Yale HOISTS LEW-1 Series Datasheet

OPERATING &
MAINTENANCE
INSTRUCTIONS
WITH PARTS LIST
LEW-1Series
Electric Wire Rope
HoistsandTrolleys
For LEW Models:
1 h.p. and under
WARNING
Publication Part No. LEW-1-680-1
Published August 2005
IMPORTANT - CAUTION
To safeguard against the possibility of personal injury or property damage, follow the recommendations and instructions
of this manual. This manual contains important information for the correct installation, operation and maintenance of this
equipment. All persons involved in the installation, operation and maintenance of this equipment should be thoroughly
familiar with the contents of this manual. Keep this manual for reference and further use.
To prevent personal injury, do not use the equipment shown in this manual to lift, support or otherwise transport people,
or to suspend unattended loads over people.
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

SECTION I INTRODUCTION Page
Paragraph 1-1 General....................................................................................................................................................................................... 2
Paragraph 1-2 Safety Standards ....................................................................................................................................................................... 2
Paragraph 1-3 Hoist Construction and Features.............................................................................................................................................. 2
Paragraph 1-4 Basic Hoist Data................................................................................................................................................................. 2 & 3
Paragraph 1-5 Application Information.............................................................................................................................................................. 3
Paragraph 1-6 Warranty ..................................................................................................................................................................................... 3
SECTION II INSTALLATION
Paragraph 2-1 Safety Notes .............................................................................................................................................................................. 3
Paragraph 2-2 Trolley Installation ...................................................................................................................................................................... 3
Paragraph 2-3 Power Supply Connection .................................................................................................................................................. 3 & 4
Paragraph 2-4 Vent Plug .................................................................................................................................................................................... 4
Paragraph 2-5 Wire Rope Lubrication............................................................................................................................................................... 4
Paragraph 2-6 Testing. ....................................................................................................................................................................................... 4
SECTION III OPERATION
Paragraph 3-1 General....................................................................................................................................................................................... 8
Paragraph 3-2 Safety Notes .............................................................................................................................................................................. 8
Paragraph 3-3 Handling The Load .................................................................................................................................................................... 8
Paragraph 3-4 Overload Limiting Protection .................................................................................................................................................... 8
SECTION IV INSPECTION
Paragraph 4-1 General....................................................................................................................................................................................... 9
Paragraph 4-2 Frequent Inspection................................................................................................................................................................... 9
Paragraph 4-3 Periodic Inspection .................................................................................................................................................................... 9
Paragraph 4-4 Load Brake Function Check ................................................................................................................................................... 11
Paragraph 4-5 Wire Rope Inspection .............................................................................................................................................................. 12
Paragraph 5-6 Hook Throat Opening .............................................................................................................................................................. 12
SECTION V MAINTENANCE AND REPORT
Paragraph 5-1 General..................................................................................................................................................................................... 13
Paragraph 5-2 Limit Switch Adjustment.......................................................................................................................................................... 13
Paragraph 5-3 Motor Brake Adjustment ......................................................................................................................................................... 13
Paragraph 5-4 Wire Rope Replacement ......................................................................................................................................................... 14
Paragraph 5-5 Lubrication................................................................................................................................................................................ 15
SECTION VI TROUBLESHOOTING .......................................................................................................................................................... 17 & 18
SECTION VII WIRING
Paragraph 7-1 Voltage Conversion.................................................................................................................................................................. 19
Paragraph 7-2 thru 7-9 Wiring Diagrams ........................................................................................................................................... 20 thru 27
SECTION VIII ILLUSTRATED PARTS LIST
Paragraph 8-1 General..................................................................................................................................................................................... 28
Paragraph 8-2 How To Use The Parts List ..................................................................................................................................................... 28
Paragraph 8-3 How To Order Replacement Parts.......................................................................................................................................... 28
Table of Contents
1-1. General Information
This manual provides information for the safe operation and
maintenance of Yale LEW-1 Series Hoists. All persons operating
or maintaining these hoists should be familiar with the
information contained herein. Adherence to the precautions,
procedures, and maintenance practices described should
ensure long reliable operation. Suggestions for improvements
to this manual are solicited.
1-2. Safety Standards
All persons concerned with the installation, operation, inspection
and maintenance of these hoists are urged to read American
National Standard (ANSI) B30.16. That Standard contains
valuable guidelines concerning practices designed to minimize
hazards associated with the use of overhead hoisting
equipment. ANSI B30.16 also contains detailed procedures for
establishing hoist inspection and maintenance programs and
can be of significant assistance in maintaining compliance with
OSHA regulations.
1-3. Hoist Construction and Features
This hoist has a steel drum and center frame for strength in
the load-bearing areas. Strong, lightweight aluminum alloy
castings provide a compact, protective enclosure for the
mechanical and electrical components.
Heat-treated alloy steel gearing operates in an oil bath to
provide the most reliable lubrication and effective heat
dissipation. LEW-1 Series Hoists incorporate the following
features:
a. Overload limiting clutch.
b. Completely independent mechanical and electrical brakes.
c. Adjustable limit switches.
d. Tough, nylon, weatherproof pushbutton stations.
e. Steel strain cable inside pushbutton cord.
f. Transformer isolated, low-voltage pushbutton controls.
g. Quick voltage conversion on dual-voltage units.
1-4. Basic Hoist Data
The basic hoist models covered by this manual are listed in
Table 1-1.
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

Page 3
SECTION I - INTRODUCTION
1-5. Application Information
This hoist is intended for general industrial use in the lifting
and transporting of freely suspended material loads within its
rated load. Prior to installation and operation, the user should
review his application for abnormal environmental or handling
conditions and to observe the applicable recommendations as
follows:
a. Adverse Environmental Conditions. Do not use the hoist
in areas containing flammable vapors, liquids, gases or any
combustible dusts or fibers. Refer to Article 500 of The
National Electric Code. Do not use this hoist in highly
corrosive, abrasive or wet environments. Do not use this
hoist in applications involving extended exposure to ambient
temperatures below - 10°F or above 130°F.
b. Lifting of Hazardous Loads. This hoist is not recommended
for use in lifting or transporting hazardous loads or materials
which could cause widespread damage if dropped. The
lifting of loads which could explode or create chemical or
radioactive contamination if dropped requires fail-safe
redundant supporting devices which are not incorporated
into this hoist.
c. Lifting of Guided Loads. This hoist is not recommended
for use in the lifting of guided loads, including dumbwaiters
and non-riding elevators. Such applications require additional
protective devices which are not incorporated into this hoist.
Refer to your state and local regulations governing the
requirements for elevator and dumbwaiter installations.
1-6. Warranty
Every hoist is thoroughly inspected and tested prior to shipment
from the factory. Should any problems develop, return the
complete hoist prepaid to your nearest Yale Authorized Warranty
Repair Station. If inspection reveals that the problem is caused
by defective workmanship or material, repairs will be made
without charge and the hoist will be returned, transportation
prepaid.
This warranty does not apply where: (1) deterioration is caused
by normal wear, abuse, improper or inadequate power supply,
eccentric or side loading, overloading, chemical or abrasive
actions, improper maintenance or excessive heat; (2) problems
resulted from repairs, modifications or alterations made by
persons other than factory or Yale Authorized Warranty Repair
Station personnel; (3) the hoist has been abused or damaged
as a result of an accident; (4) repair parts or accessories other
than those supplied by Yale are used on the hoist. Equipment
and accessories not of the seller's manufacture are warranted
Rated Lift Speed
Model Load At Rated Load Motor
Number (Lbs) (Ft. Per Min.) HP
LEW 1/2-(+) ** 10*2 1000 10 ½
LEW 1/2-(+) ** 16*2 1000 16 ½
LEW 1/2-(+) **21*2 1000 21 ¾
LEW 1/2-(+) ** 32*2 1000 32 1
LEW 1-(+) ** 10*2 2000 10 ¾
LEW 1-(+) ** 16*2 2000 16 1
+ Specify lift required - see catalog and/or price list.
* Specify reeving - S (Single), D (Double-Cross Mounted or P (Double-
Parallel Mounted).
** Specify suspension - LG, PT, GT, MT/RT.
Table 1-1. Basic Hoist Data only to the extent that they are warranted by the manufacturer.
EXCEPT AS STATED HEREIN, YALE MAKES NO OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE.
2-1. Safety Notes
a. Inspect the hoist for any evidence of shipping damage or
loose parts.
b. The supporting structure and load attaching devices should
have a load rating at least equal to that of the hoist.
c. This hoist is not suitable for use in uncovered outdoor
locations or areas containing explosive dust, vapors or gases.
d. The installation area must provide safe operating conditions
for the operator, including sufficient room for the operator
and other personnel to stand clear of the load at all times.
2-2. Trolley Installation
Yale trolleys can be mounted on American Standard I Beams
from 6 to 18 inches high. Adjustment for different beam
dimensions is accomplished with the proper placement of
spaced washers as described below.
a. "I"-Beam Adjustment. Adjustment for "I" beam sizes and
tolerances is accomplished by locating the spacer washers
as shown in Figures 2-I, 2-2, and 2-3. Tables 2-I, 2-2, and
2-3 provide an approximate guide to washer placement. Be
sure to use the proper Table, based on lift and trolley-type
of the particular installation.
BEAM MANUFACTURING TOLERANCES ALLOW WIDE
VARIATIONS FROM HANDBOOK FLANGE WIDTHS, AND
SLIGHT CHANGES TO RECOMMENDED WASHER
DISTRIBUTION MAY BE NECESSARY TO SUIT SPECIFIC
INSTALLATIONS.
The particular beam on which your hoist is to be installed
should be measured and trolley spacer washers adjusted
as required to achieve a clearance of ;/.,2" to 1/8".
Trolleys can be mounted on beam radii as small as 4 feet.
Slightly increased spacing may be required when the trolley
is mounted on curved beams to maintain freedom of
movement.
The load pin nuts for the trolleys require a tightening torque
of 100 ft. lbs. Refer to Figures 2-1, 2-2, and 2-3 for nut
identification.
b. Periodic Inspection. The trolley should be inspected
periodically for evidence of excess wear or overload. Parts
should be replaced as required.
c. Lubrication. Trolley wheels are equipped with sealed, lifetime
lubricated, precision ball bearings which should not require
lubrication for the normal service of the trolley.
2-3. Power Supply Connection
a. Disconnect power before making connections.
b. Voltage supplied to the hoist should be within plus or minus
10% of the voltage specified for the hoist. Hoists are tagged
at the factory with a tag indicating the voltage for which the
hoist is wired. Standard single-phase hoists are convertible
from 115 to 230 volts. Standard single-speed, 3 phase hoists
are convertible from 460 volts to 230 volts. See the wiring
section (paragraph 7-1) for voltage conversion instructions.
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

Page 4
SECTION I - INTRODUCTION
Do not change connections in the hoist or the pushbutton
assembly.
CAUTION
2-4. Vent Plug
This hoist has an oil-bath transmission. For shipping purposes,
a non-vented fill plug (39. Figure 8-4) was installed at the
factory. A vented plug is located in an envelope tied to one of
the hoist end covers and must be installed in place of the non
vented shipping plug before operating the hoist.
2-5. Wire Rope Lubrication
It is important that the wire rope is lubricated before the hoist
is put into service. Wire rope lubricant is packed with each
hoist. For lubrication instructions, see paragraph 5-5a. Additional
lubricant is available from your Yale distributor. Specify Part
No. 14J49.
2-6. Testing
a. Before placing the hoist into operation, check for proper
limit switch operation. Push the "UP" button and verify that
the hook block stops at least 2 inches from the bottom of
the hoist. Run the hoist down to its lower limit. At least 2
wraps of wire rope should remain on the drum. If either
switch is not correct, adjust according to the procedure
outlined in paragraph 5-2.
Note
The upper and lower limit switches are factory set to
provide the maximum allowable hook travel. This travel
adjustment should not be increased. However, the
switches may be adjusted to stop the hook sooner at
either end of its travel.
b. Wire rope life can be extended by a short breaking-in
period before the hoist is put into service. During this
breaking-in period, a small amount of twist may show up in
the rope. This twist should he removed as described below.
This break-in can be done at the time of hoist testing:
1.Attach alight load to the hook and run the hoist through
its full lift stroke fora few lifting and lowering cycles. Check
for hook drift. The hook should not drift more than one
inch.
2.If brake operation is normal with a light load, repeat the
above procedure with approximately one-half rated load,
again running the hoist through its full lilt stroke for a few
cycles. Check again for hook drift.
3.If brake operation is normal with one-half rated load,
attach rated load to the hook and continue the break-in
procedure. The hoist shall operate smoothly and the
brake should prevent hook drift in excess of one inch as
rated load. See Paragraph 5-3 if motor brake adjustment
is required.
4.Set the load on the floor. Disconnect the dead end of
the wire rope as described in paragraph 5-4.a.8. Allow
the dead end to rotate, in order to remove all twist from
the rope. Reconnect the dead end and be sure to replace
and tighten the anchor screws.
c. National Electrical Code (ANSI Cl) and local electrical codes
should be consulted and proper disconnects, branch circuit
protectors, and wiring provided.
d. Power cables furnished with the hoist have a green colored
ground wire which must be securely connected to the
electrical system ground.
e. When installing a three-phase hoist, make only temporary
connections at the power line. Push the "UP" button and
observe the direction of the hook. If it raises, the phasing is
correct and permanent connections may be made at the
power line. If the load block lowers when the "UP" button is
pushed, release the button immediately since the limit
switches will not operate to protect the hoist from overtravel.
Reverse the red and black wires at the power line connection
to correct the hook direction.
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

Page 5
I-Beam*
Size &
Weight Flange Width
Point A
Washer Between
Susp. Yoke & Sleeve
Point B
Washers Between
Sideplate & Nut Actual Spacing
Suspension
Lug to Sleeve
Point C
Clearance
Wheel to Beam.135 Thick .075 thick .135 Thick .075 thick
6" - 12.5# 3.330 0 5 8 8 .375 .099
6" - 17.25# 3.565 2 3 6 10 .495 .102
8"-18.4#4.0003459 .705 .094
8" - 23.0# 4.171 2 7 6 6 .795 .099
10" - 25.4# 4.660 1 12 7 1 1.035 .094
10" - 35.0# 4.944 6 5 2 8 1.185 .102
12" - 31.8# 5.000 4 9 4 4 1.215 .104
12" - 35.0# 5.078 7 4 1 9 1.245 .095
15" - 42.9# 5.500 7 7 1 6 1.470 .109
15" - 50.0# 5.640 8 6 0 7 1.530 .099
18" - 54.7# 6.000 6 12 2 1 1.170 .099
Table 2-1. Trolley I-Beam Adjustment Data
* American Standard I-Beam
Note: All dimensions are in inches unless otherwise specified.
WR-1 Hoists on Coffing Trolleys
Four-Wheel Trolley on 3" Suspension Yoke
(Applies to hoists with a single trolley)
Figure 2-1
14016
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

Page 6
I-Beam*
Size &
Weight Flange Width
Point A
Washer Between
Susp. Yoke & Sleeve
Point B
Washers Between
Sideplate & Nut Actual Spacing
Suspension
Lug to Sleeve
Point C
Clearance
Wheel to Beam.135 Thick .075 thick .135 Thick .075 thick
6" - 12.5# 3.330 0 1 7 8 .075 .111
6" - 17.25# 3.565 1 1 6 8 .210 .129
8" - 18.4# 4.000 3 0 4 9 .405 .106
8" - 23.0# 4.171 3 1 4 8 .480 .096
10" - 25.4# 4.660 1 8 6 1 .735 .106
10" - 35.0# 4.944 2 8 5 1 .870 .099
12" - 31.8# 5.000 4 5 3 4 .915 .116
12" - 35.0# 5.078 3 7 4 2 .930 .092
15" - 42.9# 5.500 7 3 0 6 1.170 .121
15" - 50.0# 5.640 4 9 3 0 1.215 .096
18" - 54.7# 6.000 6 8 1 1 1.410 .111
Four-Wheel Trolley on 35/8" Suspension Adapter
(Applies to hoists with a dual trolley)
Figure 2-2
Table 2-2. Trolley I-Beam Adjustment Data
* American Standard I-Beam
Note: All dimensions are in inches unless otherwise specified.
14017
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

Page 7
I-Beam*
Size &
Weight Flange Width
Point A
Washer Between
Susp. Yoke & Sleeve
Point B
Washers Between
Sideplate & Nut Actual Spacing
Suspension
Lug to Sleeve
Point C
Clearance
Wheel to Beam.135 Thick .075 thick .135 Thick .075 thick
6"-12.5#3.3303585 .780 .097
6" - 17.25# 3.565 5 3 6 7 .900 .100
8" - 18.4# 4.000 5 6 6 4 1.125 .107
8" - 23.0# 4.171 5 7 6 3 1.200 .097
10" - 25.4# 4.660 8 5 3 5 1.455 .107
10" - 35.0# 4.944 9 5 2 5 1.590 .100
12" - 31.8# 5.000 7 9 4 1 1.620 .102
12" - 35.0# 5.078 10 4 1 6 1.650 .093
15" - 42.9# 5.500 11 5 0 5 1.860 .092
15" - 50.0# 5.640 11 6 0 4 1.935 .097
18" - 54.7# 6.000 11 9 0 1 2.160 .142
Two-Wheel Trolley on 35/8" Suspension Adapter
(Applies to hoists with dual trolleys)
Figure 2-3
Table 2-3. Trolley I-Beam Adjustment Data
* American Standard I-Beam
Note: All dimensions are in inches unless otherwise specified.
14018
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

Page 8
3-1. General
This section presents information concerning the proper
operation on the Yale Electric Wire Rope Hoist. It is not intended
to serve as a handbook on rigging. Rigging, the process of
moving heavy loads using mechanical devices, requires special
knowledge and equipment. For information on the safe use of
slings and similar rigging gear, users are urged to consult a
textbook on rigging.
3-2. Safety Notes
a. Inspect the hoist for any sign of loose, broken, or
malfunctioning parts (see Section IV). Any malfunctioning
hoist should be tagged as "out of order" and removed from
service until the defect is corrected.
b. Before starting the hoist, the operator should be certain that
all personnel are clear.
c. Do not lift more than the rated load of the hoist.
d. Do not lift people or loads over people.
e. Avoid jogging controls or quick reversals of suspended loads.
f. Do not leave a suspended load unattended.
g. The operator should have a clear view of the load anytime
it is moving and should be sure that the load does not
contact any obstructions.
h. Read ANSI B30.16 Safety Standard for Overhead Hoists.
3-3. Handling The Load
a. Align hoist directly over load. Avoid side pull, since this can
cause the wire rope to jump grooves, or overwrap itself. This
condition will quickly damage the wire rope.
SECTION III - OPERATION
The overload limiting clutch is an emergency protection
device. It should not routinely be used to measure the
maximum load to be lifted.
CAUTION
b. The wire rope should not be wrapped around the load. Use
proper slings.
c. Be sure the wire rope is properly seated in the drum groove
and in the bottom block sheave.
d. Bring the hook into engagement with the load and make
sure it is well seated before proceeding to lift the load. Be
sure that the load is equalized on all supporting ropes.
e. Lift the load just clear of its supports and stop the hoist to
check for proper brake operation.
f. Avoid letting the hook or load swing excessively while moving
a trolley suspended hoist.
3-4. Overload Limiting Protection
This hoist is equipped with a factory-calibrated overload limiting
clutch, which permits lifting loads within rated capacity and
prevents lifting excessive loads which could damage the hoist.
If the load exceeds the lifting capability of the overload clutch,
the hoist will not lift the load, but the motor will run as long as
the "UP" button is pressed. Repeated attempts to lift an
excessive load will overheat the overload clutch and cause
permanent damage to the clutch.
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

Page 9
4-1. General
A scheduled inspection routine should be established for this
hoist based upon severity of use and environmental conditions.
Some inspections should be made frequently (daily to monthly)
and others periodically (monthly to yearly). It is suggested that
an Inspection and Maintenance Check List and an Inspector's
Report similar to those shown in Figures 4-1 and 4-2 be used
and filed for reference. All inspections should be made by a
designated inspector. Special inspections should be made after
any significant repairs or any situation causing suspicion that
the hoist may have been damaged. Any hoist which has been
removed from service for an extended time should receive an
inspection as described under Periodic Inspections. ANSI
B30.16, Safety Standard for Overhead Hoists, provides
guidelines for hoist operation and inspection.
SECTION IV - INSPECTION
4-2. Frequent Inspection
a. Check pushbutton station, brake, and limit switches for proper
operation.
b. Check hooks for deformation, chemical damage, or cracks.
Bent hooks or hooks damaged from chemicals, deformation,
cracks, or having excessive throat opening (see paragraph
4-6) should be replaced. Visible deformation of any hook
may be evidence of hoist abuse and overloading and
indicates that a thorough inspection of the complete hoist
should be made.
c. Check that bottom hook swivels freely.
d. Check for missing, bent or otherwise damaged hook latches.
e. Check pushbutton and power cord for cuts or other damage.
f. Check wire rope for wear, twist, distortion or kinks.
Any unsafe condition disclosed by any inspection must be
corrected before operation of the hoist is resumed.
CAUTION
4-3. Periodic Inspection
The exact period for the following inspections will depend on
the anticipated severity of hoist use. Determination of this period
should be based on the user's experience. It is recommended
that the user begin with a monthly inspection and extend the
periods to quarterly, semiannually, or annually, based on his
monthly inspection experience.
a. Clean hoist of any dirt or foreign material. Inspect bottom
block for accumulation of debris.
b. Perform all frequent inspections listed above.
c. Check for loose bolts, screws and nuts.
d. Check housings, load block, and other parts for wear,
corrosion, cracks or distortion. Check for abnormal openings
between housing sections.
e. Check motor brake for worn discs, oil contamination or
excessive clearance (see paragraph 5-3).
f. Check mechanical load brake function (paragraph 4-4).
g. Inspect the entire length of wire rope for deficiencies. See
WIRE ROPE INSPECTION, paragraph 4-5.
h. Inspect hooks and suspension parts for cracks, distortion or
extreme wear.
i. Inspect hooks for cracks using magnetic particle, dye
penetrant or other crack detecting methods.
j. Check limit switch set points and reset if necessary (see
paragraph 5-2).
k. Inspect all wiring for defective insulation, and check to be
sure all electrical connections are tight. Check motor
reversing contactor or relay for burned contacts.
l. Inspect for oil leaks. Check oil level.
m.Inspect for missing or illegible capacity or warning labels.
n. Inspect the supporting structure for continued ability to
support the hoist rated load.
For more information contact: Sievert Crane and Hoist, [phone], [email protected], www.sievertcrane.com

Page 10
Item
Frequency of Inspection
Possible Deficiencies OK Action Required
Frequent Periodic
Daily Monthly 1-12 Mo.
Operating Controls ···
Any deficiency causing improper operation
Limit Switches ···
Any deficiency causing improper operation
Pitting or detetrioration
Disc (Motor) Brake ···
·Slippage or excessive wear
Glazing, contaimnation of excessive wear
Load Brake
(Mechanical) ·Failure to support load with disc brake open
(see Figure 4-8)
Hooks
···
·
Excessive throat opening, bent or twisted
more than 10 degrees, damaged hook latch,
wear, chemical damage, worn hook bearing
Cracks (use dye penetrant, magnetic particle
or other suitable detection method)
Suspension Lug ·
·
Cracks, excessive wear or other damage
which might impair the strength of the lug
Cracks (use dye penetrant, magnetic particle
or other suitable detection method)
Wire Rope
··
·
·
·
Inadequate lubrication, wear, twist, distortion,
improper dead-ending, deposits of foreign
substance
Deterioration or wear resulting in appreciable
loss of original strength
Suspension
Lug Connections ·Cracks, bending, stripped threads, damaged
suspension studs
Pins, Bearings,
Bushings, Shafts,
Couplings, Gears
·Excessive wear, corrosion, cracks, distortion
Nuts, Bolts, Rivets ·Looseness, stripped and damaged threads,
corrosion
Sheave, Drum ·Distortion, cracks and excessive wear
Build up of foreign substances
Housing, Load Block ·Cracks, distortion, excessive wear, Internal
build up of foreign substances
Wiring and Terminals ·Fraying, defective insulation
Contact Block,
Magnetic Hoist
Control Switch, Other
Electrical Appartus
·Loose connections, burned or pitted contacts
Supporting Structure
and Trolley (if used) ·Damage or wear which restricts ability to
support imposed loads
Nameplates, Decals
Warning Labels ·Missing, damaged or illegible
Transmission
Lubricant ·Low Level, Requires Changing
Note: Refer to Maintenance and Inspection Sections of the Hoist Maintenance Manual for further details.
Figure 4-1. Recommended Inspection and Maintenance Check List
FREQUENCY OF INSPECTION:
Frequent -Indicates items requiring inspection daily to monthly. Daily inspections may be performed by the operator if properly designated.
Periodic - Indicates items requiring inspection monthly to yearly. Inspections to be performed by or under the direction of a properly
designated person. The exact period of inspection will depend on frequency and type of usage. Determination of this period will be
based on the user's experience. It is recommended that the user begin with a monthly inspection and extend the periods to
quarterly, semiannually or annually based on his monthly experience.
INSPECTION & MAINTENANCE CHECK LIST
ELECTRIC POWERED OVERHEAD WIRE ROPE HOIST
TYPE OF HOIST CAPACITY (TONS)
LOCATION ORIGINAL INSTALLATION DATE
MANUFACTURER MANUFACTURER'S SERIAL NUMBER
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Page 11
INSPECTOR’S REPORT
Item Remarks (List Deficiencies and Recommended Action)
Inspector’s
Signature Date Inspected Approved By Date
Figure 4-2 Recommended Inspector's Report
4-3. Load Brake Function Check
To check the functioning of the mechanical load brake, proceed
as follows:
a. Attach a light load to the hoist and lift it several inches.
b. Disconnect Hoist From Power Supply and remove short
end brake cover (see Figure 8-1, Index No. 1).
c. Referring to Figure 4-3 and Figure 8-9, place screwdrivers
No. 1 and No. 2 behind the plate and armature assembly
and prepare to pry against the transmission cover.
Note
Do not allow either screwdriver to contact brake disc (see
Figure 8-9, Index No. 7).
d. Carefully pry open motor brake (close solenoid gap) and
observe action of load. If the load accelerates, the
mechanical load brake is malfunctioning and must be
repaired.
Figure 4-3 Load Brake Function Check List
14019
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Page 12
4-5. Wire Rope Inspection
a. Make a thorough inspection or the wire rope at least once
each month and keep a written, dated and signed report of
rope condition on file. Any deterioration, resulting in
appreciable loss of original strength, such as described
below, shall be carefully noted and determination made as
to whether further use of the rope would constitute a safety
hazard. See Figure 4-4 for identification of wire rope
components.
1) Reduction of rope diameter below nominal due to loss of
core support, internal or external corrosion or wear of
outside wires.
2) A number of broken outside wires and the degree or
distribution or concentration of such broken wires.
3) Worn outside wires.
4) Sections of rope which are normally hidden during
inspection or maintenance procedures, such as parts
passing over sheaves, should be given close inspection
as these are points most subject to deterioration.
5) Corroded or broken wires at end connections.
6) Corroded, cracked, bent, worn or improperly applied end
connections.
7) Kinking, crushing, cutting or unstranding.
b. No precise rules can be given for determination of exact
time for replacement of wire rope, since many variable factors
are involved. Safety in this respect depends largely upon
the use of good judgment in evaluating remaining strength
in the used rope after allowance for deterioration disclosed
Use only wire rope assemblies supplied by our company
since replacement rope assemblies must be of the same
size, grade and construction rope and have the same
swagged end fittings as the original rope assembly.
CAUTION
by inspection. Safety of rope operation depends upon this
remaining strength. Conditions such as the following should
be sufficient reason for questioning rope safety and
consideration of replacement.
1) Twelve randomly distributed broken wires in one rope lay
length or four broken wires in one strand in one rope lay
length. One lay is the length, parallel to the longitudinal
axis, in which a strand makes one complete turn about
the axis of the rope. See Figure 4-4.
2) Two wires broken adjacent at the end fittings.
3) Wear of one-third of the original diameter of outside
individual wires.
4) Kinking, crushing, birdcaging or any other damage
resulting in distortion of the rope structure.
5) Evidence of any heat damage from any cause.
6) Reductions from nominal 1/4 inch diameter to 15/64 inch.
4-6. Hook Throat Opening
Check throat opening as indicated in Figure 4-5. Replace hook
if measurement exceeds the allowable.
Figure 4-4 Basic Components of Wire Rope
Figure 4-5 Hook Throat Opening
*Dimension of throat opening with internal latch.
NOTE: Add 1/16" if measured without hook latch.
14020
14021
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Page 13
5-1. General
This section provides instructions for the most common routine
maintenance and adjustments. Major repairs are not within the
scope of this manual and should be referred to qualified service
facilities.
SAFETY NOTE
Always remove load and disconnect hoist from power
supply before removing end covers or making repairs.
5-2. Limit Switch Adjustment
Limit switches are provided to protect the hoist against damage
resulting from over travel. For easy identification the upper (No.
2, Figure 5-1) and lower (No. 3, Figure 5-1) limit switch adjusting
nuts are colored brass and zinc respectively. Each limit switch
nut has ten slots for adjustment, and the increment of
adjustment is such that one slot is equivalent to approximately
3/4" of hook travel. Care should be exercised when adjusting
either limit of travel.
a. Adjusting Upper Limit (Brass Nut).
1) Carefully raise the load block to a point where its top is
2" or more from the hoist housing.
2) DISCONNECT POWER from the hoist and remove the
short end cover.
3) With a screwdriver, pry the spring guide plate (No. 1,
Figure 5-1) out of the slots in the colored limit switch nuts
(Nos. 2 and 3).
SECTION V - MAINTENANCE AND REPAIR
b. Adjusting Lower Limit (Zinc Nut)
1) Carefully lower the load block to a point where at least 2
wraps of wire rope remain on the drum.
2) DISCONNECT POWER from the hoist and remove the
short end cover.
3) Adjust the zinc limit switch nut in the same manner
described above for the brass nut.
4) Replace the short end cover and reconnect power to the
hoist.
5) Carefully lower the load block to its lower limit and observe
if it stops automatically at the desired level. At least 2
wraps of wire rope should remain on the drum.
NOTE
If upper and lower limits are not operating satisfactorily, repeat
adjustment.
5-3. Motor Brake Adjustment
When properly adjusted, the multiple disc motor brake should
release promptly, operate without noticeable chatter, and stop
the load with no more than one inch of drift. If the hoist hesitates
to lift the load promptly when the pushbutton is depressed, the
brake should be adjusted per the following procedure.
4) Turn the slotted brass nut (No. 2) toward its limit switch
until the switch clicks.
5) Release the spring guide plate and be sure it snaps back
into the slots in both nuts. Do not disturb the other slotted
nut if it has been previously set.
6) Replace the short end cover and reconnect power to the
hoist.
7) Carefully raise the load block to its upper limit and observe
to see if it stops automatically at the desired point. Do
not allow the load block to run into the hoist drum. The
stopping point should be at least 2" below the hoist drum.
a. Remove any load and DISCONNECT POWER from hoist.
b. Remove the short end cover.
c. Referring to Figure 5-2, check the gap between armature
(A) and frame (B). The correct gap is .015".
d. Adjust the gap by turning the three lock nuts (F) and check
with a feeler gauge to be sure the gap is the same on both
ends of the solenoid.
e. Replace short end cover and reconnect power. If the brake
still chatters or is hesitant to release, refer to Section V4,
Troubleshooting.
Be sure the bottom of the armature does not touch
the splined adapter (H). As wear occurs, the original
clearance will be reduced. When this clearance is
gone, the brake discs must be replaced.
CAUTION
Figure 5-2 Motor Brake Adjustment
14023
Figure 5-1 Limit Switch Adjustment
14022
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Page 14
5-4. Wire Rope Replacement
For hoists reeved Two Part Single, see paragraph 5-4a. For
hoists reeved Two Part Double see paragraph 5-4b.
a. Hoists Reeved Two Part Single:
Refer to Figure 5-3 for parts identification and proper rope
reeving.
1) Push "DOWN" button and run old rope out until stopped
by lower limit switch.
2) Dissemble the load block by removing the screws (9,
Figure 8-9A) and one spring pin (3, Figure 8-9A). Clean
and inspect the block, hook, sheave, bearings, and pin
for wear, damage, etc. Replace parts as necessary. Do
not reassemble the load block at this point.
3) DISCONNECT POWER from the hoist and remove the
short end cover.
4) With a screwdriver, push the spring guide plate (1, Figure
5-1) out of the slots in the limit switch nuts. Turn the zinc
slotted nut (3) back to about the center of the threaded
screw. DO NOT DISCONNECT THE WIRES FROM THE
LIMIT SWITCHES.
5) With the end cover off, connect hoist to power supply. Be
sure the green wire is grounded.
6) Carefully jog the "DOWN" button until all the old rope is
run off and the drum socket opening is accessible.
7) DISCONNECT POWER from the hoist.
8) Disconnect old rope dead end eye by removing one dead
end anchor screw (A, Figure 5-3) and loosening the other
screw (B) approximately three turns. Lift the dead end
eye up and slide the anchor pin back by grasping the
head of screw (B).
9) Slide the sleeve fitting out of the drum socket. Remove
and discard the old rope.
10) Place paper on floor to protect the new wire rope from
dirt and grit. Stretch the new rope out on the paper with
the sleeve fitting end toward the hoist. Relieve any twist
in the new rope.
11) Insert the new rope's sleeve fitting into the drum socket,
making sure the fitting is properly seated.
12) Push the "UP" button until about half of the new rope is
wound onto the drum. Apply slight tension to the rope
with a gloved hand to wind rope evenly on the drum.
13) Attach the dead end by placing the new rope's eye
fitting over the anchor pin, while making sure there are
no twists in the rope. Be sure to replace and tighten
both anchor pin screws.
14) Reassemble the load block onto the new wire rope. See
Figure 8-9A for aid in reassembly. Refer to Figure 5-3 to
make sure that the rope is reeved correctly.
15) Adjust the limit switches per paragraph 5-2.
16) Lubricate the wire rope per paragraph 5-5a. Test the
hoist and break-in the wire rope per paragraph 2-6b.
b. Hoists Reeved Two Part Double:
Refer to Figures 5-4 or 5-5 for parts identification and proper
rope reeving.
Figure 5-3. Two Part Single Reeving:
Standard Headroom Models
Figure 5-4. Two Part Single Reeving:
True Vertical Lift Models
14024
14025
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Page 15
(1) Push "DOWN" button and run old rope out until stopped
by lower limit switch.
2) Disassemble the load block by removing the spring pins
(12, Figure 8-9B) and the slotted nuts (9, Figure 8-9B).
The block covers (11, Figure 8-9B) will still be captured
by the rope. Clean and inspect the hook, sheaves,
bearings, and yoke for wear, damage, etc. Replace parts
as necessary. Do not reassemble the load block yet.
3) DISCONNECT POWER from the hoist and remove the
short end cover.
4) With a screwdriver, push the spring guide plate (1, Figure
5-1) out of the slots in the limit switch nuts. Turn the zinc
slotted nut (3) back to about the center of the threaded
screw. DO NOT DISCONNECT THE WIRES FROM THE
LIMIT SWITCHES.
5) With the end cover off, connect hoist to power supply. Be
sure the green wire is grounded.
6) Carefully jog the "DOWN" button until all the old rope is
run off and the drum socket openings are accessible.
7) DISCONNECT POWER from the hoist.
8) Remove the equalizer sheave (A, Figure 5-4 or 5-5) by
removing one retaining ring (B) and the sheave pin (C).
Clean and inspect these parts.
9) Slide the sleeve fittings out of the drum sockets and out
of the block covers. Remove and discard the old rope.
10) Place paper on floor to protect the new wire rope from
dirt and grit. Stretch the new rope out in one length and
relieve any twist. The double the rope by bringing the two
sleeve fittings together.
11) Pass each sleeve fitting through the rope openings in the
block covers only. The block should remain disassembled
at this point.
12) Insert each sleeve fitting into the drum sockets, making
sure the fittings are properly seated.
Figure 5-5. Two Part Single Reeving:
Low Headroom Models
13) Push the "UP" button until a few wraps of rope are wound
onto the drum. Apply slight tension to the ropes with
gloved hands to wind the rope evenly on the drum.
14) Place the looped end over the equalizer sheave and return
the sheave to its frame. Reinstall the sheave pin and
retaining ring.
15) At this point, only the block covers will be hanging from
the two loops of rope.
Figure 5-6. Assembly of Load Block
Two Part Double Reeved
16) Refer to Figure 5-6 for assembly of load block. Pull a
loop of rope to the inside of the block cover (A), and
place a sheave (B) in this loop. Angle the top of the
sheave into the cover, while keeping the rope seated in
the sheave groove. The sheave will now drop to the inside
wall of the cover. Place the sheave and cover, as one
unit, over the yoke (C), and hand tighten the slotted nut.
Repeat for the other side. Tighten both slotted nuts and
install the spring pins. Refer to Figure 5-4 or 5-5 to make
sure that the rope is reeved correctly.
17) Adjust the limit switched per paragraph 5-2.
18) Lubricate the wire rope for paragraph 5-5a. Test the hoist
and break-in the wire rope per paragraph 2-6b.
5-5. Lubrication
Proper lubrication is necessary for long, trouble-free hoist
operation. Refer to the following and to Table 5-1,
Recommended Lubrication Schedule, for lubrication points, type
of lubricant and frequency of lubrication.
a. Wire Rope: Lubrication of the wire rope is important. The
action within the rope as it moves over the drum or around
the sheave is for the strands to slide one against the other.
Lubrication will reduce this friction and prevent the entrance
of moisture which can cause corrosion. Frequent light
applications of lubricant are better than infrequent heavy
applications. For best results, use Yale Wire Rope Lubricant
(Part No. 14J49), or other wire rope lubricant. As alternative,
use SAE 30 motor oil.
b. Gearing: The gear case of the hoist is filled at assembly
with 46 oz. of a gear oil containing special friction-reducing
additives.
14026
14027
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Page 16
Figure And
Index No. Component Type of Lubricant
Type of Service and Frequency of Lubrication
Heavy Normal Infrequent
Figure 8-5C, No. 26
Figure 8-5B. No, 44
Figure 8-5A, No. 17 Wire Rope Coffing Wire Rope Lubricant (Kit No.
14J49 contains 8 fl. oz) or SAE 30
Gear or Motor Oil Daily Weekly Monthly
Figure 8-4 Hoist Gearing Coffing No. H-7813 transmission oil (Kit No. 14J1 contains quantity of oil
sufficient for one oil change
At periodic inspection
(see Figure 4-1. paragraph 5-5b)
Figure 8-6. No. 9 Limit Switch Shaft "WD-40" or general purpose spray
lubricant Monthly Yearly Yearly
Figure 8-9B. No. 5
Figure 8-9A. No. 11 Load Hook Bearing SAE 30 Gear or Motor Oil Weekly Monthly Yearly
Figure 8-9B. No. 3
Figure 8-9A. No. 7 Sheave Bearings NLGI #2 multipurpose lithium-base
grease (Coffing No. H-7610) At periodic inspection (see Figure 4-1)
Figure 8-11 Trolley Gear Box NLGI #2EP lithium-base grease.
(Coffing No. H-7610) At periodic inspection (see Figure 4-1)
Figure 8-10B. No. 23
Figure 8-10A. No. 17 Gears Trolley Wheel NLGI #2 multipurpose lithium-base grease (Coffing No. H-7610) Weekly Monthly Yearly
a. To check the oil level, remove the 1/8" pipe plug from the
side of the hoist. With the hoist hanging level, transmission
oil should be even with the edge of the tapped plug hole.
b. The length of time between necessary oil changes will
depend on the severity of use the hoist receives. In general,
the oil should be changed every 12 months of normal
operation, or every 200 hours of actual hoist on-time. Very
heavy use or operation in high ambient temperatures (over
105°F) will require that oil be changed more often. An
indication of the need for oil replacement is load brake noise.
If an erratic tapping sound is made when lowering a load,
the oil should be changed.
The use of gear oils other than that recommended
in Table 5-1 can cause brake chatter or can render
the load brake incapable of holding a load.
A 46 oz. container of this oil is available from
YaleLift-Tech. (Part No. 14J1).
WARNING c. Limit Switch Shaft: To prevent rust, the threaded limit switch
shaft should be given a light coat of grease or sprayed with
a general purpose lubricant.
d. Hook Bearing: Apply a few drops of SAE 30 oil around the
edge of the bearing.
e. Sheave Bearings: At periodic inspections (see Figure 4-1),
and when the wire rope is replaced, wash out the old grease
with solvent and pack with new grease.
f. Trolley Gear Box: At periodic inspections (see Figure 4-1)
check grease level by removing end cap (22, Figure 8-11).
The gear box should be approximately half full of grease. In
general, the trolley gear box lubricant does not require
changing.
g. Trolley Wheel Gears: Apply a light coat of grease to the
pinion and both gears.
Table 5-1. Recommended Lubrication Schedule* Model LEW-1 Electric Wire Rope Hoist
Note: All bearings except hook and sheave bearings are pre-lubricated and sealed.
* This lubrication schedule is based on a hoist operating in normal environmental conditions. Hoists operating in adverse atmospheres
containing excessive heat, corrosive fumes or vapors, abrasive dust, etc., should be lubricated more frequently.
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Page 17
6-1. General
Use the following table as an aid to troubleshoot your hoist. If
you do not have an experienced machinist-electrician to do
SECTION VI - TROUBLESHOOTING
your repair work, we recommend that you send your hoist to
an approved service center for repairs.
TROUBLE REMEDY
Hook Fails to Stop at End of Travel
1. Limit switches not operating.
2. Limit switch nuts not moving on shaft.
3. Magnetic reversing switch malfunction.
1. Check adjustment. See paragraph 5-2. Check connections against
wiring diagram. Tighten loose connections or replace.
2. Check for stripped threads or bent nut guide. 3. Remove electrical
cover and check reversing switch.
3. Remove electrical cover and check reversing switch.
Hoist Does Not Respond to Pushbutton
1. Power failure in supply lines.
2. Wrong voltage or frequency.
3. Improper connections in hoist or pushbutton
station.
4. Motor brake does not release.
5. Faulty magnetic hoist control switch.
1. Check circuit breakers, switches and connections in power supply
lines.
2. Check voltage and frequency of power supply against the rating on the
nameplate of the hoist.
3. Check all connections at line connectors and on terminal block. Check
terminal block on dual-voltage hoists for proper voltage connections.
4. Check connections to the solenoid coil. Check for open or short circuit.
Check for proper adjustment. See paragraph 5-3.
5. Check coils for open or short circuit. Check all connections in control
circuit. Check for burned contacts. Replace as needed.
Hook Does Not Stop Promptly
1. Hoist Overloaded
2. Brake not holding 1. Reduce load to within rated capacity of hoist. 2. Check motor brake adjustment (see paragraph 5-3) and load brake
(Figure 4-4).
Hook Moves in Wrong Direction
1. Three-phase reversal.
2. Improper connections.
1. Reverse any two wires (except the green ground wire) at the power
source (see paragraph 2-3).
2. Check all connections against Wiring Diagram.
Hoist Hesitates to Lift When Energized
1. Hoist overloaded.
2. Motor brake requires adjustment.
3. Worn overload limiting clutch.
4. Low voltage.
5. Faulty SINPAC starting switch or start
capacitor (single phase hoists only).
1. Check circuit breakers, switches and connections in power supply
Reduce load within rated capacity of hoist.
2. Check motor brake adjustment. See Figure 5-3.
3. Replace clutch.
4. Check voltage at hoist power cord with hoist starting. Voltage
should be no less than 90% of voltage specified on hoist.
5. Replace faulty component.
Hook Raises But Will Not Lower (Motor not running)
1. "Down" circuit open.
2. Broken conductor in pushbutton cable.
3. Faulty magnetic hoist control switch.
1. Check circuit for loose connections. Check "Down" limit switch for
malfunction.
2. Check each conductor in the cable. If one is broken, replace entire
cable.
3. Check coils for open or short circuit. Check all connections in control
circuit. Check for burned contacts. Replace as needed.
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Page 18
TROUBLE REMEDY
Hook Raises But Will Not Lower When Motor is Operating.
Consult Factory Or Authorized Duff-Norton Warranty Repair Station.
Hook Lowers But Will Not Raise
1. Hoist overloaded.
2. Low voltage.
3. "UP" circuit open.
4. Broken conductor in pushbutton cable.
5. Faulty magnetic hoist control switch.
6. Faulty capacitor (single-phase hoists only).
7. Worn overload limiting clutch.
1. Reduce load to within rated capacity.
2. Determine cause of low voltage and bring up to at least 90% of the
voltage specified on hoist. Line voltage should be measured while
holding or lifting load.
3. Check circuit for loose connections. Check "UP" limit switch for
malfunction.
4. Check each conductor in the cable. If one is broken, replace entire
cable.
5. Check coils for open or short circuit. Check all connections in
control circuit. Check for burned contacts. Replace as needed.
6. Check starting capacitor in motor. Replace if necessary.
7. Replace clutch.
Lack of Proper Lifting Speed
1. Hoist Overloaded
2. Motor brake is dragging.
3. Low voltage.
4. Overload limiting clutch intermittently
slipping.
1. Reduce load to within rated capacity of hoist.
2. Check for proper brake adjustment or other defects.
See paragraph 5-3.
3. Bring up voltage to plus or minus 10% of voltage specified on hoist.
Line voltage should be measured while hoist is lifting load.
4. Replace clutch.
Load Brake "Noise" (Erratic tapping sounds or squeals)
1. Need transmission oil change or improper
lubricant has been used.
2. Load brake malfunctioning.
1. Change transmission oil. See Table 5-1.
Note: Hoist Warranty is void if unapproved oil is used.
2. Check load brake operation. See paragraph 4-4.
Motor Brake Noise or Chatter (While starting hoist)
1. Brake needs adjustment.
2. Low voltage. 1. Adjust as per paragraph 5-3. 2. Check voltage at hoist power cord with hoist starting. Voltage should
be no less than 90% of the voltage specified. 115 volt hoists are
particularly subject to voltage drop problems due to their high current
draw. Conversion to 230 volt operation is suggested in extreme cases.
Motor Brake "Buzz" (Anytime hoist is running)
1. Brake needs adjustment.
2. Broken shading coil on brake frame. 1. Adjust as per paragraph 5-3. 2. Replace shading coil or complete brake frame assembly.
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Page 19
SAFETY NOTES
Disconnect power from hoist before removing end
covers.
7-1. Voltage Conversion
Standard single phase units are convertible from 115 to 230
volts and standard single speed three phase units are
convertible from 460 to 230 volts. Conversion to the alternate
voltage can be accomplished with the following procedure.
a. Be sure power is disconnected from hoist. Remove long
end cover.
b. Single Phase Hoists (With SINPAC' switch): Transfer leads
2. H2, H3, T2, S1, and T3 per the appropriate terminal block
schematic.
c. Three Phase Hoists: Transfer leads T4, T5, T6, T7, T8,T9,
H2, H3, S1, and S2 per the appropriate terminal block
schematic.
SECTION VII - WIRING
d. After converting voltage, check for proper phasing of three
phase units and check for proper limit switch operation.
7-2. Wiring Diagrams
The wiring diagrams for standard hoist models are reproduced
on the following pages. In addition, every hoist should have a
wiring diagram located inside the long end cover.
Figure 7-1. Wiring Diagram
115/230V, 1 Phase, Single Speed Hoist
with SINPAC Switch
14028
Do not move any wires or make any changes to the
wiring except at the terminal block.
CAUTION
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Page 20
Figure 7-2. Wiring Diagram
230/460V, 3 Phase, Single Speed Hoist
14029
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