Instruction/ maintenance manual of the product Series Y80 Yale
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Page 1 May , 2003 Copyright 2003, Y ale • Lift-T e ch , division of Columb us McKinnon Corporation P art No. 117404-10 Printed in U.S.A. OPERA TION, SERVICE & P AR TS MANUAL SERIES Y80 Y ALE ® .
Page 2 INDEX SECTION I GENERAL DESCRIPTION P age P aragraph 1-1 General . ................................................................................................................................................................ 3 P aragraph 1-2 Basic Constr uction .
Page 3 This brak e requires periodic adjustment. SECTION II — INST ALLA TION 2-1. GENERAL. Y ALE electric hoists are lubr icated and tested bef ore being shipped from the f actor y .
Page 4 F or trolleys which are to be mounted along the span of a beam not having open ends, measure e xact width of beam flange and assemble trolle y to hoist so that spacing between wheel flanges is 1/4" (see Figure 2-1) greater than beam width (3/8" if beam has cur ves).
Page 5 (2) T emporarily connect hoist to power source . (3) Operate á b utton briefly to deter mine direction of hook tra vel. (4) If hook raises, phase is correct. T ur n power off and make tempora r y connections per manent. (5) If hook lowers , hoist is “Re v erse Phased”.
Page 6 Saf e operation of an o verhead hoist is the oper ator’ s responsibility . Listed below are some basic rules that can make an oper ator aw are of dangerous practices to avoid and precautions to take f or his own safety and the saf ety of others .
Page 7 ak. DO NOT adjust or repair a hoist unless qualified to perform hoist maintenance. al. DO NOT attempt to lengthen the wire r ope or repair damaged wire r ope . am . DO NO T allow per sonnel not physicall y fit or properl y qualified to operate hoist.
Page 8 repor ts. Inspections are recommended each month and should be performed thoroughly enough to info r m the hoist user of deficiencies f or any item listed. This f or m does not supersede the Inspection and Maintenance Schedule listed below but ma y be used to record scheduled inspection and maintenance ser vices required.
Page 9 5-2. INSPECT LO WER BLOCK. a. Chec k lubr ication of all par ts. If the thr ust bear ing is not equipped with a grease fitting, lubricate with SAE No . 50 oil. Also lubricate the shank of the hook which passes through the lower b lock body . b .
Page 10 * See te xt for D AIL Y & WEEKL Y REQUIREMENTS. SIGNED & D A TED REPORT REQ UIRED – OSHA. INSPECTION INTER V AL. X MAGNETIC P ARTICLE OR EQ UIV ALENT EXAMINA TION REQUIRED . INSPECTION SCHEDULE AND MAINTENANCE REPOR T HOIST SERIAL NO .
Page 11 Figure 5-3. Vie w of Gearcase – Cover Remo v ed. b . T o inspect gear ing, pull out intermediate gear and pinion assembly and roller thrust bearings (Figure 5-4), and load brak e assemb ly (Figure 5-5). Do not remov e drum gear unless visual inspection indicates replacement is necessar y .
Page 12 Figure 5-4. Removing Intermediate Gear and Pinion Assembly . Figure 5-5. Remo ved Load Br ake Assemb ly . d. T o disassemble drum gear , remov e e xternal snap r ing from splined shaft, using heavy-duty snap ring pliers, and pull off gear . e.
Page 13 (4) The brak e spring must be pre-loaded at assembly to a torque of from 10 to 14 lb .-ft. This is accomplished using a plumber’ s strap wrench to wind (rotate) load br ake gear to set up spring (Figure 5-10) while pressing brake flange into place using an arbor press.
Page 14 Bef ore removing the old rope, ref er to ree ving diagr ams, (Figures 5-12, 5-14, 5-15 and 5-17). F ace the rope drum on y our hoist from the side which the rope comes off dr um. T o assist with reree ving your hoist, select the ree ving diagram f or your hoist.
Page 15 With ne w rope installed on the drum as described in paragraph 5-9c single reev ed above , proceed with reree ving follo wing steps below: (1) P ass other end of rope thru bottom opening of hoist, between floating limit rod and motor , and attach rope to cast dead end anchor fitting.
Page 16 Figure 5-13. Upper Sheave Installed. (T ypical 3 and 5 T on) (3) P ass free end of rope thru bottom opening of hoist between floating limit rod and motor , and inser t rope in anchor fitting at hoist frame . Be cer tain power is off bef ore attempting to place rope in anchor fitting.
Page 17 Figure 5-16. Upper Sheave Installed (T ypical). (3) Place sheav e with rope into upper shea ve poc ket and slide pin par tially thr u shea ve . Install remaining washer and push pin thru side plates. Install snap r ing on each end of pin to secure pin in place.
Page 18 (1) Using a kno wn load, equal to the hoist rated load, energiz e hoist to lift the load. Raise this load just high enough to be cer tain hoist is lifting the entire load. Clutch should not slip with the rated load. Lower load to rest position.
Page 19 SECTION Vl - TR OUBLE SHOO TING T rouble Probab le Cause Remedy a. Check s witches, circuit break ers or fuses and connections in power supply lines . Check pow er collectors. b . Chec k voltage required on motor data plate against power supply .
Page 20 SECTION Vl - TROUBLE SHOO TING (Continued) T rouble Probab le Cause Remedy 6-5. Hoist Will Not Lift Rated Load. 6-6. Hoist Motor Overheats . 6-7. Load Drifts Excessively When Hoist Is Stopped. 6-8. Hoist Operates Intermittently a . See that power supply current is same voltage Iisted on motor data plate.
Page 21 SECTION Vll — ADJUSTMENTS 7-1. MECHANICAL LO AD BRAKE. The mechanical load brak e on Series 800 Y ALE hoists is a pa wl and ratchet “Weston” type automatic brak e. The brake is not adjustab le and requires only periodic inspection and occasional replacement of the friction washers.
Page 22 9-2. INDEX OF EXPLODED VIEW P AR TS ILLUSTRA TIONS Figure No. Title P age No. 9-1 Frame , Gearcase and External Part s ........................................................................................................... 23 9-2 Gear ing and Load Br ake P ar ts .
Page 23 Ref. P art Qty . No. Number Description Req’ d 1 800-197 Plug — Oil Lev el 2 2 800-192 Cov er & Bearing Assemb ly — Gearcase 1 3 800-105 Dowel 2 4† 800-106 Gask et — Gearcase 1 5 800-107 Gearcase & Bear ing Assembl y 1 6 Drum & Hub Assembly (Doub le Ree ved Models) 1 1/2 & 1 T on (3/6" Dia.
Page 24 Figure 9-1. F rame, Gearcase & External Parts. (Cont’ d.) Ref. P ar t Qty . No. Number Description Req’ d . 8 800-116 Screw — He x, Sock et Button Head — Self-Loc king 4 9 F rame A.
Page 25 NO TES Figure 9-1. F rame, Gearcase & External Parts. (Cont’ d.) Ref. P a rt Qty . No. Number Description Req’ d. 49 800-166 Loc kwasher 2 50 800-167 Screw — He x Head Cap 2 51 800-1.
Page 26 Figure 9-2. Gear ing and Load Br ake P ar ts . Ref. P ar t Qty . No. Number Description Req’ d. 1† 800-201 Bearing Assembly — Needle , Intermediate & Dr um Gear Shaft 2 2† 800-202 .
Page 27 Figure 9-2. Gearing and Load Brake P ar ts. (Cont’ d.) Ref. P a rt Qty . No. Number Description Req’ d. 15 800-219 Ring — Retaining, Drum Shaft Bearing 1 17 800-221 Ring — Retaining 1 .
Page 28 Figure 9-3. Hoist Motor Brake - Later V ersion. Ref. P ar t Qty . No. Number Description Req’ d. 800-2401 Mot or Brak e Assemb ly (Includes Ref.
Page 29 NO TES Figure 9-3. Hoist Motor Bra ke . (Cont’ d.) Kit Description P art Number Reference Numbers Included Brak e Disc 800-2405† 23, 24, 26 Brak e Le v er 800-2406 6, 15, 17, 18, 19, 20, 2.
Page 30 Figure 9-4. Hoist Motor Bra ke - Early V ersion. Ref. P a rt Qty . No. Number Description Req’ d . Motor Brak e Assembly (Includes Ref . Nos.
Page 31 NO TES Figure 9-4. Hoist Motor Brake . (Cont’d.) Kit Description P ar t Number Reference Numbers Included Brak e Disc 800-1406 24, 25, 27 Solenoid 800-1407 5, 6, 8, 11, 17 Brak e Le v er 800.
Page 32 Figure 9-5. Three Phase Motor Assembly . Ref. P ar t Qty . No. Number Description Req’ d. Motor Assembly (Includes Ref . Nos. 1 thru 8) 1 1 Horsepow er (1 Speed) 800-1301 200 V olt 800-1302 .
Page 33 Figure 9-6. Upper Limit Switch Parts. Ref. P ar t Qty . No. Number Description Req’ d. 1 800-501 Pin — Pivot 2 2 Arm — Lev er 1 800-502 Shor t F rame 800-503 Long F rame 800-526 First Ex.
Page 34 Figure 9-7. Electr ical Control Equipment. Ref. P a rt Qty . No. Number Description Req’ d . 3 800-670 Cord Grip — Conductor 2 5 800-654 Scre w — Self-T apping 4 6† 800-655 Contactor .
Page 35 Figure 9-8. Push Button Station and Conductor Cab le Assembly . Single Speed Hoists. Ref. P a rt Qty . No. Number Description Req’ d. 800-2701 Push Button Station and Conductor Cable Assemb ly (Includes Ref. Nos. 1 thru 17) 1 800-2702 Push Button Station (Includes Ref .
Page 36 Ref. P ar t Qty . No. Number Description Req’ d . 800-1821 Push Button Station and Conductor Cable Assemb ly (Includes Ref . Nos. 1 thru 30) 1 1 800-1822 Grommet 1 7 800-1823 Conductor Cab le As Req’ d 11 800-1812 Operator W ar ning Label 1 800-1813 Push Button Station (Includes Ref .
Page 37 Figure 9-9. Push Button Station and Conductor Cab le Assembly . (Cont’ d.) Ref. P a rt Qty . No. Number Description Req’ d. 20 * Clamp — Conductor 1 21 * Contact Bloc k Assemb ly 1 800-1.
Page 38 Figure 9-10. Push Button Station and Conductor Cable Assembly . T wo Speed Hoists Only - Early V ersion. Ref. P a rt Qty . No. Number Description Req’ d.
Page 39 Figure 9-10. Push Button Station and Conductor Cable Assembly . (Cont’ d.) Ref. P a rt Qty . No. Number Description Req’ d. 13 * Suppor t — Strain Cab le 1 14 * Screw — Slotted Head 4 .
Page 40 Figure 9-11. Lower Bloc k Assembly — T wo P ar ts Rope , Single Reev ed. Ref. P ar t Qty . No. Number Description Req’ d. 800-801 Block Assemb ly — Lower , Complete , 2 T on 1 800-802 Bl.
Page 41 Figure 9-12. Lower Block Assemb ly—T wo P ar ts Doub le Ree ved. Ref. P ar t Qty . No. Number Description Req’ d . 800-851 Bloc k Assembly — Lo wer , Complete , 2 T on 1 800-852 Bloc k A.
Page 42 Quantity Required Ref. P ar t Reeving No. Number Description 3-T on/4 PS 5-T on/6 PS 800-1501 Bloc k Assembly — Lo wer , 4 P ar t Single (Complete) 1 — 800-1502 Bloc k Assembly — Lo wer .
Page 43 Figure 9-14. Screw-T ype Limit Switch P ar ts. Ref. P a rt Qty . No. Number Description Req’ d. 1 800-1655 Lim it Switch Assembly (Includes Ref . Nos. 2, 3 and 4) 1 2 800-1651 Cap Screw — He x Soc ket Head 3 3 800-1652 Sealing Washer 3 4 800-1657 Dr um Shaft Inser t 1 F or switch element replacement order 800-1654.
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.
An important point after buying a device Yale Series Y80 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Yale Series Y80 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Yale Series Y80 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Yale Series Y80 you will learn all the available features of the product, as well as information on its operation. The information that you get Yale Series Y80 will certainly help you make a decision on the purchase.
If you already are a holder of Yale Series Y80, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Yale Series Y80.
However, one of the most important roles played by the user manual is to help in solving problems with Yale Series Y80. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Yale Series Y80 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
