Yale RS2 User's Manual
Contents
1. SAFETY PRECAUTIONS Each Yale RS2 Manually Lever Operated Hoist is built in accordance with the specifications contained herein and at the time of manufacture complies with our interpretation of applicable sections of ASME B30 21 ANSI ASME HST 3M and the Occupational Safety and Health Act 1970 The safety laws for elevators and for dumbwaiters specify construction details that are not incorporated in Yale industrial hoists We recommend the use of equipment that meets state and national safety codes for such use Yale Hoists cannot be responsible for applications other than those for which Yale equipment is recommended THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH IF NOT FOLLOWED COULD ENDANGER THE PERSONAL SAFETY AND OR PROPERTY OF YOURSELF AND OTHERS READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL AND ANY PROVIDED WITH THE EQUIPMENT BEFORE ATTEMPTING TO OPERATE YOUR YALE LEVER HOIST Copies of these standards may be obtained from ASME Order Department 22 Law Drive Box 2300 Fairfield NJ 07007 2300 a eae oS 12 13 14 15 16 17 18 19 20 21 22 23 24 NWARNING Improper operation of a hoist can create a potentially hazardous situation which if not avoided could result in death or serious injury To avoid such a potentially hazardous situation the operator shall NOT operate a malfunctioning or un2. 673 48 e Spline of liftwheel 673 10 e Outside surface of locking pins 673 78 B Alight coat of Lubrico M 32 Master Lubricant Co or equal grease to inside diameter of lever head 673 39 C Alight coat of Moly Duolube 67 Hercules Packing Co or equal dry film lubricant to threads and spline of pinion 673 9 D Alight coat of a graphite grease mixture to knob of upper and lower hooks 673 35 and bearing journals of 3 ton lower sheave 673 70 E 1 2 oz on 3 4 ton unit and 2 3 oz on 1 1 2 and 3 ton units of Texaco Novatex 2 or equal grease to pinion 673 9 teeth liftwheel gear 673 11 teeth and in gear cavity of frame 673 2 F A light coat of a graphite oil mixture to tip of lever plunger 673 46 for approximately 1 inch 25 4mm and threaded end up to including the spline of the pinion shaft 673 9 G See above for lubricating load chain graphite grease mixture consists of 1 Ib 46 Kg Superior Graphite Co 590 flake graphite and 2 Ib 92 Kg of Master Lubricant Co Lubricko M 32 grease graphite oil mixture consists of 1 oz of Superior Graphite Co 590 flake graphite and 1 qt 946 ml of Acheson Industries 7 DAG 154RFU oil a WARNING USING ANY GREASE OR LUBRICANT ON THE BRAKING SURFACES WILL CAUSE BRAKE SLIPPAGE AND LOSS OF LOAD CONTROL WHICH ULT IN INJURY AND OR PROPERTY TO AVOID INJURY DO NOT USE ANY GREASE OR LUBRICANT ON BRAKING SURFACES THE BRAKE IS DESIGNED
3. FRAME FREE TO SWIVEL NOT A STRAIGHT LINE BETWEEN UPPER AND LOWER l A HOOKS FRAME NOT Py amp FREE TO SWIVEL PROPER ATTACHMENT SAFE PULLING IMPROPER ATTACHMENT DANGEROUS PULLING TO PULL OR LIFT LOAD Move lever trigger to UP position Operate lever in up and down motion to shorten the distance between hooks and thus pull or lift the load When pulling or lifting move the load only enough to slightly load the unit then check to be sure that the attachments to the hooks and load are firmly seated Continue movement only after you are assured the load is free of all obstructions The hoist has been designed for hand powered operation only Do not use an extension on the lever Lever pulls of 45 pounds 21kg on the 3 4 ton unit 55 pounds 25kg on the 1 1 2 ton unit and 62 pounds 28kg on the 3 ton unit will result in rated capacity on the unit Any greater pull is an indication of either an overload or an incorrectly maintained unit TO LOOSEN OR LOWER LOAD POWER OPERATION MAY CAUSE STRUCTURAL DAMAGE OR PREMATURE WEAR THAT IN TURN MAY CAUSE A PART TO BREAK AND ALLOW THE LOAD TO FALL TO AVOID INJURY OPERATE THE RS2 LEVER HOIST USING HAND POWER ONLY Move lever trigger to DN position Again operate lever in an up and down motion to increase the distance between hooks and thus loosen or lower the load 7 Note that the cam is NOT changed when changing from up to down or fr
4. but in many cases match them in selecting the right hoist for the job a valuable load DO NOT OPERATE DAMAGED OR MALFUNCTIONING UNIT a WARNING DO NOT OPERATE WITH TWISTED KINKED OR DAMAGED INSPECT Load chain should be properly lubricated Hooks that are bent worn or whose openings are enlarged beyond normal throat opening should not be used If latch does not engage throat opening of hook hoist should be taken out service All hoists should be visually inspected before use in addition to regular periodic maintenance inspections f Under no circumstances should you operate Inspect hoists for operational warning a malfunctioning hoist notices and legibility Chains should be checked for deposits of foreign material which may be carried into Check chain for gouged twisted distorted thanaist mechanism AR a oe ees brought to links and foreign material Do not operate Se ee hoists with twisted kinked or damaged defective hoists are tagged and taken out of chaimlinks Check brake for evidence of slippage under service until repairs are made load DO NOT PULL AT AN ANGLE BE SURE LEVER HOIST AND LOAD ARE IN A STRAIGHT LINE DO NOT USE UNLESS FRAME AND CHAIN FORM A a WARNING STRAIGHT LINE BETWEEN HOOKS DO NOT USE IF FRAME IS IN CONTACT WITH ANY OBJECT DO NOT USE LOAD CHAIN AS A SLING DO NOT USE AN EXTENSION ON THE LEVER USE HOIST PROPERLY Be sure the hoist is solidly held i
5. chain that enters the hook side of the frame printed on the nameplate Tighten the hook block screw 673 51 firmly and then lock it in place by prick punching two spots 180 apart on edge of counterbore to drive metal into serrations on head of OO W VA ENS wa Pw Gi CEED CHD ICD LLY NLD NID screw If screw has been removed and replaced always use new spots for locking On the 3 ton unit hang it in the vertical position Making sure there are no twists in the chain feed the end of chain thru the hook block 673 71 and around lower sheave 637 70 Secure end of chain to hoist hanger using the dead end pin 673 76 G Assemble the end ring 673 53 to the free loose end of chain by rotating the last link 1 4 turn and passing the ends of the ring thru the link as shown below Hammer or squeeze the ends of the ring together to secure it to the chain Load Chain 673 52 Rotate Last Bend Link Of u Ends To Chain 90 Secure To As Shown Chain End Ring 73 53 CUTTING CHAINS Hoistaloy load chain is hardened for wear resistance and is difficult to cut However the following methods are recommended when cutting a length of new chain from stock or cutting off a length of worn chain 1 Use a grinder and nick the link on both sides then secure the link in a vise and break off with a hammer 2 Use a 7 inch 177 8mm minimum diameter by 1 8 inch 3 175mm thick abrasive wheel o
6. for the RS2 1 case 12 12 oz Aerosol Cans of Yellow Touch up Paint Part Number 40215 Touch up paints are only available in case quantities NOTE When painting the hoists also order warning labels and capacity labels that may be coating during painting 13 Note When ordering parts always furnish rated load and serial number of hoist on which the parts are to be used For the location of the nearest Yale Authorized Hoist Parts Depot see inside front cover LIMITATION OF WARRANTIES REMEDIES AND DAMAGES THE WARRANTY STATED BELOW IS GIVEN IN PLACE OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED OF MERCHANTABILITY FITNESS FORA PARTICULAR PURPOSE OR OTHERWISE NO PROMISE OR AFFIRMATION OF FACT MADE BY ANY AGENT OR REPRESENTATIVE OF SELLER SHALL CONSTITUTE A WARRANTY BY SELLER OR GIVE RISE TO ANY LIABILITY OR OBLIGATION Seller warrants that on the date of delivery to carrier the goods are free from defects in workmanship and materials SELLER S SOLE OBLIGATION IN THE EVENT OF BREACH OF WARRANTY OR CONTRACT OR FOR NEGLIGENCE OR OTHERWISE WITH RESPECT TO GOODS SOLD SHALL BE EXCLUSIVELY LIMITED TO REPAIR OR REPLACEMENT F O B SELLER S POINT OF SHIPMENT OF ANY PARTS WHICH SELLER DETERMINES TO HAVE BEEN DEFECTIVE or if Seller determines that such repair or replacement is not feasible to a refund of the purchase price upon return of the goods to Seller Any action against Seller for breach of warranty negligence or
7. include e Alloy steel liftwheel to reduce chain wear e Hoistaloy load chain for long and dependable service e Grease lubricated hardened alloy steel gears for smooth operation e Forged steel upper and lower latch type hooks e Patented free chaining mechanism for quick and easy attachment to the load e Lightweight aluminum frame covers and lever e Ball or needle bearings at rotating points e Compact yet rugged design provides minimum headroom and long trouble free service e Sealed automatic brake with two holding pawls for positive load control e Short lever 12 inches 305 mm long on 3 4 ton unit 16 3 4 inches 425 mm long on 1 1 2 and 3 ton units for operation in close quarters e Rocking and swivel upper hook 3 4 and 1 1 2 ton units e Backed by Yale s life time warranty YALE REPAIR REPLACEMENT POLICY All Yale RS2 Lever Hoists are inspected and performance tested prior to shipment If any properly maintained hoist develops a performance problem due to a material or workmanship defect as verified by Yale repair or replacement of the unit will be made to the original purchaser without charge This repair replacement policy applies only to hoists installed maintained and operated as outlined in this manual and specifically excludes hoists subject to normal wear abuse improper installation improper or inadequate maintenance hostile environmental effects and unauthorized repairs modifications We re
8. parts of the load Make sure the load is free to move and will clear all obstructions Avoid swinging the load or hook Avoid lever fly back by keeping a firm grip on the lever until operating stroke is completed and the lever is at rest Inspect the hoist regularly replace damaged or worn parts and keep appropriate records of maintenance Use the hoist manufacturer s recommended parts when repairing the unit Lubricate load chain per hoist manufacturer s recommendations NOT use the hoist load limiting or warning device to measure load NOT operate except with manual power NOT permit more than one operator to pull on lever at the same time More than one operator is likely to cause hoist overload NOT allow your attention to be diverted from operating the hoist NOT allow the hoist to be subjected to sharp contact with other hoists structures or objects through misuse NOT adjust or repair the hoist unless qualified to perform such adjustments or repairs HOIST SAFETY IS UP TO YOU a WARNING _ponortapply MORE THAN RATED LOAD CHOOSE THE RIGHT HOIST FOR THE JOB Choose a Yale Lever Hoist with a capacity The application the size and type of load Remember the hoist was designed to ease for the job Know the capacities of your the attachments to be used and the period our burden and carelessness not only hoists and the weight of your loads Then of use must also be taken into consideration endangers the operator
9. to move a load in their area E Do not leave a load on the unit unattended F Read warnings and instructions on the lever before each use G Do not hold the load chain while operating the hoist Should the hoist not operate properly serious injury may occur H Never operate the hoist when flammable materials or vapors are present Contact between metal parts may produce sparks that can cause a fire or explosion STAY ALERT Watch what you are doing and use common sense Do not use the hoist when you are tired distracted or under the influence of drugs alcohol or medication causing diminished control MALFUNCTION OF UNIT RIGGING SLIP OR LOSS OF FOOTING MAY CAUSE USER TO SLIP RESULTING IN INJURY TO AVOID INJURY ALWAYS HAVE A FIRM AND SECURE FOOTING WHEN USING THE RS2 LEVER HOIST CAM RN FREE CHAINING FAILURE TO PROPERLY USE THE FREE CHAIN MECHANISM MAY CAUSE INJURY AND OR PROPERTY DAMAGE TO AVOID INJURY USE THE FREE CHAIN MECHANISM AS DIRECTED BELOW In this mode of operation the gearing is disengaged to allow the chain to be easily pulled through the hoist by hand for quick attachment to the load To free chain the RS2 Lever Hoist 1 Make sure there is no load on the lower hook 2 Turn the lever trigger 1 4 turn from UP or DN LEVER 3 Rotate the cam knob 1 4 turn clockwise to right from OPERATE to FREE CHAIN A click will be heard or felt and th
10. 1 1 8 28 5mm 1 1 2 ton 1 5 16 33 3mm 3 ton 1 7 16 36 5mm Twisted Do Not Use Normal Ok To use Any hook that is twisted or has excessive throat opening indicates abuse or overloading of the unit Other load sustaining components of the hoist should be inspected for damage On latch type hooks check to make sure that the latch is not damaged or bent and that it operates properly with sufficient spring pressure to keep the latch tightly against the tip of the hook and allow the latch to spring back to the tip when released If the latch does not operate properly it must be replaced See previous illustration to determine when the hook must be replaced Replace Hook If Opening Is Greater Than 1 1 8 28 5 mm on 3 4 and 1 1 2 ton units or 1 15 16 49 2mm on 3 ton unit Replace Hook If Seat Is Less Than 21 32 16 7 mm on 3 4 and 1 1 2 ton units or 1 1 8 28 5mm on 3 ton unit On Latchlok type hooks measure seat wear and throat Opening as shown above and replace hook if measurements indicate the need to do same LOAD CHAIN Chain should feed smoothly into and away from the hoist If chain binds jumps or is noisy first clean and lubricate it see below If trouble persists inspect chain and mating parts for wear distortion or other damage Chain Inspection First clean chain with a non caustic non acid type solvent and make a link by link inspection for nicks gouges twisted li
11. HE UNIT INA STRAIGHT LINE HOOK TO HOOK MANNER AND KEEP FRAME FREE TO SWIVEL SEE FIGURE ON PAGE 3 Regardless of how the hoist is used make sure that the upper hook is firmly attached to a support or anchor that has sufficient strength to hold several times the rated load of the hoist TE Using the upper hook attach the hoist to support Be sure hoist is solidly held in the uppermost part of the hook arc and the latch is tightly against the hook tip ATTACHING THE HOIST FROM AN INADEQUATE SUPPORT MAY ALLOW THE HOIST AND LOAD TO FALL AND CAUSE INJURY AND OR PROPERTY DAMAGE TO AVOID INJURY MAKE SURE THE STRUCTURE HAS SUFFICIENT STRENGTH TO HOLD SEVERAL TIMES THE HOIST AND ITS RATED LOAD OPERATION IF NOT USED AS DIRECTED HOIST MAY CAUSE INJURY TO AVOID INJURY USE ONLY AS DIRECTED BELOW READ ALL INSTRUCTIONS BEFORE OPERATING THE RS2 LEVER HOIST GENERAL A The hoist must be kept clean to assure proper operation Before use check to be sure the load chain is clean that there is no foreign material in the liftwheel area and that the lever operates freely B Do not load beyond the rated capacity Overload can cause immediate failure or cause damage resulting in future failure even at less than rated capacity C Do not use this hoist or any other material handling equipment for lifting or moving people or lifting loads over people D Stand clear of all loads and warn other people of your intention
12. LATE BAR AND CHAIN OIL 10 R AS A LUBRICANT FOR THE LOAD CHAIN When lubricating the chain apply sufficient lubricant to obtain natural run off and full coverage especially in the interlink area LUBRICATION Refer to Exploded View and Parts List pages 10 thru 13 THE LUBRICANTS USED IN AND RECOMMENDED FOR THE RS2 LEVER HOIST MAY CONTAIN HAZARDOUS MATERIALS THAT MANDATE SPECIFIC HANDLING AND DISPOSAL PROCEDURES TO AVOID CONTACT AND CONTAMINATION HANDLE AND DISPOSE OF LUBRICANTS ONLY AS DIRECTED IN APPLICABLE MATERIAL SAFETY DATA SHEETS AND INACCORDANCE WITH APPLICABLE LOCAL STATE AND FEDERAL REGULATIONS NOTE To assure extra long life and top performance be sure to lubricate the various parts of the hoist using the recommended lubricants These lubricants may be purchased from Yale Refer to page 13 for information on ordering the lubricants Except for lubricating the load chain frequently the hoist requires no additional lubrication unless it has been disassembled for cleaning inspection and or repairs If the unit has been disassembled remove the old lubricant from the parts and apply new lubricants as follows A Alight coat of Texaco Novatex 2 or equal grease to e Needle bearings in gear cover 673 5 and frame 673 2 e Inside of pinion bushing 673 25 e Outside surface of cam pins 673 47 e Inside diameter and the cam pin slots in cam 673 18 e Outside surface of suspension bolt
13. O Z A Remove the lower hook block assembly from the load chain on the 3 4 and 1 1 2 ton units On the 3 ton unit disengage the load chain from the hoist hanger 673 75 g by removing the dead end pin 673 76 B Put unit in free chaining see page 2 C Pull on the end ring 673 53 and pull the chain out of the hoist and out of the lower hook block on the 3 ton unit D Remove the end ring from the load chain INSTALLING LOAD CHAIN 3 4 ton unit uses 1 4 in 6 3mm stock disc grade load IMPROPER INSTALLATION REEVING OF THE LOAD CHAIN CAN RESULT INA DROPPED LOAD TO AVOID INJURY e VERIFY USE OF PROPER SIZE AND TYPE OF LOAD CHAIN FOR SPECIFIC RS2 LEVER HOIST e INSTALL LOAD CHAIN PROPERLY AS INDICATED BELOW chain 1 1 2 and 3 ton units use 5 16 in 7 9mm stock disc grade load chain A Feed a piece of soft wire thru one chain opening in the Liftwheel Welds Out And Away From Liftwheel Load Chain 673 52 bottom of the frame up and over the liftwheel until it comes out the other opening Attach the wire to the load chain to be installed Make sure the unit is in free chaining See page 2 Position the chain so that the welds on the upstanding links will be up and away from the liftwheel and the first link entering the hoist is an upstanding link E Pull on the wire to pull the chain up and over the liftwheel F On 3 4 and 1 1 2 ton units attach the lower hook block to the strand of
14. OPERATING MAINTENANCE amp PARTS MANUAL MANUALLY LEVER OPERATED CHAIN HOIST Yale RS Lever Hol Capacities 3 4 1 1 2 3 ton 750 1500 3000 kg Follow 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 operator Failure to operate equipment as directed in manual may cause injury Before installing hoist fill in the information below Model No Serial No Purchase Date Rated Load 73907 A HOISTS 414 WEST BROADWAY AVENUE MUSKEGON MICHIGAN 49443 Manual No Y673 A YALE HOIST PARTS AND SERVICES AVAILABLE IN THE UNITED STATES As a Yale Hoist and Trolley user you are assured of reliable repair and parts services through a network of Authorized Parts Depots that are strategically located in the United States These facilities have been selected on the basis of their demonstrated ability to handle all parts and repair requirements promptly and efficiently To quickly obtain the name of the Authorized Parts Depot located nearest you call 866 805 2962 Fax 800 742 9270 NOTES
15. OR ALLOW THE CHAIN TO BREAK AND THE LOAD TO DROP TO AVOID INJURY DUE TO SIZE REQUIREMENTS AND PHYSICAL PROPERTIES USE ONLY HOISTALOY LOAD CHAIN IN THE RS2 LEVER HOIST Use only a Knife Edge caliper to eliminate possibility of false reading by not measuring full pitch length Note that worn chain can be an indication of worn hoist components For this reason the hoist s frame stripper and liftwheel should be examined for wear and replaced as necessary when replacing worn chain Also the load chain is specially heat treated and hardened and should never be repaired IMPORTANT Do not use replaced chain for other purposes such as lifting or pulling Load chain may break suddenly without visual deformation For this reason cut replaced chain into short lengths to prevent use after disposal Chain Lubrication A small amount of lubricant will greatly increase the life of load chain Do not allow the chain to run dry Keep it clean and lubricate at regular intervals with Lubriplate Bar and Chain Oil 10 R Fiske Bros Refining Co or equal lubricant Normally weekly cleaning and lubrication is satisfactory but under hot and dirty conditions it may be necessary to clean the chain at least once a day and lubricate it several times between cleanings 4 amp WARNING USED MOTOR OILS MAY CONTAIN KNOWN CARCINOGENIC MATERIALS TO AVOID INJURY NEVER USE USED MOTOR OILS AS A CHAIN LUBRICANT ONLY USE LUBRIP
16. OT allow the chain or hook to be used as an electrical or welding ground NOT allow the chain or hook to be touched by a live welding electrode NOT remove or obscure the warnings on the hoist NOT operate a hoist which has Not been securely attached to a suitable support NOT operate a hoist unless load slings or other approved single attachments are properly sized and seated in the hook saddle 25 26 27 28 29 10 11 12 13 14 15 16 NOT lift loads that are Not balanced and that the holding action is Not secure taking up slack carefully NOT operate a hoist unless all persons are and remain clear of the supported load Report malfunctions or unusual performances of a hoist after it has been shut down until repaired NOT operate a hoist on which the safety placards or decals are missing or illegible Be familiar with operating controls procedures and warnings N CAUTION Improper operation of a hoist can create a potentially hazardous situation which if not avoided could result in minor or moderate injury To avoid such a potentially hazardous situation the operator shall Maintain a firm footing or be otherwise secured when operating the hoist Check brake function by tensioning the hoist prior to each lift or pulling function Use hook latches Latches are to retain slings chains etc under slack conditions only Make sure the hook latches are closed and not supporting any
17. When lubricating parts adjacent to the brake DO NOT use an excessive amount of lubricant which could seep onto the brake surfaces EXTERIOR FINISH The exterior surface of the RS2 Lever Hoist has a durable scratch resistant baked powder coating Normally the exterior surfaces can be cleaned by wiping with a cloth However if the finish is damaged compatible touch up paint can be purchased from Yale Refer to page 13 for information on ordering paint PREVENTATIVE MAINTENANCE A preventative maintenance program should be established to prolong the useful life of the hoist and maintain its reliability and continued safe use The program should include frequent and periodic inspections see page 5 with particular attention paid to lubrication of various components using the recommended lubricants see Lubrication section for lubricating load chain and other parts RECOMMENDED SPARE PARTS To insure continued operation it is recommended that two friction discs Key No 673 13 be kept on hand at all times to replace friction discs that are worn glazed or contaminated Refer to page 12 for ordering information DISASSEMBLY When disassembling and assembling the RS2 Lever Hoist refer to the exploded view and parts list on pages 10 thru 13 These show the proper relationship of the parts part names and the required quantities of the parts In addition please observe the following A The liftwheel gear 673 11 is under s
18. ad Limiter from the stop in the full clockwise position to the stop in the full counterclockwise position From stop to stop there should be 10 to 45 of rotation If the rotation does not fall within this range remove the locking pins ratchet hub or Load Limiter pawl assemblies see step J friction discs ratchet and ratchet bushing Slide the friction hub partially off of the pinion until the splines disengage Rotate the friction hub slightly clockwise if the rotation is more than 45 or counterclockwise if the rotation is less than 10 Repeat steps 1 4 until the rotation from stop to stop is 10 to 45 Note The ratchet hub or Load Limiter can be started onto the thread of the pinion in one of four poisons Each time the ratchet hub or Load Limiter is threaded onto the pinion maintain the same orientation Install the pawl assemblies per step K M Assemble the snap ring 673 31 to the stripper pin 673 34 Slide the stripper 673 15 into the recess in the bottom of the frame and secure by sliding the stripper pin thru the holes in the frame and stripper Assemble brake cover 673 8 to frame Assemble the lever assembly step A to ratchet hub 673 14 or Load Limiter 673 59 and secure by attaching the lever cover 673 17 to the ratchet hub or Load Limiter P Install load chain 673 52 see removal and installation of load chain Q After assembly test the unit as indicated on page 9 REMOVAL OF LOAD CHAIN
19. ain Specify Length Regd 85839 73750 73752 1 Patent Label no longer avaiable order 67355 o 1 Load Limiter Label Only for units 73763 73316 7309 P Upper hook block assembly includes 73606 673 16 673 30 and 673 35 2 73340 If latchlok hook is required part numbers are 3 4 ton upper and lower hooks 1001 1 1 2 ton upper and lower hooks 1002 3 ton lower hook 1004 3 ton upper hook 1010 40606 50454 40882 i 982885 945820 85757 0166 40689 40806 40382 982335 13324 40851 673 77 If latchlok hook is required contact Yale PART NUMBERS FOR PACKAGED LUBRICANTS USED IN THE RS2 LEVER HOISTS REFER TO PAGE 6 FOR LUBRICATION INSTRUCTIONS LUBRICANT TYPE OF PART NUMBERS AND USAGE LUBRICANT PACKAGED QUANTITIES OF LUBRICANTS 3 TON LOWER SHEAVE BEARING GREASE GRAPHITE 40626 1 LB 46 Kg CAN JOURNALS AND SEAT FOR HOOK KNOB MIXTURE 3 4 AND 1 1 2 TON TIP OF LEVER PLUNGER AND DRY LUBE OIL 40628 1 PT 5L CAN THREADED END OF PINION SHAFT GRAPHITE MIXTURE INSIDE OF LEVER HEAD GREASE 40630 1 LB 46 Kg CAN GEARS LIFTWHEEL SPLINE NEEDLE BEARINGS PINION BUSHING CAM AND 28610 1 LB 46 Kg CAN LOCK PINS CAM SLOTS AND I D OF CAM GREASE 28632 4 LB 1 8 Kg CAN THREADS OF PINION SPRAY DRY 46698 16 OZ CAN LUBRICANT LOAD CHAIN OIL 28608 1 PT 5L CAN When ordering lubricants specify the type of lubricant part number and packaged quantity required Touch up paint
20. applying an overload and removing it by external means the brake may become locked This results in not being able to operate the unit in the down direction Should this occur move the trigger to the DN position and give the lever a sharp pull and then additional strokes to lower the load and remove tension from the unit Use as directed above Failure to do so may cause injury to you or others Do not exceed capacity shown on frame or lower hook block Do not use to lift people or loads over people Do not use unless the hoist s frame and chain form a Straight line between hooks Do not use if the frame is in contact with any object Do not use if the unit is damaged or malfunctions Do not use extension on lever Use hand power only Do not use if chain is twisted kinked or damaged INSPECTION To maintain continuous and satisfactory operation a regular periodic inspection procedure must be initiated so that worn damaged and missing parts can be replaced before the unit becomes unsafe The frequency of inspection must be determined by the individual application The following list gives an inspection procedure for normal usage under normal conditions When the unit is subjected to heavy usage or dusty gritty moist or corrosive atmospheric conditions shorter time periods must be assigned Inspection must be made of all parts for unusual wear corrosion or damage in addition to those speci
21. d or worn parts Do not take up the load chain to the point where the end ring or lower hook block becomes jammed against the frame ATTACHING TO LOAD Attach the lower hook to the load so that it is seated in the bowl of the hook and is not bearing against the tip of the hook and the latch is tight against the hook tip ALLOWING THE LOAD TO BEAR AGAINST THE HOOK LATCH AND OR HOOK TIP CAN RESULT IN LOSS OF LOAD TO AVOID INJURY DO NOT ALLOW THE LOAD TO BEAR AGAINST THE HOOK LATCH AND OR HOOK TIP APPLY LOAD TO HOOK BOWL OR SADDLE ONLY Do not wrap the load chain around the load and hook onto itself as a choker chain sling or bring the load in contact with the hoist Doing this will result in the loss of the swivel effect of the hook which could cause twisted chain and a jammed liftwheel Also the chain may be damaged at the hook Make sure the upper and lower hooks are in a straight line and the frame is free to swivel on the upper hook If the proposed use prevents straight line attachment use an Anchor Sling See page 1 or a chain sling to obtain a straight line pull IF THE UNIT IS NOT RIGGED IN A STRAIGHT LINE HOOK TO HOOK MANNER AND IF THE FRAME IS NOT FREE TO SWIVEL LEVER PULL MAY BREAK FRAME AND CAUSE PHYSICAL INJURY AND LOSS OF LOAD TO AVOID INJURY RIG THE UNIT INA STRAIGHT LINE HOOK TO HOOK MANNER AND KEEP FRAME FREE TO SWIVEL SEE BELOW UPPER AND LOWER HOOKS IN STRAIGHT LINE
22. e cam cannot be rotated further in the clockwise position N DO NOT X EDN ai 4 Pull on hook side and loose end side of load chain to make sure chain feeds freely into and out of the hoist 5 Grasp unit by frame or upper hook and pull on end ring or lower hook to pull the chain through hoist to the length required to attach lower hook to load Pull on end ring to take up slack in chain and THEN LET GO OF END RING 6 Rotate the cam counterclockwise to left until the arrow points to operate 7 Pull sharply on the loose end of chain and THEN LET GO OF CHAIN Pull sharply on the lower hook side of chain to make sure gearing is fully engaged FAILURE TO FULLY ENGAGE THE GEARING WILL ALLOW LOAD TO RELEASE AND THUS CAUSE INJURY TO AVOID INJURY AFTER ROTATING CAM KNOB TO OPERATE PULL EACH CHAIN SHARPLY TO RE ENGAGE GEARING AS DIRECTED ABOVE 8 The hoist is now ready for operation Move trigger to UP position and operate lever in and up and down motion to shorten the distance between hooks and thus pull or lift load Only move the load enough to slightly load the hoist Check free play of cam knob The arrow tip should not move more than 3 16 inch 4 7mm If movement is greater than this move trigger to DN position and operate the lever to remove the load Repeat step 7 and if the free play is still more than 3 16 inch 4 7mm the hoist should be disassembled to check for damage
23. f type recommended by wheel supplier that will clear adjacent links Grinder Nicks Cutting Chain by Nicking 3 Chain may also be cut using a bolt cutter with special jaws for cutting hardened chain 1 inch 25 4mm long cutting edge Cutting Chain with a Bolt Cutter 4 amp WARNING CUTTING CHAIN CAN PRODUCE FLYING PARTICLES TO AVOID INJURY e WEAR EYE PROTECTION e PROVIDE A SHIELD SUCH AS A HEAVY RAG OVER THE CHAIN TO PREVENT FLYING PARTI CLES TESTING Prior to initial use all altered or repaired hoists or hoists that have not been operated for the previous 12 months must be tested by the user for proper operation Test the unit first in the unloaded state and then with a light load of 50 pounds 23kg times the number of load supporting strands of load chain to be sure it operates properly and the brake holds the load when the lever is released then test with a load of 125 of rated capacity In addition hoists in which load sustaining parts have been replaced shall be tested with 125 of rated capacity by or under the direction of an appointed person and a written report prepared for record purposes If unit is equipped with a Load Limiter it may refuse to lift the 125 overload Should this occur reduce the test load to rated capacity Also on such units the function of the Load Limiter should be checked To do this attach the lower hook to a load of 180 of rated capacity and operate the
24. fically mentioned in the schedule on page 5 Make certain that the unit is complete and contains all parts including hook latches and end ring Any parts that are deemed unserviceable must be replaced with new parts before the unit is returned to service It is very important that the unserviceable parts be destroyed and properly disposed of to prevent their possible future use as a repair item Use only Yale Hoist supplied repair parts as other parts may look the same but may not be to proper specifications Inspection of hoists is divided into two general classifications designated as frequent and periodic Frequent Inspections These inspections are by the operator or other designated personnel Frequent inspections are to be performed daily or prior to each use and they are to include the following Check for free movement of the lever trigger and cam Operate hoist with no load and check for visual signs or abnormal noises that could indicate a potential problem Check brake for evidence of slippage Check chain for lubrication wear damaged links or foreign material see page 6 Check hooks for damage cracks twist latch engagement and latch operation see below F Check lever for bends cracks and damage G Check support or anchor for damage m OO WPL Any deficiencies noted during the frequent inspections must be corrected before using the hoist Periodic Inspections These are visual ins
25. n Be sure the hoist and load areina Be sure load is hooked securely Do not operate with hoist frame Never use an extension on the the uppermost part of the support straight line Do not use unless Do not tip load the hook Do not resting against any object Apply lever You re dangerously hook arc frame and chain form a straight load hook latch Hook latch is to the load gently Do not jerk it overloading the hoist if you exceed line between hooks prevent detachment of load under the rated lever pull or if you have slack chain conditions only to use a lever extension to lift or pull a load PRACTICE CAUTION ALWAYS OPERATOR SERVICE CLEANING Lever Hoists should be kept clean and free of dust dirt moisture etc which will in any way affect the operation or safety of the equipment LUBRICATION Chain should be properly lubricated AFTER REPAIRS Carefully operate the hoist before returning it to full service Do not lift co workers with a Yale Lever Hoist Make sure everyone is clear of the load when you apply tension Do not remove or obscure operational warning notices VIOLATION OF ANY OF THESE WARNINGS LISTED MAY RESULT SERIOUS PERSONAL INJURY TO THE OPERATOR OR NEARBY PERSONNEL BY RELEASED LOAD OR BROKEN HOIST COMPONENTS SPECIFICATIONS The Yale RS2 Lever Hoist is a highly versatile manually lever operated chain hoist that can be used to efficiently pull lift drag or stretch Standard features of the hoist
26. nks weld spatter corrosion pits striations minute parallel lines cracks in weld areas wear and stretching Chain with any one of these defects must be replaced Slack the portion of the chain that normally passes over the 250 6 3 mm for 3 4 ton unit 312 7 9 mm for 1 1 2 and 3 ton units Weld Wear In These Areas liftwheel Examine the interlink area for the point of maximum wear polishing Measure and record the stock diameter at this point of the link Then measure stock diameter in the same area on a link that does not pass over the liftwheel use the link adjacent to the end ring for this purpose Compare these two measurements If the stock diameter of the worn link is 0 010 inches 0 254mm or more less than the stock diameter of the unworn link the chain must be replaced Vernier Caliper Measure 11 Pitches One Pitch Also check chain for stretch using a vernier caliper as shown above Select an unused unstretched section of chain usually at the loose end and measure and record the length over 11 chain links pitches Measure and record the same length on a worn section of chain Obtain the amount of stretch and wear by subtracting the measurement of the unworn section from the measurement of the worn section If the result amount of stretch and wear is greater than 0 145 inch 3 7 mm the chain must be replaced USING OTHER THAN YALE SUPPLIED LOAD CHAIN MAY CAUSE THE CHAIN TO JAM IN THE HOIST AND
27. om down to up operation TURNING THE CAM WITH ALOAD ATTACHED WILL ALLOW THE LOAD TO RELEASE AND MAY CAUSE INJURY TO AVOID INJURY NEVER TURN THE CAM WHEN THE HOIST IS UNDER LOAD INSPECT THE RS2 LEVER HOIST Inspect the RS2 before each use and at specified intervals as directed in the inspection section see next column LOAD LIMITER The operation of a RS2 Lever Hoist equipped with a Load Limiter is the same as described above In fact as long as you are pulling or lifting loads that are within the rated capacity of the hoist the Load Limiter will not function and you will not notice any difference in operation However if attempting to pull or lift load that is approximately 20 greater than rated capacity the Load Limiter will function As a result the lever will move but there will be no corresponding movement of the lower hook or load when the unit is operated in the up direction Should this occur immediately move the trigger to the DN position and operate the lever until the overload is set down and removed from the unit Reducing the load to rated capacity or less will automatically return the hoist to normal operation CAUTION THE LOAD LIMITER IS SUBJECT TO OVERHEATING AND WEAR WHEN EXCESSIVELY OPERATED FOR THIS REASON WHEN AN OVERLOAD IS DETECTED THE EXCESS LOAD MUST BE REMOVED AS QUICKLY AS POSSIBLE WITHOUT CONTINUED OPERATION OF THE LEVER Under certain conditions such as
28. on It will not open accidentally even if the load chain goes slack Once opened it can be shut with one hand or by the weight of the load when it is lifted Latchlok hooks can be supplied with the hoist or it can be provided in kit form for lever hoists already in service Anchor Sling for 3 4 and 1 1 2 ton units only Anchor Sling is an upper hook extender that simplifies attachment when application or space limitation makes it impossible to pull in a straight line from hook to hook A swiveling hook block is securely anchored to the housing and the upper hook swivels through a full 360 Anchor Sling may be ordered as a feature of your new hoist or in kit form for simple installation on units now in use UNPACKING After removing the hoist from the carton check it for damage that may have occurred during shipment If there is damage refer to the packing slip envelope for claims procedure INSTALLATION The RS2 Lever Hoist is designed for operation at ambient temperatures of 0 to 100 F 17 to 38 C It can be used in any position for pulling a load at an angle horizontal pulling or vertical lifting provided it is rigged to pull ina straight line from hook to hook and the frame is free to swivel on the upper hook IF THE UNIT IS NOT RIGGED INA STRAIGHT LINE HOOK TO HOOK MANNER AND IF THE FRAME IS NOT FREE TO SWIVEL LEVER PULL MAY BREAK FRAME AND CAUSE PHYSICAL INJURY AND LOSS OF LOAD TO AVOID INJURY RIG T
29. otherwise must be commenced within one year after such cause of action occurs NO CLAIM AGAINST SELLER FOR ANY DEFECT IN THE GOODS SHALL BE VALID OR ENFORCEABLE UNLESS BUYER S WRITTEN NOTICE THEREOF IS RECEIVED BY SELLER WITHIN ONE YEAR FROM THE DATE OF SHIPMENT Seller shall not be liable for any damage injury or loss arising out of the use of the goods if prior to such damage injury or loss such goods are 1 damaged or misused following Seller s delivery to carrier 2 not maintained inspected or used in compliance with applicable law and Seller s written instructions and recommendations or 3 installed repaired altered or modified without compliance with such law instructions or recommendations UNDER NO CIRCUMSTANCES SHALL SELLER BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES AS THOSE TERMS ARE DEFINED IN SECTION 2 715 OF THE UNIFORM COMMERCIAL CODE INDEMNIFICATION AND SAFE OPERATION Buyer shall comply with and require its employees to comply with directions set forth in instructions and manuals furnished by Seller and shall use and require its employees to follow such instructions and manuals and to use reasonable care in the use and maintenance of the goods Buyer shall not remove or permit anyone to remove any warning or instruction signs on the goods In the event of personal injury or damage to property or business arising from the use of the goods Buyer shall within 48 hours thereafter give Seller written n
30. otice of such injury or damage Buyer shall cooperate with Seller in investigating any such injury or damage and in the defense of any claims arising therefrom If Buyer fails to comply with this section or if any injury or damage is caused in whole or in part by Buyer s failure to comply with applicable federal or state safety requirements Buyer shall indemnify and hold Seller harmless against any claims loss or expense for injury or damage arising from the use of the goods Ay WARNING ALTERATIONS OR MODIFICATIONS OF EQUIPMENT AND USE OF NON FACTORY REPAIR PARTS CAN LEAD TO DANGEROUS OPERATION AND INJURY TO AVOID INJURY e DO NOT ALTER OR MODIFY EQUIPMENT e DO USE ONLY FACTORY PROVIDED REPLACEMENT PARTS Yale HOISTS 414 WEST BROADWAY AVENUE MUSKEGON MICHIGAN 49443 1 866 805 2962 Fax 1 800 742 SS 5 2001 2001 Yale Hoist Printed in USA
31. pections by an appointed person who records conditions to provide a basis for a continuing evaluation of the hoist Periodic inspections are to be performed semi annually and they should include the following A All items listed under frequent inspections B Evidence of loose screws C Evidence of worn corroded cracked or distorted upper and lower hook blocks frame end ring hook block screws covers lever Suspension bolt gears bearings pawls pawl springs cam cam pins lever cover free chaining spring ratchet hub stripper Load Limiter if equipped with same ratchet and hoist hanger D Evidence of worn glazed or oil contaminated friction discs Friction discs should be replaced if their thickness is less than 075 inch 2 mm E Warning label for legibility NOTE To perform some of the periodic inspections it is necessary to partially disassemble the hoist Refer to Disassembly Assembly starting on page 7 Also the external conditions may show the need for more detailed inspection which in turn may require the use of non destructive type testing Any deficiencies noted during the periodic inspection must be corrected before using the hoist Hook Inspection Hooks damaged from chemicals deformations or cracks or that have more than a 10 twist from the plane of the unbent hook or excessive opening or seat wear must be replaced Te Replace Hook hen Opening Is Greater Than the following 3 4 ton
32. pring pressure and may spring out when the gear cover 673 5 is removed B Needle bearings are pressed into the gear cover 673 5 and frame 673 2 Unless they are to be replaced do not attempt to remove these bearings C If so equipped do not attempt to disassemble the Load Limiter 673 59 The Load Limiter is calibrated by Yale and no attempt should be made to recalibrate the device If it is not functioning properly the entire Load Limiter must be replaced D Refer to page 8 for removal and installation of load chain E The brake cover 673 8 includes a rubber seal and care should be taken to make sure it is not cut or damaged ASSEMBLY When reassembling the unit lubricate the various parts as specified on page 6 and observe the following A Maintain the proper relationship of the lever plunger 673 46 tip and the trigger 673 43 as shown above B Assemble pinion washer 673 26 and then bushing Lever Plunger 673 46 673 25 to pinion 673 9 and slide this assembly into the frame 673 2 C Place liftwheel bearing 673 1 on liftwheel 673 10 and slide this assembly into frame 673 2 D Place the large end of the free chain spring 673 20 in the recess of the liftwheel gear 673 11 and slide the gear onto the liftwheel 673 10 spline spring end first E Assemble snap ring 673 33 to suspension bolt 673 48 Assemble upper hook 673 35 and hook blocks Liftwheel Gear 673 11 F
33. ree Chain Spring 673 20 673 16 Place this assembly in recess on top of frame 673 2 and secure by sliding the suspension bolt thru holes in frame and hook block Snap ring on suspension bolt must be on gear side of frame F Push on liftwheel gear to compress the spring and attach the gear cover 673 5 to the frame 673 2 G Insert the cam pins 673 47 ROUND END OUT in the holes above and below boss on gear cover 637 5 H Assemble the cam 673 18 to the gear cover 673 5 so that the arrow is pointing towards operate Cam Pins 673 47 Round End Out screw 673 29 J Assemble pawls 673 19 to pawl shafts 673 22 and secure with snap rings 673 32 Place pawl springs 673 21 on pawl shafts and insert these assemblies into frame 673 2 K Slide friction hub 673 12 onto pinion 673 9 and place one friction disc 673 13 on top of friction hub Frame 673 2 Assemble ratchet bushing 673 24 to ratchet 673 23 Spring apart pawls and slide ratchet bushing assembly on friction hub as shown below L To assemble and adjust the brake place the second friction disc 673 13 on top of the ratchet Thread the Ratchet Bushing 673 24 Frame Ratchet 673 2 673 23 Pawl Assembly ratchet hub 673 14 or Load Limiter 673 59 onto the pinion 673 9 Insert the two locking pins 673 78 into the holes of the ratchet hub or Load Limiter Holding the pinion steady rotate the ratchet hub or Lo
34. serve the right to change materials or design if in our opinion such changes will improve our product Abuse repair by an unauthorized person or use of non Yale replacement parts voids the guarantee and could lead to dangerous operation For full Terms of Sale see Sales Order Acknowledgment Also refer to the back cover for Limitations of Warranties Remedies and Damages and Indemnification and Safe Operation ALTERATIONS OR MODIFICATIONS OF EQUIPMENT AND USE OF NON YALE REPAIR PARTS CAN LEAD TO DANGEROUS OPERATION AND INJURY TO AVOID INJURY e DO NOT ALTER OR MODIFY EQUIPMENT e DO USE ONLY YALE PROVIDED REPLACEMENT PARTS OPTIONS Load Limiter The Load Limited is a friction device that is designed and factory calibrated to prevent lifting excessive overloads An excessive overload is indicated by lever movement without corresponding movement of the lower hook or load when the hoist is operated in the up direction Should this occur operate the lever in the down direction to remove the overload Reducing the load to rated capacity or less will automatically restore normal operation The Load Limiter can be ordered as part of a new lever hoist or in kit form that can be added to units now in service Latchlok Hooks Latchlok hooks are available to replace the standard latch type hooks The unique design of the Latchlok hook assures that it will stay locked until the operator releases it by depressing the release butt
35. unit in the up direction When attempting to lift this load the lever should slip If it does not the Load Limiter must be replaced After this test operate the unit in the down direction to remove tension in the chain NOTE For additional information on inspection and testing refer to the current issue of ASME B30 21 Manually Lever Operated Hoists obtainable from ASME Order Department 22 Law Drive Box 2300 Fairfield NJ 07007 2300 U S A 10 KEY NO 673 1 673 2 673 3 673 4 673 5 673 6 673 7 673 8 673 9 673 10 673 11 673 12 673 13 673 14 673 15 673 16 673 17 673 18 673 19 673 20 673 21 673 22 673 23 673 24 673 25 673 26 673 27 673 28 673 29 673 30 673 31 673 32 673 33 673 34 673 35 673 36 673 39 673 40 673 41 673 42 673 43 673 44 673 45 673 46 673 47 673 48 673 49 673 50 NO REQ D 1 _ RS2 LEVER HOIST PARTS LIST Liftwheel Bearing Gear Cover includes 673 6 and 673 7 PART NAME Brake Cover with seal Pawl Suspension Bolt Snap Ring Stripper Pin Hook with Latch Latch type Latch Kit Lever Assembly Includes 673 40 673 41 673 42 673 43 673 44 673 45 and 673 46 Hook Block Drilled Hook Block Tapped PART NUMBER ao e oo re ms 200 a o on ora won o o 673 77 For complete 3 4 or 1 1 2 ton upper hook block assembly 673 61 Anchor Sling optional for 3 4 and 1 1 2 ton
36. units 673 5 673 54 673 62 3 4 and 1 1 2 Ton Lower Hook Block Assembly 3 Ton Lower Block I 11 673 72 673 76 ae a oe 673 8 p oO D 673 14 673 78 a 673 73 N 673 27 673 74 673 17 fi s e iF ar 673 44 673 39 673 45 Load Limiter Optional Exploded View USING COMMERCIAL OR OTHER MANUFACTURER S PARTS TO REPAIR THE RS2 me RS2 Lever Hoist USE ONLY YALE SUPPLIED REPLACEMENT PARTS 673 66 PARTS MAY LOOK ALIKE BUT YALE PARTS ARE MADE OF SPECIFIC MATERIALS OR PROCESSED 3 71 TO ACHIEVE SPECIFIC PROPERTIES ORDERING INFORMATION The following information must accompany all correspondence or repair parts orders 1 Capacity 2 Serial Number this is stamped on the frame For parts orders also specify 1 Quantity desired 2 Key number of part 3 Part Name 4 Part number of the part When ordering replacement parts consideration should be given to the need to replace other items lock Hook bushings fasteners etc and items that may be damaged or lost during disassembly or just unfit for future use because of deterioration from age or service Parts should be ordered from Yale Master Parts Depots conveniently located throughout the United States Refer to the back of front cover of this manual to locate the Parts Depot nearest you 12 KEY NO PART NAME PART NUMBER NO REQ D 3 4 TON 1 1 2 TON 3 TON 673 51 40854 673 62 Load Ch
37. usually performing hoist NOT operate the hoist until you have thoroughly read and understood this Operating Maintenance and Parts Manual NOT operate a hoist which has been modified without the manufacturer s approval or certification to be in conformity with applicable OSHA regulations NOT lift or pull more than rated load for the hoist NOT use damaged hoist or hoist that is Not working properly NOT use hoist with twisted kinked damaged or worn load chain NOT operate with any lever extension cheater bar NOT attempt to free chain the hoist while a load is applied NOT use the hoist to lift support or transport people NOT lift loads over people and make sure all personnel remain clear of the supported load NOT attempt to lengthen the load chain or repair damaged load chain Protect the hoist s load chain from weld splatter or other damaging contaminants NOT operate hoist when it is restricted from forming a straight line from hook to hook in the direction of loading NOT use load chain as a sling or wrap load chain around load NOT apply the load to the tip of the hook or to the hook latch NOT apply load unless load chain is properly seated in the chain wheel s or sprocket s NOT apply load if bearing prevents equal loading on all load supporting chains NOT operate beyond the limits of the load chain travel NOT leave load supported by the hoist unattended unless specific precautions have been taken N
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