wiring for loose connections.

Page 20

SECTION Vll — ADJUSTMENTS

7-1.

MECHANICAL LOAD BRAKE. The mechanical load brake on Series 800 YALE hoists is a pawl and ratchet “Weston” type automatic brake. The brake is not adjustable and requires only periodic inspection and occasional replacement of the friction washers.

7-2.

MOTOR BRAKE. Instructions for adjusting the brake are inside the brake cover and are repeated below. Check brake adjustment after the first 30 days of service and regularly thereafter during the six-month inspection procedure. Two versions of the motor brake occur in this manual.

12759C

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

c.

On the early version of the brake (Figure 7-1), if the tang is below the midway position of the two adjustment points shown on the brake, the brake should be adjusted to bring the tang back up alongside the NORMAL position on the brake.

d.

Remove the hex key (1/8" size) from the holster on the cover mounting stud and carefully turn the ADJUSTING SCREW

(located above the solenoid coil) clockwise. The indicating tang will move a large distance for a small turn of the adjusting screw, therefore turn the screw no more than one quarter turn before checking adjustment.

e.

After adjustment operate the brake by hand to assure brake disc running clearance. The outboard brake pad should separate from the brake disc by approximately .010".

f.

Replace hex key in holster.

g Replace brake cover.

7-3.

BLOCK OPERATED LIMIT SWITCH. The block operated upper limit stop, fur nished as standard equipment, is nonadjustable and designed to stop lower block at its high point of travel to guard against over-travel with possible damage to hoist. When high point is reached, limit stop switch automatically stops hook travel. If hook drifts upward slightly after stop switch is actuated, a reversing switch will close and automatically reverse direction of hook travel.

7-4.

SCREW-TYPE LIMIT SWITCH. This limit switch has a rotary screw driven by a gear reduction which is coupled to the end of the drum shaft. Adjustment discs operate the contacts of separate switches; one for the hoisting circuit and one for the lowering circuit. The switch assembly must be wired in accordance with the appropriate wiring diagram, which is packaged with hoist. Adjustment of this screw-type limit switch is accomplished as follows: (Refer to Figure 7-2).

WARNING

Before attempting actual adjustments, be certain main power switch is OFF and locked in the open position.

12759

Figure 7-1. Motor Brake - Early Version.

a.

Examine position of indicating tang located below the solenoid coil (Figure 7-1 or 7-1A).

b.

On the later version of the brake (Figure 7-1A), if the tang is below the line by more than 1/8", the brake should be adjusted to bring the top of the tang back up alongside the line on the adjust label.

LOCKING

PLATE

ADJUSTMENT

DISCS

SWITCH

12758B

SWITCH

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

(Wires not Shown for Clarity.) a.

Remove four screws and lift off switch cover.

b.

Loosen locking plate screws. Slide locking plate away from adjustment discs.

Page 21

c.

Turn proper adjustment disc (right for up, left for down) toward stitch to reduce hook travel or away from switch to increase hook travel.

d.

Slide locking plate back into position ensuring slots on adjustment discs are fully engaged, tighten locking plate screws to 4 in-lbs.

e.

Replace cover.

hoist is furnished as a separate insert and shipped with hoist.

We suggest you carefully file the wiring diagram with this book for future reference.

WHEN ORDERING PARTS OR INFORMATION ON THIS

EQUIPMENT, ALWAYS INCLUDE MODEL AND SERIAL

NUMBER ON ORDER.

WARNING

Check limit switch operation carefully, without load, before placing hoist in service. If misadjusted, SEVERE

DAMAGE AND/OR A DROPPED LOAD COULD RESULT.

Allow 6" for hook drift in both directions. Never allow less than 1-1/2 complete wraps of rope on drum with hook in lowest position.

Provide a light film of NLGI No. 2 grease on bevel gear of limit switch.

7-5.

OVERLOAD CLUTCH ADJUSTMENT. When properly adjusted, the overload device is designed so that the hoist will lift its full rated load but will refuse to lift an excessive overload.

The overload clutch is not externally adjustable. It is necessary to remove the overload clutch assembly from the hoist for proper adjustment. Therefore, it is strongly recommended that when adjustment and/or replacement parts are required, a SHAWBOX

Authorized Repair Station be contacted. Consult your SHAWBOX

Distributor for nearest Repair Station.

SECTION VIII — WIRING DIAGRAMS

Wiring diagrams for SHAWBOX electric hoists have been omitted from this book because of many possible variations. This is due to different currents and types of electrical components used in their construction. A print of the correct wiring diagram for each

SECTION IX — PARTS LIST

9-1.

GENERAL. The parts lists and illustrations in this section of the manual, cover parts for all standard 800 SHAWBOX

Electric Hoists. A typical hoist is shown as the basis for the exploded parts illustrations; therefore, certain variations may occur from the information given. For this reason, always give the Hoist Serial Number, Catalog Number, Motor Horsepower,

Voltage, Phase, Frequency and Rated Load of Hoist when ordering parts.

Certain parts of your hoist will, in time, require replacement under normal wear conditions. It is suggested that these parts be purchased for your hoist as spares for future use. These parts are indicated by a (†) symbol at the right side of the parts reference numbers.

WARNING

NON-FACTORY AUTHORIZATIONS OR MODIFICATION

OF EQUIPMENT AND USE OF NON-FACTORY REPAIR

PARTS CAN LEAD TO DANGEROUS OPERATION AND

INJURY.

TO AVOID INJURY:

• Do not alter or modify equipment without factory authorization.

• Do use only factory provided replacement parts.

The numbers assigned to the parts of our various assemblies in our parts lists are not the part numbers used in manufacturing the part. They are identification numbers, that when given with the model number, permit us to identify, select or manufacture, and ship the correct part needed.

9-2.

INDEX OF EXPLODED VIEW PARTS ILLUSTRATIONS

Figure No.

9-1

9-2

9-3

9-4

9-5

9-6

9-7

9-8

9-9

9-10

9-11

9-12

9-13

9-14

Page 22

Title Page No.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

11455C

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

Ref.

No.

5

6

1

2

3

4†

Part

Number

800-197

800-192

800-105

800-106

800-107

800-109

800-111

800-2100

800-108

800-110

800-2101

7

800-113

800-115

800-112

800-114

800-2102

800-2103

800-2104

800-2105

Description

Plug — Oil Level

Cover & Bearing Assembly — Gearcase

Dowel

Gasket — Gearcase

Gearcase & Bearing Assembly

Drum & Hub Assembly (Double Reeved Models)

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

18' Lift

34' Lift

47' Lift

2 Ton (1/4" Dia. Rope)

14' Lift

25' Lift

36' Lift

Drum & Hub Assembly (Single Reeved Models)

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

25' Lift

50' Lift

2 Ton (5/16" Dia. Rope)

20' Lift

40' Lift

3 Ton (5/16" Dia. Rope)

30' Lift

45' Lift

5 Ton (5/16" Dia. Rope)

20' Lift

30' Lift

Qty.

Req’d

2

1

2

1

1

1

1

Page 23

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

Ref.

No.

Part

Number Description

8

9

47

48

800-116

800-117

800-118

800-2106

800-2107

800-2117

800-2118

800-164

800-165

Screw — Hex, Socket Button Head — Self-Locking

Frame Assembly (Single Reeved Models)

1/2, 1 & 2 Ton

Short Frame

Long Frame

3 Ton

First Extension

Second Extension

9A

800-2108

800-2109

800-2110

800-2111

800-2112

12 800-121

14

15

19

20

21

22†

23

24 800-136

25 800-137a

26 800-138

27 800-139

29

30

32

34

800-124

800-125

800-130

800-131

800-2113

800-2114

800-132

800-133

800-134

800-135

800-194c

800-2121

800-146a

800-2122

5 Ton

First Extension

Second Extension

Frame Assembly (Double Reeved Models)

1/2, 1 & 2 Ton

Short Frame

Long Frame

First Extension

Closure — 1/2" Plug

Nut — Hex (Double Reeved Models)

Lockwasher (Double Reeved Models)

Shaft — Extension, Drum

Short Frame

Long Frame

First Extension

Second Extension

Key — Woodruff (“Hi-Pro” Type)

Ring — Retaining, Hub (Internal)

Bearing — Drum Shaft

Ring — Retaining, External

Ring — Retaining, Beveled Hub (Internal)

Plate Assembly — Base

Lockwasher

Screw — Hex Socket Head Cap

35 800-149 Screw — Self-Tapping

41 See Fig. 9-3 Motor & Brake

& Fig. 9-4

43 800-155

44

45†

800-156

Screw — Hex Socket Head

Lockwasher

Rope & Thimble Assembly (Single Reeved Models)

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

800-158

800-161

800-157

800-160

800-2115

800-2116

Cover Assembly — Electrical

Screw — Self-Tapping

Plate Assembly — Base (Short Frame)

Shell — Brake, Short Frame

25' Lift

50' Lift

2 Ton (5/16" Dia. Rope)

20' Lift

40' Lift

3 Ton (5/16" Dia. Rope)

30' Lift

45' Lift

5 Ton (5/16" Dia. Rope)

20' Lift

30' Lift

Screw — Hex Socket Head

Roll Pin

Page 24

Qty.

Req’d.

4

1

1

4

1

3

4

1

1

1

2

2

1

1

1

16

4

1

1

1

1

1

1

1

4

2

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

Ref.

Part

No.

Number

49

50

51

52

53

800-166

800-167

800-168

800-169

800-170

54† 800-171

55† 800-172

56†

800-174

800-176

800-2119

57

58

61

800-173

800-175

800-2120

800-177

800-178

800-196

†Recommended spares.

Description

Lockwasher

Screw — Hex Head Cap

Key Plate

Shaft — Sheave (Double Reeved Models)

Bracket, Sheave (Double Reeved Models)

Bearing, Sheave (Double Reeved Models)

Sheave Assembly, Upper (Double Reeved Models) Includes Bearing

Rope & Thimble Assembly (Double Reeved Models)

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

18' Lift

34' Lift

47' Lift

2 Ton (1/4" Dia. Rope)

14' Lift

25' Lift

36' Lift

Plug, Pin

Bolt, Hex Head

Label, Rated Load (Specify Rated Load)

NOTES

Qty.

Req’d.

1

1

1

2

2

1

1

1

2

12

1

Page 25

11456LC

Figure 9-2. Gearing and Load Brake Parts.

Ref.

Part

No.

Number

5

7

1† 800-201

2† 800-202

3† 800-203

4

800-204

800-205

800-266

800-206

800-2205A

800-207

800-209

800-210

800-2209

8

800-211

800-212

800-2211

Page 26

Description

Bearing Assembly — Needle, Intermediate & Drum Gear Shaft

Race — Thrust Bearing

Bearing Assembly — Needle Thrust

Gear — Intermediate

104 Teeth

109 Teeth

103 Teeth

90 Teeth

107 Teeth

Key — Woodruff

Gear — Drum

71 Teeth

61 Teeth

71 Teeth

Shaft — Intermediate Gear

14 Teeth

24 Teeth

14 Teeth

1

1

1

Qty.

Req’d.

2

1

2

4

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

38†

39†

40†

*

**

Ref.

No.

15

17

18†

19

20

21†

22†

23†

24

25

26

27

28*

29

30

31

32

33†

34†

35

36

37

Part

Number

800-219

800-221

800-222

800-269

800-224

800-225

800-226

800-227

800-228

800-229

800-230

800-231

800-267

800-232

800-2232A

800-233

800-234

800-235

800-236

800-237

800-238

800-239

800-240

800-241

800-242

800-243

800-244

800-245

800-268

800-246

800-2246A

800-247

800-248

800-249

800-250

800-251

Spring Retainer

Brake Gear, Center

}

Available only as part of

800-250 or 800-251 above

Clutch Assembly

Ring — Retaining

Oil Seal — Drum Shaft

Bearing Assembly — Ball, Drum Shaft

Shaft — Drum

Description

Ring — Retaining, Drum Shaft Bearing

Ring — Retaining

Bearing Assembly — Roller, Intermediate Shaft

Cover — Oil Hole

Pipe Plug — Hex Socket

Oil Seal — Motor Shaft

Bearing Assembly — Ball, Motor Shaft

Bearing Assembly — Needle, Load Brake Shaft

Ring — Retaining, Motor Shaft Bearing

Washer — Thrust (Steel)

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

23 Teeth

36 Teeth

24 Teeth

18 Teeth

20 Teeth

Ring — Retaining, Brake Flange

Flange — Load Brake

Washer — Friction

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

Bushing — Ratchet

Gear & Center Assembly

Pin — Groove

Cam — Load Brake

Spring — Load Brake

Retainer — Spring, Load Brake

Key — Woodruff

Shaft & Integral Pinion — Load Brake

23 Teeth

36 Teeth

24 Teeth

18 Teeth

20 Teeth

Washer — Thrust (Used With 800-246 Only)

Washer — Thrust (Bronze)

Bearing Assembly — Needle, Load Brake Shaft

Load Brake — Clutch Assembly With Bearings (Complete)

Load Brake — Clutch Assembly (Includes Items 26 thru 30, 34, 36 thru 38 and 43 thru 45)

43

44

45

46

47

48

49

800-254

800-253

800-252

800-260

800-263

800-261

800-262

† Recommended spares.

* Recommended Replacement Kit for Load Brake Clutch (Complete).

** Replacement Complete, Less Bearings and Thrust Washers.

For hoists built prior to March, 1997, gearing part numbers, with four digits (rather than three) after “800-”, must be replaced in sets.

For hoists built between March 1, 1997 and July 1, 1997, contact the factory for gearing requirements.

Qty.

Req’d.

1

1

1

1

1

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

2

1

1

1

2

1

1

1

2

1

1

1

Page 27

12756H

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

Ref.

Part

No.

Number Description

4

5

6

800-2401

1 *

2 800-2402

3 *

*

*

*

7 *

8 800-2410†

9 *

10 *

11 800-2411

14 *

15 800-2403

16 *

17 *

18

19

20

*

*

*

21

22

23

24

25

*

*

*

*

26 *

27 800-2404

28 *

29

30

31

*

*

Motor Brake Assembly (Includes Ref. Nos. 1 thru 31)

Acorn Nut - Plated (#10-32)

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

Cover Stud

Gasket

Phillips Pan Head Self Tapping Screw - Plated (#10-32 x 1-3/4)

Solenoid Frame Cover Assembly

Hex Key (1/8 - 3/4 x 2)

Solenoid Coil Assembly

Tubing

Hex Nut - Plated (#10-32)

Solenoid Frame

Hex Head Self Locking Nut - Plated (#10-32)

Solenoid Support

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

Solenoid Plunger

Hex Socket Head Set Screw - Oval Point (1/4-28 x 1)

Hex Socket Shoulder Screw (#10-24 x 1)**

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

Brake Spring (Use Red Spring Only)

Brake Lever Assembly

Pressure Pad

Brake Disc (Non-asbestos)

Brake Support Stud

Separating Spring

Brake Mounting Plate

Hex Socket Head Self Locking Set Screw - Cup Point (1/4-20 x 3/8)

Brake Hub

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

Lock Washer (3/8)

Wire Nuts — Not Shown (No. 22 thru 14 AWG)

* Not available as individual parts. See replacement kits listed below.

** Later models have a hex socket head screw (1/4-20 x 1-1/2) with a hex head self locking nut - plated (1/4-20).

Kits include quantities shown above.

Page 28

Qty.

Req’d.

2

1

2

2

1

1

1

2

2

4

1

2

1

1

1

1

2

1

2

1

2

1

1

3

1

4

1

1

2

1

2

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

Kit Description

Brake Disc

Brake Lever

Part Number

800-2405†

800-2406

Rectifier

Hardware

Brake Hub

† Recommended spares.

800-2407

800-2408

800-2409

Reference Numbers Included

23, 24, 26

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

Adjusting Screw Label, Brake Adjust Label —

Discard Zinc Colored Spring

12, 13, 4 Wire Nuts

1, 3, 4, 5, 7, 9, 10, 12, 16, 18, 20, 25, 28, 30, 31,

Instruction Label, Power Warning Label

28, 29, Hub Drive Key (Shown Elsewhere)

NOTES

Page 29

12756A

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

Ref.

No.

25

26

27

28

29

30

31

32

16

17

18

20

21

22

23

24

8

9

10

11

14

15

5

6

7

1

2

3

4

Part

Number

800-1400

800-1401

*

800-1402

*

*

*

*

*

*

*

*

*

*

800-1403

*

*

800-1404

*

*

*

*

*

*

*

*

*

*

*

800-1405

*

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

Short Frame Models Only

Other Models

Acorn Nut (#10-32)

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

Cover Stud

Gasket

Hex Washer Head Thread Forming Screw (#10-32 x 1 -3/4)

Solenoid Frame Cover Assembly

Hex Key (1/8-3/4 x 2-1/4)

Solenoid Coil Assembly

Tubing

Hex Nut (#10-32 Pltd.)

Solenoid Frame

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

Solenoid Support

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

Solenoid Plunger

Hex Socket Head Self-Locking Set Screw - Oval Point (1/4 - 28 x 1)

Clevis Pin (3/16 x 1-1/4)

Flat Washer

Brake Spring

Brake Lever Assembly

Pressure Pad

Brake Disc (Non-asbestos)

Brake Support Stud

Separating Spring

Hex Socket Head Self-Locking Set Screw - Cup Point (1/4 - 20 x 3/8)

Brake Hub

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

Brake Mounting Plate

Description

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

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

Page 30

Qty.

Req’d.

1

2

1

2

1

4

1

2

2

1

1

1

2

2

2

1

1

1

2

1

1

3

2

4

1

1

2

1

2

1

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

Kit Description

Brake Disc

Solenoid

Brake Lever

Brake Hub

Special Hardware

Part Number

800-1406

800-1407

800-1408

800-1409

800-1410

Hardware 800-1411

Reference Numbers Included

24, 25, 27

5, 6, 8, 11, 17

18, 20, 21, 22, 23

28, 29, Hub Drive Key (Shown Elsewhere)

3, 4, 9, 26, Instruction Label inside cover,

Adjust Label, Adjusting Screw Label on brake lever assembly, Power Warning Label on cover

1, 5, 7, 10, 12, 14, 16, 18, 20, 21, 28, 30

NOTES

Page 31

12724

Figure 9-5. Three Phase Motor Assembly.

Ref.

No.

Part

Number

800-1301

800-1302

800-1303

800-1304

800-1305

800-1306

800-1307

800-1308

800-1309

800-1310

800-1311

800-1312

800-1313

800-1314

800-1315

800-1316

800-1317

800-1318

800-1319

800-1320

800-1321

6

7

4

5

8

1

2

3

800-1322

800-1323

800-1324

800-1325

*

*

*

*

*

*

*

*

* Furnished only as part of motor assembly.

Description

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

1 Horsepower (1 Speed)

200 Volt

230/460 Volt

575 Volt

2 Horsepower (1 Speed)

200 Volt

230/460 Volt

575 Volt

4 Horsepower (1 Speed)

200 Volt

230/460 Volt

575 Volt

1 - 1/3 Horsepower (2 Speed)

200 Volt

230 Volt

460 Volt

575 Volt

2 - 2/3 Horsepower (2 Speed)

200 Volt

230 Volt

460 Volt

575 Volt

3 - 1 Horsepower (2 Speed)

200 Volt

230 Volt

460 Volt

575 Volt

4 - 2 Horsepower (2 Speed)

200 Volt

230 Volt

460 Volt

575 Volt

Bell — End

Ring — Retaining

Bearing — Ball

Ring — Retaining

Key — Brake

Rotor and Shaft Assembly

Stator Assembly

Bolt — Motor

Page 32

Qty.

Req’d.

1

1

1

1

1

4

1

1

1

11460

Figure 9-6. Upper Limit Switch Parts.

Ref.

No.

1

2

Part

Number

800-501

800-502

800-503

800-526

800-527

3

16

17

18

19

20

12

13

14

15

8†

9

10†

11

6

7

4

5

800-504

800-505

800-528

800-529

800-506

800-507

800-525

800-509

800-510

800-511

800-512

800-513

800-514

800-515

800-516

800-517

800-518

800-519

800-520

800-521

800-522

† Recommended Spares.

Description

Pin — Pivot

Arm — Lever

Short Frame

Long Frame

First Extension

Second Extension

Lever — Floating

Short Frame

Long Frame

First Extension

Second Extension

Washer

Pin — Cotter

Coupling

Pin — Roll

Switch Assembly — Limit, Reversing (Includes Wire Leads)

Connector — Wire

Switch Assembly — Limit, Stop (Includes Wire Leads)

Screw — Round Head

Screw — Socket Head Shoulder

Shaft & Cam Assembly

Insulator — Limit Switch

Bearing — Nylon

Screw — Socket Head Cap

Lockwasher

Nut — Lock

Bracket Assembly — Mounting

Nut — Hex

Qty.

Req’d.

2

1

1

1

1

2

2

2

1

2

1

1

1

4

1

3

1

2

2

2

Page 33

12748A

Figure 9-7. Electrical Control Equipment.

Ref.

Part

No.

Number

3

5

800-670

800-654

6† 800-655

7† 800-656

8 800-657

9† 800-671

10 800-663

11† 800-672

12 800-673

800-674

13

14

800-675

800-676

† Recommended Spares.

Description

Cord Grip — Conductor

Screw — Self-Tapping

Contactor — Two Speed

Contactor

Screw — Self-Tapping

Transformer

Screw — Self-Tapping

Terminal Board (Reconnectable Hoist Only)

Fuse, Fuse Holder and Wire Assembly

Fuse Only (2A, 300V)

Brake Module

Screw — Self Tapping

NOTES

Qty.

Req’d.

4

1

2

1

1

1

2

4

1

2

1

1

Page 34

12763

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

Single Speed Hoists.

Ref.

No.

13

14

15

16

17

9

10

11

12

7

8

5

6

3

4

1

2

Part

Number

800-2701

800-2702

*

*

*

800-2703

*

800-2704

800-2705

*

*

*

*

*

*

800-2706

*

800-2707

800-2708

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 (M 3.5 x 0.6 x 12 Pltd.)

Lockwasher (M 3.5 Pltd.)

Rear Cover

Gasket

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

Contact Assembly

Button Assembly

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

Lockwasher (M 6 Pltd.)

Plain Washer (M 6 Pltd.)

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

Lockwasher (M 3.5 Pltd.)

Housing Cap

Grommet

Housing

Conductor Cable Assembly

Plastic Warning Tag

* Not available separately. Order Push Button Station.

Qty.

Req’d.

1

1

2

2

1

1

1

1

1

1

1

2

1

1

1

7

7

1

1

Page 35

12721A

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

Two Speed Hoists Only - Later Version.

Ref.

Part

No.

Number

800-1821

16

17

18

19

1

7

800-1822

800-1823

11 800-1812

800-1813

12 800-1814

13 *

14

15

*

*

*

*

*

*

Page 36

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

Qty.

Req’d.

1

1

As Req’d

1

1

4

1

1

1

2

4

1

2

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

Ref.

No.

20

21

22

Part

Number

27

28

29

30

23

24

25

26

* Not available separately. Order Push Button Station.

** Not available separately. Order Push Button Assembly.

Description

**

**

**

**

**

*

**

**

*

*

800-1815

800-1816

Clamp — Conductor

Contact Block Assembly

Contact Block (ZB2-BE101)

Contact Block (ZB2-BE201)

* Interlock—Mechanical

800-1817 Up Push Button Assembly (Includes 1 Each of Ref. Nos. 23 and

25 thru 29)

800-1818 Down Push Button Assembly (Includes 1 Each of Ref. Nos. 23,

25 thru 28 and 30)

Ring — Retaining

Enclosure — Front

Seat — Spring

Spring

Seal

Plate — Push Button

Push Button — Up

Push Button — Down

NOTES

1

2

1

2

2

1

1

2

1

2

Qty.

Req’d.

2

2

1

1

1

Page 37

12721

Ref.

Part

No.

Number

800-1801

7

8

5

6

3

4

1

2

800-1802

800-1803

800-1804

800-1805

800 1806

800-1807

800-1808

800-1809

9 800-1810

10 800-1811

11 800-1812

800-1813

12 800-1814

Page 38

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

Two Speed Hoists Only - Early Version.

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)

Sleeve — Conductor

Qty.

Req’d.

1

1

2

1

1

1

1

1

1

1

As Req’d.

1

1

1

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

Ref.

No.

17

18

19

20

21

13

14

15

16

22

Part

Number

27

28

29

30

23

24

25

26

* Not available separately. Order Push Button Station.

** Not available separately. Order Push Button Assembly.

Description

**

**

**

**

**

*

**

**

*

*

*

*

*

*

*

*

Support — Strain Cable

Screw — Slotted Head

Lockwasher

Enclosure — Rear

Gasket

Screw — Slotted Head

Screw — Slotted Head

Clamp — Conductor

*

800-1815

800-1816

*

Contact Block Assembly

Contact Block (ZB2-BE101)

Contact Block (ZB2-BE201)

Interlock — Mechanical

800-1817 Up Push Button Assembly (Includes 1 Each of Ref. Nos. 23 and

25 thru 29)

800-1818 Down Push Button Assembly (Includes 1 Each of Ref. Nos. 23,

25 thru 28 and 30)

Ring — Retaining

Enclosure — Front

Seat — Spring

Spring

Seal

Plate — Push Button

Push Button — Up

Push Button — Down

NOTES

1

2

1

2

2

1

1

2

1

2

Qty.

Req’d.

2

1

1

2

4

1

1

4

2

1

1

2

Page 39

11464

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

Ref.

No.

Part

Number

1

2

3

800-801

800-802

800-803

800-804

800-805

800-806

800-807

800-808

4

5

6

800-809

800-810

800-811

800-812

800-813

800-814

† 800-815

800-816 7

8

7

8

800-817

† 800-818

800-819

800-820

9 800-821

800-822

800-823

10 † 800-824

11

† 800-825

800-826

800-827

12 † 800-828

13

† 800-829

800-830

14

800-831

800-832

15

800-833

800-834

† Recommended Spares.

Page 40

Description

Block Assembly — Lower, Complete, 2 Ton

Block Assembly — Lower, Complete, 1 Ton

Block Assembly — Lower, Complete, 1/2 Ton

Screw — Flat Head, Self-Threading

Cover — 2 Ton

Cover — 1 Ton

Cover — 1/2 Ton

Ring — Retaining, 2 Ton

Ring — Retaining, 1/2 & 1 Ton

Lube Fitting

Pin — Sheave, 2 Ton

Pin — Sheave, 1/2 & 1 Ton

Spacers — 2 Ton

Spacers — 1/2 Ton & 1 Ton

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

Bearing

Sheave

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

Bearing

Sheave

Cover — Lower Block, 2 Ton

Cover — Lower Block, 1 Ton

Cover — Lower Block, 1/2 Ton

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

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

Shroud — Thrust Bearing, 2 Ton

Shroud — Thrust Bearing, 1/2 & 1 Ton

Bearing Washer -— Thrust, 2 Ton

Bearing Washer — Thrust, 1/2 & 1 Ton

Body — Lower Block, 2 Ton

Body — Lower Block, 1/2 & 1 Ton

*Safety Hook Latch Kit — 2 Ton

*Safety Hook Latch Kit — 1/2 & 1 Ton

Screw — Flat Head, Self-Threading

Qty.

Req’d.

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

1

1

2

1

1

2

1

1

1

2

1

1

11465

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

5

6

3

4

†

9

10

7

8

11 †

†

12

Ref.

No.

1

2

13 †

14

15

†

Part

Number Description

800-851 Block Assembly — Lower, Complete, 2 Ton

800-852 Block Assembly — Lower, Complete, 1 Ton

800-853 Block Assembly — Lower, Complete, 1/2 Ton

800-804 Screw — Flat Heads Self-Threading

800-854 Cover — Lower Block, 2 Ton

800-806 Cover — Lower Block, 1 Ton

800-807 Cover — Lower Block, 1/2 Ton

800-809 Ring — Retaining

800-810 Fitting — Lube

800-855 Pin — Sheave

800-814 Spacer

800-818 Sheave Assembly — (Consists of Items 7 and 8)

800-819

800-820

Bearing

Sheave

800-856 Cover — Intermediate

800-834 Screw — Flat Head, Self-Threading

800-824 Hook Assembly — (Consists of Hook, Nut & Grooved Pin), 2 Ton

800-825 Hook Assembly — (Consists of Hook, Nut & Grooved Pin), 1/2 & 1 Ton

800-826 Shroud — Thrust Bearing, 2 Ton

800-827 Shroud — Thrust Bearing, 1/2 & 1 Ton

800-828 Bearing — Thrust, 2 Ton

800-829 Bearing — Thrust, 1/2 & 1 Ton

800-857 Body — Lower Block, 2 Ton

800-858 Body — Lower Block, 1/2 & 1 Ton

800-832 *Safety Hook Latch Assembly — 2 Ton

800-833 *Safety Hook Latch Assembly — 1/2 & 1 Ton

† Recommended Spares.

* Furnished as Standard with hook.

Qty.

Req’d.

1

4

2

2

4

2

1

1

2

2

2

2

1

4

1

1

1

1

1

1

1

1

1

1

1

1

Page 41

12197LA

Ref.

No.

Description

22

23

24

25

26

27

4

5

6

7†

1

2

3

800-1501

800-1502

800-1503

800-1504

800-1505

800-1506

800-1507

800-1508

800-1509

8†

9

800-1510

800-1535

11 800-1513

12† 800-1514

13† 800-1515

14 800-1516

15 800-1517

16† 800-1518

800-1530

800-1531

17 800-1519

18† 800-1520

19

20

21

800-1521

800-1522

800-1523

800-1524

800-1525

800-1526

800-1527

800-1528

800-1529

Block Assembly — Lower, 4 Part Single (Complete)

Block Assembly — Lower, 6 Part Single (Complete)

Screw — Hex Head Cap

Lockwasher

Key Plate

Fitting — Grease

Pin — Upper Sheave

Spacer Washer — Upper Sheave

Bearing — Upper Sheave (Includes Outer Race)

Sheave — Upper

Pin — Rope Guide

Spacer Washer — Lower Sheave

Bearing — Lower Sheave (Includes Outer Race)

Sheave — Lower

Pin — Roll, Hook Nut

Nut — Hook*

Bearing — Thrust, Hook

Shield — Bearing (Not Shown)

Washer — Thrust (Not Shown)

Fitting — Grease

Hook Assembly — (includes Hook, Latch & Nut)

Plate — Capacity

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

Guard — Sheave

Body — Lower Block

Pin — Lower Sheave

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

Ring — Retaining, External

Lockwasher — (Capacity Plate)

Spacer — Upper Block, 9/16"

† Recommended Spares.

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

Page 42

Part

Number

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

Quantity Required

Reeving

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

4

2

1

1

4

2

1

1

1

2

2

4

1

1

1

2

1

4

2

1

2

2

1

1

1

1

—

2

2

1

4

2

1

1

4

—

—

—

1

1

2

4

1

1

1

3

1

6

3

2

2

4

2

1

1

—

1

2

2

1

12757A

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

Ref.

No.

3

4

1

2

Part

Number

800-1655

800-1651

800-1652

800-1657

Description

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

Cap Screw — Hex Socket Head

Sealing Washer

Drum Shaft Insert

For switch element replacement order 800-1654.

NOTES

Qty.

Req’d.

3

1

1

3

Page 43

Recommended Spare Parts for Your Yale Hoist

Certain parts of your hoist will, in time, require replacement under normal wear conditions.

It is suggested that the following parts be purchased for your hoist as spares for future use.

One Friction Disc Kit

One Motor Brake Solenoid Coil

One Set Of Contactors

One Transformer

One Wire Rope Assembly

One Gearcase Gasket

Note: When ordering parts always furnish Hoist Serial Number, Catalog Number, Motor Horsepower, Voltage,

Phase, Frequency and Rated Load of Hoist on which the parts are to be used.

Parts for your hoist are available from your local authorized SHAW-BOX repair station.

For the location of your nearest repair station, write:

IN USA

Yale ŸŸŸŸŸ Lift-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.