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Yale HOISTS YJL Series Operating, Maintenance & Parts Manual

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Operating, Maintenance &
YJL Series
Capacities
F
ollow all instructions and warnings for
inspecting, maintaining and operating this hoist.
The use of any hoist presents some risk of personal injury
or property damage. That risk is greatly increased if proper
instructions and warnings are not followed. Before using this
hoist, each operator should become thoroughly familiar with
all warnings, instructions, and recommendations in this
manual. Retain this manual for future reference and use.
Forward this manual to the hoist operator.
Failure to operate the equipment as directed in the manual
may cause injury.
Should you have any questions regarding this product,
please call Yale Hoists at (866) 805-2962.
Made in the U.S.A.
Before using the hoist, fill in the information below:
Model No.
Serial No.
Purchase Date
Muskegon, Michigan USA
Tel: 866.805.2962 • Fax: 800.742.9270
www.yalehoists.net
YJC680
Parts Manual
1/8 Ton
1/4 Ton
1/2 Ton
1 Ton
2 Ton
414 Broadway Avenue
P.O. Box 769

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Summary of Contents for Yale HOISTS YJL Series

  • Page 1 Failure to operate the equipment as directed in the manual may cause injury. Should you have any questions regarding this product, please call Yale Hoists at (866) 805-2962. Made in the U.S.A. Before using the hoist, fill in the information below: Model No.

  • Page 2: Safety Precautions

    21. NOT remove or obscure the warnings on the hoist. 22. NOT operate a hoist on which the safety placards or decals Each Yale YJL Series Electric Chain Hoist is built in accordance are missing or illegible. with the specifications contained herein and at the time of manufacture complies with our interpretation of applicable 23.

  • Page 3: Table Of Contents

    Replacement Parts List................................18 Warranty ..................................Back Cover HOIST SPECIFICATIONS Yale YJL series electric chain hoists are rugged, portable hoists Table 2 - Motor Amperage of 1-Speed Hoist Models that provide quick, precise lifting. The hoists are constructed of Full Load Amps tough, but lightweight, die cast aluminum alloy housings.

  • Page 4: Application Information

    This hoist is intended for general industrial use for lifting and requirements of your equipment. transporting freely suspended material loads within its rated capacity. Yale Hoists cannot be responsible for applications 7. Inspect the unit daily before operating the hoist. other than those for which Yale equipment is recommended.
  • Page 5 Go To Index For installations where the trolley can not be slid onto the CHAIN CONTAINER (Optional Accessary) end of a beam, leave the load pin nuts loose enough to get Refer to Table 4. the wheels around the beam flange. Check the flange width For installations where the slack chain hanging from the hoist setting before tightening the nuts to 125 ft-lbs.

  • Page 6: Operation

    Go To Index 2. Run load hook down to its lowest position. Place the slack end OVERLOAD LIMITING PROTECTION of chain in chain container. Do not remove the chain stop. This hoist is equipped with a factory-calibrated overload 3. Place chain container flush against housing with chain limiting clutch that will permit the lifting of loads within its rated stripper between top lugs.
  • Page 7 Go To Index HOOKS Chain Replacement with Chain in Hoist Refer to Figures 3 & 4. Refer to Figure 2. 1. Run hook up to its top limit. 1. Inspect hooks once daily for cracking, extreme wear or spreading. Replace hooks showing any of these signs. If the 2.
  • Page 8 Go To Index LIMIT SWITCH ADJUSTMENT IMPORTANT: Before placing hoist in operation, check the limit switch adjustment. Limit switches are provided to protect the hoist against damage resulting from overtravel or to allow setting the hook travel within the factory-set limits of travel. The standard limit switch is designed for lifts of 50 ft or less on single-chained hoists and 25 ft or less on the 2 ton, double-chained models.
  • Page 9 Go To Index Check Both Upper and Lower Limits 1. Connect the hoist to the power supply. Be sure the green ground wire is properly grounded (See Installation 3-b, page 5). Be sure the bottom of the armature does not bear against the splined adapter “H”.
  • Page 10 Go To Index Bearings All bearings except hook and idler sheave bearings are lubricated at the factory and should not require additional lubrication. Noisy or worn bearings should be replaced. Limit Switch Shaft Remove any dirt accumulation and spray with a general purpose lubricant.
  • Page 11 Go To Index 6. Inspect gears for broken or severely worn teeth and inspect Periodic inspections of the top suspensions can be made all bearings. Replace as necessary. The overload slip clutch without disassembly. For more extensive inspections the lug is factory calibrated and must not be disassembled or maybe removed as follows: readjusted.

  • Page 12: Trouble Shooting

    Go To Index TROUBLE SHOOTING Failure to follow proper lockout/tagout procedures may present the danger of electrical shock. Always disconnect unit from the power supply system before TO AVOID INJURY: Disconnect power and lockout/tagout disconnecting removing hoist covers or the back cover of control station. means before removing cover or servicing this equipment.

  • Page 13: Wiring Diagrams

    Go To Index TROUBLE SHOOTING CONTINUED Lack of proper lifting speed Hoist overloaded 1. Reduce load to within rated capacity of hoist. Brake dragging 2. Check for proper brake adjustment or other defects. Low voltage 3. Ensure that the voltage at the reversing contactor is within ±10% of the nominal voltage while lifting a load. Overload limiting clutch intermittently slipping 4.
  • Page 14 Go To Index Figure 9B — Wiring Diagram for 1-Speed, 230/460V - 3 Phase Models Figure 9C — Wiring Diagram for 1-Speed, 208V, 380V, 575V - 3 Phase Models * Factory supplied diagrams will be numbered beginning with 985 for 575V, 987 for 208V, and 988 for 380V.
  • Page 15 Go To Index Figure 9D — Wiring Diagram for 2-Speed, 3 Phase Models * Factory supplied diagrams will be numbered beginning with 983 for 230 or 460V, 985 for 575V, 987 for 208V, and 988 for 380V.

  • Page 16: Inspection And Maintenance Check List

    Go To Index INSPECTION AND MAINTENANCE CHECK LIST ELECTRIC POWERED OVERHEAD CHAIN HOIST Type of Hoist ___________________________________________________________ Capacity (Tons) _________________________________________________ Location _______________________________________________________________ Original Installation Date _______________________________________ Manufacturer___________________________________________________________ Manufacturer’s Serial No. _______________________________________ Item Frequency of Inspection Possible Deficiencies Action Required Frequent Periodic Daily Monthly...

  • Page 17: Recommended Lubrication Schedule

    Go To Index INSPECTOR’S REPORT ITEM REMARKS (LIST DEFICIENCIES AND RECOMMENDED ACTION) Inspector’s Date Signature Inspected Approved by Date Figure 10B — Recommended Inspector’s Report RECOMMENDED LUBRICATION SCHEDULE* YALE ELECTRIC POWERED CHAIN HOIST PAGE AND COMPONENT TYPE OF LUBRICANT TYPE OF SERVICE AND REFERENCE NO.

  • Page 18: Replacement Parts List

    Go To Index Figure 12 - Basic Hoist Parts List for Basic Hoist Description Part Description Part Motor — 1 ton JLC675K-10 (See Figures 13 & 14) 2 ton JLC675K-20 Cover Screw H2976P Nylon Cover Trim Cover JM37 †1/8 ton 08770W Transmission Housing JM3533...
  • Page 19 Go To Index Figure 13 - Hoist Motor, 115/230V - 1 Phase ‡ (‡) Refer to the motor nameplate for part number voltage, full load amperage, horsepower, and other motor information. Parts List for Hoist Motor, 115/230V - 1 Phase Description Part Description...
  • Page 20 Go To Index Figure 14 - Hoist Motor, 3 Phase ‡ (‡) Refer to the motor nameplate for part number voltage, full load amperage, horsepower, and other motor information. Parts List for Hoist Motor, 3 Phase Description Part Description Part Hoist Motor (1-Speed) 1/2 hp, 575V-3Ph-60Hz 873JM10...
  • Page 21 Go To Index Figure 15 - Brake & Solenoid Parts NOTE: Refer to wiring diagram inside electrical cover of hoist or Figures 9A, 9B, 9C or 9D, when connecting any wires. Parts List for Brake & Solenoid Parts Description Part Description Part Disc Brake Assembly*...
  • Page 22 Go To Index Figure 16 - Electrical Parts, 1-Speed Models 17 18 Parts List for Electrical Parts, 1-Speed Models Description Part Description Part Transmission Cover JM34 Terminal Block Panel Plate 257JM200 115/230V 909J14 Reversing Contactor* End Plate 1/2 hp & under: 115/230V 909J15 24V Coil...
  • Page 23 Go To Index Figure 17 - Electrical Parts, 2-Speed Models Parts List for Electrical Parts, 2-Speed Models Description Part Description Part Transmission Cover JM34 Pri.: 575V, Sec.: 24V 821J452 Panel Plate 257JM200 Pri.: 575V, Sec.: 115V 821J451 Reversing Contactor* Pri.: 208V, Sec.: 24V 821J472 1/2 hp &...
  • Page 24 Go To Index Figure 18 - 1-Speed Pushbutton Station...
  • Page 25 Go To Index Parts List for 1-Speed Pushbutton Station Ref. Description Part Pushbutton Station & Control Cable Assembly 6 ft Cable Length PB2100-6 11 ft Cable Length PB2100-11 16 ft Cable Length PB2100-16 Special Drop PB2100-S† Pushbutton Station Assembly 36900R Control Cable Assembly 6 ft Cable Length PBC2100-6...
  • Page 26 Go To Index Figure 19 - 2-Speed Pushbutton Station...
  • Page 27 Go To Index Parts List for 2-Speed Pushbutton Station Ref. Description Part Pushbutton Station & Control Cable Assembly 6 ft Cable Length PB2200-6 11 ft Cable Length PB2200-11 16 ft Cable Length PB2200-16 Special Drop PB2200- S† Pushbutton Station Assembly 36800R Control Cable Assembly 6 ft Cable Length...
  • Page 28 Go To Index Figure 20 - Limit Switch Assembly Parts List for Limit Switch Assembly Description Part Description Part Transmission Cover JM34 Bushing JF531-4 Limit Switch Assembly 918JG4 Limit Switch Shaft JF117-3S (Includes items 4-12) Limit Switch Nut (silver) SK6000-63Z Limit Switch Bracket Assembly 918JG3 Limit Switch Nut (gold)
  • Page 29 Go To Index Figure 21 - Long Lift Limit Switch Parts Parts List for Long Lift Limit Switch Parts Description Part Description Part Transmission Cover JM34 Switch 815J1 Limit Switch Assembly 944JG6 6-32UNC X 1" Screw H1402P (Includes items 3-21) 6-32UNC Elastic Locknut H3944 Post...
  • Page 30 Go To Index Figure 22 - Transmission **33 (*) NOTE: This stage of gearing is not required on 32 FPM models. (**) NOTE: Orient output gear (32) with long boss towards gear housing (2) on 1/2 ton & under models and towards transmission cover (3) on 1 &...
  • Page 31 Go To Index Parts List for Transmission Ref. Description Part Sheave Housing JM3533 Transmission Gasket JM560 Transmission Cover JM34 (Includes Oil Seals) Spring Washer 360J1 O-ring H5605 Pressure Relief Fitting SK1912-21W Chain Guide JM273 Oil Plug - Drain H6297 Oil Plug - Fill H6296 Oil Plug - Level H6295...
  • Page 32 Go To Index Figure 23 - Chaining Parts 1 Ton Under Models 2-Ton Models...
  • Page 33 Go To Index Parts List for Chaining Parts Description Part Description Part Housing JM3533 Bottom Hook Assembly Transmission Cover JM34 with Latch for 1 Ton & Under 3JG20S Electrical Cover JM36 Bottom Block Assembly Anchor Pin (2 ton only) JM111 for 2 Ton JF914-6 Anchor (2 ton only)
  • Page 34 Go To Index NOTES...
  • Page 35 Go To Index NOTES...

  • Page 36: Warranty

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

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