Yale HOISTS YJC680 Operating, Maintenance & Parts Manual Download | Manualshive

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Operating, Maintenance &

Parts Manual

YJC680

YJL

Series

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

F

ollow all instructions and warnings for

inspecting, maintaining and operating this hoist.

Electric Chain

414 Broadway Avenue

P.O. Box 769

Muskegon, Michigan USA

Tel:

866.805.2962

•

Fax:

800.742.9270

www.yalehoists.net

Capacities

1/8 Ton

1/4 Ton

1/2 Ton

1 Ton

2 Ton

Go To Index

1
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Summary of Contents for YJC680

Page 1: ... 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 Follow all instructions and warnings for inspecting maintaining and operatin...

Page 2: ...attended unless specific precautions have been taken 19 NOT allow the load chain or hook to be used as an electrical or welding ground 20 NOT allow the load chain or hook to be touched by a live welding electrode 21 NOT remove or obscure the warnings on the hoist 22 NOT operate a hoist on which the safety placards or decals are missing or illegible 23 NOT operate a hoist unless it has been securel...

Page 3: ... of the nominal voltage while lifting a load Low voltage will result in higher amp draw damage to the hoist and potential fire hazards Yale Hoists is not responsible for any damages caused by an inadequate power source Failure to comply with Safety Precautions outlined throughout this manual can result in serious injuries or death Before using this hoist each operator should become thoroughly fami...

Page 4: ...ts of your equipment 7 Inspect the unit daily before operating the hoist 8 Cluttered areas and benches invite accidents 9 The operator should not engage in any practice which will divert his attention while operating the hoist 10 Before using the hoist the operator should be certain that all personnel are clear 11 Do not operate hoist with loads exceeding its rated capacity 12 Supporting frames or...

Page 5: ...t adjust according to LIMIT SWITCH ADJUSTMENT page 8 CHAIN CONTAINER Optional Accessary Refer to Table 4 For installations where the slack chain hanging from the hoist may be objectionable or hazardous the use of a chain container is recommended Available chain containers include the standard containers designed for lifts of up to 50 ft on single chained hoists and 25 ft on double chained hoists F...

Page 6: ...ifting of loads within its rated capacity but will prevent the lifting of damaging overloads while the hoist is being operated If the load being lifted exceeds the lifting capability of the overload clutch the hoist motor will continue to run causing overheating of both the clutch and hoist motor This condition should be avoided by immediately releasing the UP button and reducing the load to withi...

Page 7: ... POWER SUPPLY and remove the electrical cover 3 Using a screwdriver pry the spring guide plate out of the slots in the limit switch nuts See Figure 3 Turn the gold nut back to about the center of the threaded screw Do not disconnect the wires from the limit switches 4 Remove the load block assembly from the old chain On double chained hoists detach the chain from the chain support and pull it thro...

Page 8: ...1 ft on the 2 ton models The upper and lower limit switch adjusting nuts are color coded gold and silver respectively Each limit nut has 10 slots for fine adjustment and the increment of adjustment is such that one slot is equivalent to approximately one link of chain travel with the standard limit switch Movement of the limit switch nuts toward or away from each other increases or decreases the h...

Page 9: ...urned contacts If replacement is necessary see Figures 16 17 18 and 19 for replacement parts WIRING Refer to Figures 9A 9B 9C 9D Single phase units 115 230V are shipped wired for 115V and the 1 speed 230 460V 3 phase units are wired for 460V unless otherwise specified when ordered Hoists wired for other voltages and 2 speed units are single voltage only Conversion of dual voltage hoists to either ...

Page 10: ...by removing the stand off screws See Figures 16 17 The limit switch and brake are now accessible as shown in Figure 6 3 Remove the transformer bolted to the back of the panel plate if it requires replacement 4 Refer to Figure 15 to disassemble the brake See BRAKE ADJUSTMENT on page 9 to properly set the brake 5 Refer to Figures 20 and 21 to disassemble the limit switch See LIMIT SWITCH ADJUSTMENT ...

Page 11: ...oist and remove it to workbench 2 Remove the lug retaining screw 3 Remove the lug retainer 4 Remove the lug Care must be taken during reassembly to have the hook in proper orientation Refer to figures 8A 8B for proper orientation The transmission must be disassembled in order to inspect load sheave and chain guide see CHAIN REPLACEMENT WITH NO CHAIN IN HOIST page 8 When reassembled recheck the lim...

Page 12: ...circuit Check for burned contacts Replace as needed 4 Loose screw clamps 4 Ensure that screw clamps are tightened on the terminal blocks and reversing contactor Hook raises but will not lower 1 Hoist overloaded 1 Reduce load to within rated capacity of hoist 2 Low voltage 2 Determine cause of low voltage and bring up to within plus or minus 10 of the voltage specified on the motor Measure voltage ...

Page 13: ...Ensure that the voltage at the reversing contactor is within 10 of the nominal voltage while lifting a load Motor brake noise or chatter while starting hoist 1 Hoist overloaded 1 Reduce load to within rated capacity of hoist 2 Brake dragging 2 Check for proper brake adjustment or other defects 3 Low voltage 3 Ensure that the voltage at the reversing contactor is within 10 of the nominal voltage wh...

Page 14: ...iagram 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 Go To Index ...

Page 15: ...15 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 Go To Index ...

Page 16: ...olts Rivets Looseness stripped and damaged threads corrosion Sheaves Distortion cracks and excessive wear Build up of foreign substances Housings Load Block Cracks distortion Excessive wear internal build up of foreign substances Wiring and Terminals Fraying defective insulation Hoist Reversing Contactor other Electrical Loose connections burned or pitted contacts Apparatus Supporting Structure an...

Page 17: ...tion Schedule RECOMMENDED LUBRICATION SCHEDULE YALE ELECTRIC POWERED CHAIN HOIST PAGE AND COMPONENT TYPE OF LUBRICANT TYPE OF SERVICE AND REFERENCE NO FREQUENCY OF LUBRICATION HEAVY NORMAL INFREQUENT Pages 32 33 Load Chain SAE 90 gear oil Daily Weekly Monthly Ref No 8 Pages 30 31 Gearing SAE 90 extreme pressure EP gear oil At periodic inspection see Figure 10A Pages 28 29 Limit Switch Shaft Multi ...

Page 18: ...ecal YJL677 2 14 Capacity Decal 250 lbs JLC675K 01 1 1 4 ton JLC675K 02 1 1 2 ton JLC675K 05 1 1 ton JLC675K 10 1 2 ton JLC675K 20 1 Nylon Cover 1 8 ton 08770W 1 1 4 ton 08771W 1 1 2 ton 08772W 1 1 ton 08773W 1 2 ton 08774W 1 Chain Container 08348W 1 Plain Trolley Lug Mounted 1 Ton Under 09292 1 2 Ton 09293 1 Also requires Suspension Lug Suspension Lug Cross Mounted JM50C 1 Parallel Mounted 50JM1 ...

Page 19: ... Rear Bearing 500K3 1 6 Front Bearing 732012C 1 7 Shim Washer JL4301 01 1 8 Thru Bolt HA3100A56 4 9 10 Spring Lockwasher H4082P 4 Ref Description Part Qty Ref Description Part Qty No No No No Not available as an individual part 2 6 7 3 8 1 9 5 4 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...

Page 20: ...p 460V 3Ph 60Hz 873JM5 1 1 2 hp 460V 3Ph 60Hz 873JM6 1 1 hp 460V 3Ph 60Hz 873JM8 1 1 4 hp 575V 3Ph 60Hz 873JM9 1 1 2 hp 575V 3Ph 60Hz 873JM10 1 1 hp 575V 3Ph 60Hz 873JM12 1 1 4 hp 208V 3Ph 60Hz 873JM13 1 1 2 hp 208V 3Ph 60Hz 873JM14 1 1 hp 208V 3Ph 60Hz 873JM16 1 2 Stator Assembly 1 3 Rotor Assembly 1 4 End Shield 35EP3100D09 1 5 Rear Bearing 500K3 1 6 Front Bearing 732012C 1 7 Shim Washer JL4301 ...

Page 21: ...6 Spring 344J6 3 7 Retainer JF710 1 8 Plate Frame Assembly JF857 1 9 Brake Coil 115V 853JL1 1 230V 853JL2 1 460V 853JL3 1 575V 853JL4 1 208V 853JL5 1 380V 853JL6 1 415V 853JL7 1 10 Locknut H3978 3 11 Adapter JL142 1 12 Screw H2976P 3 13 Retaining Ring H5501 2 14 Shading Coil 860J1 2 Shading Coil Adhesive H7812 1 15 Lockwasher H4134 3 16 Spacer for 1 4 1 2 hp 141J2 3 Ref Description Part Qty Ref De...

Page 22: ...09J13 3 Single Voltage Models 909J13 1 9 Marking Strip 909J11 1 10 15 ft Power Cord Assembly 115 230V 1 2 hp 3 cond 951JM1 1 115 230V 1 hp 3 cond 952JM1 1 3 Phase 4 cond 953JM1 1 11 PB Cable Assembly See Figures 18 19 1 12 Panel Standoff Spacer 200J4 3 13 1 4 Internal tooth Lockwasher H4134 3 14 1 4 20UNC X 4 Screw H1027P 3 15 8 32UNC X 5 16 Screw H2751 2 16 8 External tooth Lockwasher H4158 2 17 ...

Page 23: ...75V Sec 24V 821J452 1 Pri 575V Sec 115V 821J451 1 Pri 208V Sec 24V 821J472 1 Pri 208V Sec 115V 821J471 1 Pri 380V Sec 24V 821J482 1 Pri 380V Sec 115V 821J481 1 6 15 ft Power Cord Assembly 953JM1 1 7 PB Cable Assembly 1 See Figures 18 19 8 Panel Standoff 200J4 3 9 1 4 Internal tooth Lockwasher H4134 3 10 1 4 20UNC X 4 Screw H1027P 3 11 8 32UNC X 5 16 Screw H2751 2 12 8 External tooth Lockwasher H41...

Page 24: ...24 Figure 18 1 Speed Pushbutton Station 12 6 7 10 11 4 5 13 14 15 4 8 4 9 16 3 2 1 Go To Index ...

Page 25: ...Cable Length PBC2100 6 1 11 ft Cable Length PBC2100 11 1 16 ft Cable Length PBC2100 16 1 Special Drop PBC2100 S 1 4 Enclosure 36998 1 5 Gasket 36986 1 6 Contact Assembly Includes item 7 36987 1 7 Button Assembly 36988 1 8 Grommet 36989 1 Hardware Kit 36939 1 Includes items 9 16 Warning Tag 687K3W 1 Parts List for 1 Speed Pushbutton Station Ref Description Part No No Qty Equal to cable length pushb...

Page 26: ...26 Figure 19 2 Speed Pushbutton Station 12 6 7 10 11 4 5 13 14 15 4 8 4 9 16 3 2 1 Go To Index ...

Page 27: ...Cable Length PBC2200 6 1 11 ft Cable Length PBC2200 11 1 16 ft Cable Length PBC2200 16 1 Special Drop PBC2200 S 1 4 Enclosure 36998 1 5 Gasket 36986 1 6 Contact Assembly Includes item 7 36868 1 7 Button Assembly 36869 1 8 Grommet 36866 1 Hardware Kit 36939 1 Includes items 9 16 Warning Tag 687K3W 1 Parts List for 2 Speed Pushbutton Station Ref Description Part No No Qty Equal to cable length pushb...

Page 28: ...cket JF900 3 1 Includes Item 8 8 Bushing JF531 4 1 9 Limit Switch Shaft JF117 3S 1 10 Limit Switch Nut silver SK6000 63Z 1 11 Limit Switch Nut gold SK6000 63W 1 12 Retaining Ring H5520 1 13 Insulator JF754 1 14 Spring JF343 3 1 15 10 24UNC X 1 2 Screw H2970 2 10 12 9 11 14 7 3 2 4 15 13 1 6 5 6 4 5 8 Figure 20 Limit Switch Assembly Parts List for Limit Switch Assembly Ref Description Part Qty Ref ...

Page 29: ...ing PB287 1 12 Bushing JF531 4 2 13 Switch 815J1 2 14 6 32UNC X 1 Screw H1402P 4 15 6 32UNC Elastic Locknut H3944 4 16 Mounting Plate 129J1 1 17 Frame and Guide Assembly 258JG7 1 18 End Plate 258J8 1 19 8 32UNC X 3 8 Screw H2741P 2 20 Drive Pinion 427J1 1 21 Retaining Ring H5520 1 22 10 24UNC X 3 8 Screw H2981P 2 Ref Description Part Qty Ref Description Part Qty No No No No Figure 21 Long Lift Lim...

Page 30: ...6 24 33 25 27 28 12 32 30 34 34 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 2 ton models Figure 22 Transmission 18 16 19 20 18 NOTE This stage of gearing is not required on 32 FPM models Go To Index ...

Page 31: ...19 High Speed Pinion for 8 16 fpm JL426 1 20 Intermediate Pinion 1 4 1 2 ton 16 fpm JL402A 1 1 2 ton JL403A 1 21 Bearing 500K39 2 22 Output Pinion JL401 1 23 Overload Clutch Assembly 1 8 ton 32 fpm 591JG22 1 1 4 ton 16 fpm 591JG25 1 1 4 ton 32 fpm 591JG22 1 1 2 ton 16 fpm 591JG16 1 1 2 ton 32 fpm 591JG21 1 1 2 ton 591JG17 1 24 Retaining Ring H5503 2 25 Bearing 500K28 1 26 Bearing P003255 1 27 Spac...

Page 32: ...32 Figure 23 Chaining Parts 2 Ton Models 1 Ton Under Models 1 4 5 3 2 6 9 18 8 19 15 14 26 24 15 28 32 12 29 7 25 31 16 14 30 23 22 24 7 21 13 17 13 20 10 11 Go To Index ...

Page 33: ...ut H3986P 1 18 Bearing JF510 1 19 Latch Kit 4X1304 1 20 Bottom Hook Assembly with Latch for 1 Ton Under 3JG20S 1 21 Bottom Block Assembly for 2 Ton JF914 6 1 22 3 8 24 Hex Locknut H3964P 2 23 Load Block Screw H2403P 2 24 Load Block Frame JF30 1 2 25 Sheave Shaft Assembly JF917 1 1 26 Sheave Shaft JF122 1 1 27 Sheave Bearing Assembly JF916 1 28 Roll Pin H5234 2 29 3 8 24 Hex Locknut H3991P 1 30 Bea...

Page 34: ...34 NOTES Go To Index ...

Page 35: ...35 NOTES Go To Index ...

Page 36: ...ion prepaid This warranty does not apply where deterioration is caused by normal wear abuse improper or inadequate power supply improper or inadequate maintenance eccentric or side loading overloading chemical or abrasive actions excessive heat unauthorized modifications or repairs or use of non Yale repair parts EXCEPT AS STATED HEREIN YALE HOISTS MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED INCL...

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