CPV Operating Manual - 2010
CPV Operating Manual - 2010
Model CPV/F
Capacity 125kgs - 2000kgs
OPERATING,
MAINTENANCE,
SPARE PARTS AND
WIRING DIAGRAMS
Yale
Industrial Products
®
Yale
CPV/F
®
Fig. 1
*Changing the gear ratio results in different lifting speeds. **Optionally available with 11m/min.
2
Yale
®
CPV/F
1. General information 3 Attention: All users must read these operating instructions carefully
prior to the initial operation. These instructions are intended to
1.1 Decibel Levels 3
acquaint the user with the hoist / trolley and enable them to use it to
2. Correct operation 3
the full extent of its intended capabilities.
Maximum capacity 3
Danger zones 3 The operating instructions contain important information on how to
Attaching the hoist / trolley 3 operate the hoist / trolley in a safe, correct and economic way. Acting
Temperature range 4 in accordance with these instructions helps to avoid dangers, reduce
Regulations 4 repair costs and downtime and to increase the reliability and lifetime
Maintenance / repair 4 of the hoist / trolley.
3. Incorrect operation 4
Anyone involved in doing any of the following work with the hoist /
4. Assembly 4
trolley must read the operating instructions and act accordingly:
4.1 Inspection before assembly 4
4.2 Electric chain hoist with suspension bracket 4/5 • Operation, including preparation, trouble shooting and
4.3 Electric chain hoist with trolley 5 cleaning.
Assembly of the trolley 5/6 • Maintenance, inspection, repair.
4.4 Electrical connection 6 • Transport.
Preparation 6
Mains supply connection 6 Apart from the operating instructions and the Health & Safety
4.5 Motor data 7 Regulations, which are valid for the respective country and area where
5. Functional test after assembly 8 the hoist / trolley is to be used, the commonly accepted regulations
6. Commissioning 8 for safe and professional operation must be adhered to.
Inspection before initial operation 8
The user is responsible for the proper and professional instruction of
7. Operation 8 the operating personnel.
Installation, service, operation 8
Inspection before starting work 8 Every unit leaving the factory is furnished with a test certificate that
Inspection of load chain 8 shows the serial number of the hoist / trolley. This certificate has to
Inspection of chain end stop 8 be filed together with the inspection manual to form a service file which
Inspection of chain reeving 8 should be maintained throughout the life of the hoist.
Inspection of load hook 8
Attaching the load 8
1.1 DECIBEL LEVELS
Inspect the traverse (for trolleys) 8
Check adjustment of trolley width 8 The continuous sound level at the place of work is equal to >73dB.
Traversing the trolley 8 The measurements were taken at a distance of 1 m from the hoist at
Attaching the load 9 9 positions in accordance with DIN 45635, precision class 2.
Lifting / lowering the load 9
Emergency stop 9
Limit switch 9
8. Service 9 2. CORRECT OPERATION
8.1 Daily checks 9 Maximum capacity:
8.2 Regular inspections, service and testing 10 The Yale electric chain hoist series CPV/F has been designed to lift
8.3 Load chain 10 and lower loads up to the rated capacity. The lifting capacity indicated
Lubricating the load chain 10 on the hoist / trolley is the maximum safe working load which must
Inspecting the load chain for wear 10 not be exceeded.
Replace the load chain 10
1 fall design, 2 fall design 10/11 Danger zones:
8.4 Maintenance of load hook 11 • Do not lift or transport loads
8.5 Maintenance of trolley 12 while personnel are in the danger
8.6 Maintenance of overload protection device 12 zone.
• Do not allow personnel to pass
Overload protection 12
under a suspended load ( Fig. 2).
Adjustment of overload protection 12
• After lifting or tensioning, a load
8.7 Maintenance of gearbox 12
must not be left unattended for
Oil change 12 a long period of time.
8.8 Maintenance of motor 13 • Start moving the load only after
Motor 13 it has been attached correctly
Spring activated disc brake 13 and all personnel are clear of the
Changing of rotor with friction lining 13 danger zone.
Disassembly of disc brake 13 Fig. 2
8.9 Electric chain hoist in general 13
9. Inspection chart 14 Attaching the hoist / trolley:
10. Spare parts list 15-22 The operator must ensure that the hoist / trolley is attached in
11. Wiring diagrams 22 a manner that does not expose himself or other personnel to
12. EC Declaration of Conformity 23 danger by the hoist, trolley, chain(s) or the load.
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Yale
CPV/F
®
Temperature range
The units can be operated in ambient temperatures between -10OC
and + 40OC. Consult Yale in the case of extreme working conditions.
Note: At ambient temperatures below 0OC check the brake is not
frozen.
Regulations
The Accident Prevention Act and / or Safety Regulations of the
respective country for using manual and electric hoists must be strictly
adhered to.
Maintenance / repair
In order to ensure correct operation, not only the operating
instructions, but also the conditions for inspection and maintenance Fig. 7 Fig. 8
must be complied with. If defects are found stop using the hoist /
trolley immediately.
Fig. 4
4. ASSEMBLY
Fig. 3
4.2 ELECTRIC CHAIN HOIST WITH SUSPENSION BRACKET
(Standard version)
block (Fig. 5) is not permitted. The standard version of the Yale electric chain hoist is provided with
Lift only when the load chain forms a straight line between a suspension bracket. The bracket is connected with the housing of
suspension bracket and hook. the chain hoist by means of two pins. Make sure that the load hook
• The load chain must not be used for lashing purposes – irrespective of the reeving – is always positioned vertically under the
(sling chain) (Fig. 6). suspension bracket.
4
®
On single fall units, the suspension bracket is installed with the long 6. Loosely replace the second side plate (item 6) on the cross bars
bracket side to the right, on dual fall units with the long bracket side (item 1). The washers (item 3), hex. nuts (item 2) and locknuts
to the left (see Fig. 11). (item 9) can be fitted loosely.
Fig. 11
A 98 180 27
B 180 300 27
Tab. 1
4. Replace one side plate (item 6), ensuring that the roll pins (item
10) engage into one of the bores in the round nuts (item 8). To
achieve this, it may be necessary to rotate the round nuts slightly.
5. Replace the washers (item 3) and tighten the hex. nuts (item 2).
Screw on the locknuts (item 9) fingertight and tighten a further
1/4 to 1/2 turn. Attention: The locknuts must always be fitted.
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Yale®
CPV/F
Yale Electric Chain Hoist - CPV/F
8. Engage the second side plate (item 6) ensuring that roll pins 4.4 ELECTRICAL CONNECTION
(item 10) engage into one of the bores in the round nuts
(item 8). To achieve this, it may be necessary to rotate the round Attention!
Work at electrical installations may be carried out only by
nuts slightly.
qualified electrical engineers. The local regulations have
to be strictly observed, e.g. EN 60204-32 / VDE 0113.
9. Tighten the hex. nuts (item 2) on the second side plate.
Tighten locknuts (item 9) finger tight and then, a further 1/4 to Preparation
1/2 turn. • Before beginning work on electrical components, the mains
Attention: The locknuts must always be fitted. current switch must be switched OFF and secured against
unintentionally being switch back on.
10.By traversing the trolley, check the following:
• A clearance of 2mm is maintained on each side between • Before connecting the chain hoist, ensure that the electrical
the trolley wheel flanges and the beam outer edge. data on the nameplate match the local specifications.
• The suspension traverse is centred below the beam.
• The mains supply cable must be an insulated cable with 4
• All 4 locknuts (item 9) are fitted.
flexible leads. The ground (earth) lead must be longer than
the live leads. For wire cross-section and fusing of the
11.Model CPV/F-VTG only: various models, see tables on page 7. Cable ends have to
To fit the hand chain, position the slot on the outer edge of be provided with end sleeves.
the hand chain wheel below the chain guide. Place any one link
of the endless hand chain vertically into the slot and turn • The length of the pendant control cable is determined by
the hand chain wheel until the link has passed the chain working conditions. Attach the tension relief wire so that the
guides on both sides. Please note that geared trolleys are pendant control cable hangs free of the load.
moved by operating the hand chain.
• Wiring and terminal connecting diagrams are included with
Attention: Do not twist the hand chain when fitting.
the hoist and shown on the inside of the control cover.
5. After replacing the terminal box cover, connect the other end
of the supply cable to the disengaged mains switch and power
supply system respectively.
6
®
CPV 2-8
0.37 2890 50 Y / delta 1.38/0.8 84% 300 IP55 S3 6
CPV 5-4
CPV 5-8
0.75 2890 50 Y / delta 2.8/1.6 85% 300 IP55 S3 10
CPV 10-4
CPV 10-8
1.5 2860 50 Y / delta 5.5/3.2 85% 300 IP55 S3 16
CPV 20-4
CPV/F 2-8
0.09/0.37 640/2850 17/33 Y/Y 0.55/1.0 59%/78% 200/100 IP55 S3 6
CPV/F 5-4
CPV/F 5-8
0.18/0.75 620/2800 17/33 Y/Y 0.95/2.0 65%/82% 200/100 IP55 S3 10
CPV/F 10-4
CPV/F 10-8
0.37/1.5 640/2850 17/33 Y/Y 1.60/3.3 64%/89% 200/100 IP55 S3 16
CPV/F 20-4
CPV 2-8
0.44 3480 50 Y 0.8 85% 300 IP55 S3 6
CPV 5-4
CPV 5-8
0.9 3480 50 Y 1.6 86% 300 IP55 S3 10
CPV 10-4
CPV 10-8
1.8 3450 50 Y 3.2 86% 300 IP55 S3 16
CPV 20-4
CPV/F 2-8
0.11/0.44 770/3420 17/33 Y/Y 0.55/1.0 59%/78% 200/100 IP55 S3 6
CPV/F 5-4
CPV/F 5-8
0.25/0.90 740/3360 17/33 Y/Y 0.95/2.0 65%/82% 200/100 IP55 S3 10
CPV/F 10-4
CPV/F 10-8
0.44/1.8 780/3380 17/33 Y/Y 1.60/3.3 64%/89% 200/100 IP55 S3 16
CPV/F 20-4
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Yale
CPV/F
®
6. COMMISSIONING
Inspection before initial operation
Each hoist / trolley must be inspected prior to initial operation Inspecting the load hook
by a competent person. The inspection is visual and functional. Check the load hook for deformations, cracks, damages,
Inspections must ensure that the hoist is safe and has not been abrasion and signs of corrosion.
damaged by incorrect transport, storage or installation.
Inspect the traverse (for trolleys)
Inspections should be made by a representative of the Inspect the traverse for correct assembly and visually check for
manufacturer or the supplier although the user can assign its external defects, deformations, superficial cracks, wear or signs
own suitably trained personnel. Inspections are instigated of corrosion. Especially, make sure that the roll pins are properly
by the user and controlled via the Lifting Operations & Lifting fitted to the centre traverse (Fig. 12).
Equipment Regulations (L.O.L.E.R).
Check adjustment of trolley width
Inspection by a crane expert
If the hoist is used as a crane, it has to be inspected and On chain hoists with trolley (CPV/F-VTP/G/E) check that the
approved by a crane expert before initial operation. This clearance between the trolley wheel flange and the beam outer
inspection has to be registered in the crane inspection book. edge is equal on both sides and within the tolerances given (see
The inspection by the crane expert has to be instigated by the page 5, Fig. 12).
user and controlled via L.O.L.E.R. Enlarging the clearances, e.g. to enable the trolley to negotiate
tighter curves, is strictly forbidden.
bearing components every time for visual defects. Furthermore, By operating the resp. button. For trolleys with two speeds:
test the brake and make sure that the load and hoist / trolley The first stage of button depression activates the slow speed.
are correctly attached by carrying out a short work cycle of Further depression activates the fast speed. Use the slow speed
lifting, lowering and travelling in both directions. Selection for short periods only. Consider the braking distance of the
and calculation of the proper suspension point and beam trolley. Do not use the beam end stops as operational limit
construction are the responsibility of the user. devices.
8
®
Oil change. • •
Adjustment of brake. •
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Yale
CPV/F
®
• Before the chain is lubricated it must be cleaned. Flame 1. Disassemble the bottom block.
cleaning is forbidden. Use only cleansing methods and agents Unscrew both screws and separate the housing halves.
that do not corrode the chain material. Avoid cleansing methods 2. Remove the chain end stop.
that can lead to hydrogen brittleness, eg. spraying or dipping Remove the 2 screws. The chain is now free.
chain in caustic solvents. Also avoid surface treatments that can 3. Fitting the new chain.
hide cracks and flaws or other surface damage. Cut the second to last link open on the loose end of the load
chain to form a “C”. Remove the last link and connect the new
• The chain must be lubricated in a no-load condition so that chain. The new chain must be fitted so that the welds on the
lubricant can enter between the links, eg. by dipping in oil. standing links face towards the chain guide and away from the
load sheave. Operate the hoist in the lowering direction to feed
• Motor oil of the viscosity 100, e.g. Shell Tonna T68 can be the chain through the hoist.
used to lubricate the chain. For very dusty applications use a 4. Fitting lower block and chain end stop.
dry lubricant. Slide the end buffers over the loose ends of the load chain and
refit bottom block and chain end stop. The chain end stop must
be fitted so that at least 1 link remains free (see Fig. 1).
Inspecting the load chain for wear Attention: Install new hex. nuts with clamping part.
Load chains must be inspected every 3 months or the latest 5. Before initial operation lubricate the unloaded chain and test
after 200 operating hours. Adverse working conditions such as, all hoist functions under no-load condition.
excessive dust or continued heavy duty can dictate shorter
periods between lubrication.
Visually inspect the chain over its full length for damage, • 2-fall design
deformation, cracks, flaws, elongation, wear or corrosive pitting.
Link chains must be replaced when the nominal thickness “d” 1. Remove the chain anchor bolt.
on any part of the chain has been reduced by more than 10% The chain anchor bolt is situated on the underside of the hoist
or when the pitch “t” is elongated by more than 5% or over 11 body. First unscrew the four screws of the chain anchor. Then
pitches (11 x t) by 2%. Nominal dimensions and wear limits are tap out the anchor bolt with a drift.
shown in the following table 2. Attention: Do not damage anchor bolt or bore.
Chains that do not fulfil all requirements must be replaced 2. Pull the load chain through the bottom block and remove the
immediately. chain end stop.
10
®
Now insert the chain anchor bolt through the side bore. Move 8.4 MAINTENANCE LOAD HOOK
the last chain link back and forth while entering the chain anchor
bolt to ensure that the chain is not trapped or damaged by the Inspect the hooks for deformation, damage, surface cracks,
anchor bolt. wear and signs of corrosion as required but at least annually.
Finally attach the chain anchor with the housing again. Adverse working conditions may dictate shorter periods. Hooks
Fastening torque for the locking screws: that do not fulfill all requirements must be replaced immediately.
M6 = 10Nm / M8 = 25Nm Welding on hooks to compensate for wear or damage is not
Functional fixed after 60 minutes. Curing time at room permissible.
temperature is 24hrs. Hooks must not be replaced when the mouth of the hook has
Attention: Screws should be used only once. opened more than 10% (Fig. 15) or the nominal value of other
dimensions has decreased by 5% due to wear. Nominal
dimensions and wear limits are shown in the following table.
Replace damaged or missing safety catch.
Chain anchor
Anchor bolt
Weld on link
to outside
Fixing screws
Attention:
Use only original Fig. 15
Yale chain anchor
bolt and fixing
screws.
CPV 2-8 CPV 10-4 CPV 20-4
CPV 5-4/5-8 CPV 10-8
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Yale
CPV/F
®
mRC = Rated capacity of the hoist (kg) Oil change (Fig. 16.2)
The gearbox oil should be changed after every 10 years,
mH = Hoist load (kg) however, latest after 800 operating hours (oil volume see table 4).
Attention: During oil change the electric power supply must be
Hoist load mH : Load which includes all the masses of an equal shut off.
load to the rated capacity of the hoist, the hoist medium and
the fixed load lifting attachments, e.g. hooks, grabs, magnets, Disassemble the gear cover (item 2) by removing the cylinder
lifting beams, vacuum lifters. screws (item 1). Place the hoist horizontally and turn so that
the oil can drain from the fill hole into a suitable container
g = Acceleration due to gravity (9.81) m/s2 (approx. 30 mins). Replenish the gearbox oil. We recommend
a mineral oil viscosity class ISO-VG 320, e.g. FINA GIRAN L 320.
Finally, re-adjust the device with new gasket.
Adjustment of overload device (Fig. 16.1)
Attention: The adjustment of the overload device device may Model Oil volume
only be done by authorised, competent personnel.
CPV/F 2-8, 5-4, 5-8, 10-4 0.3 litre
Attention: During this job, the hoist remains operable which
CPV/F 10-8, 20-4 0.3 litre
can result in danger of injury by rotating parts.
Tab. 4
• Loosen the four socket screws (1) of the fan guard (2).
• Take off fan guard (2) and remove snap ring (3), fan (4) and
key (5).
• Loosen the adjusting nut (6) with a pin type face wrench acc.
to DIN 3116 in anti-clockwise direction until blocked.
• Turn the adjusting nut in a clockwise direction, until the test
load is raised.
Fig. 16.2
12
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The table below shows the dimensions of the brake air gap that
have to be maintained:
Tab. 5
Fig. 17
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Yale
CPV/F
®
9. INSPECTION CHART
By:
REGULAR INSPECTIONS:
* competent person
14
®
CPV/F
SPARE PARTS
LISTS AND
WIRING DIAGRAMS
15
Yale
Industrial Products
®
Yale
CPV/F
®
CPV/F MOTOR
16
®
CPV/F
19 Cable sleeve (KT 11) 1 0670213 0670213 0670213 0670213 0670213 0670213
20 Gear box gasket** mtr 0670077 0670077 0670077 0670077 0670077 0670077
21 Control board (1 Sp.) 1 0670346 0670346 0670346 0670346 0670346 0670346
21 Control board (2 Sp.) 1 0670060 0670060 0670060 0670060 0670060 0670060
22 Mounting plate 1 0670236 0670236 0670236 0670236 0670238 0670238
42 Chain end stop assy. 1 0670239 0670239 0670240 0670240 0670241 0670241
43 Bumper bottom block 1 0670137 0670226 0670134 0670231 0670251 0670263
44 Bottom block assy. 1 0670135 0670209 0670133 0670194 0670256 0670260
45 Lug 1 0670048 0670048 0670048 0670048 0670184 0670184
45a Top hook 1 0670425 0670425 0670425 0670425 0670470 0670470
46 Capacity plate 1 0670321 0670235 0670235 0670320 0670268 0670325
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Yale
CPV/F
®
GEAR BOX - Model: CPV/F 2-8/5-4/5-8/10-4 GEAR BOX - Model: CPV/F 2-8/5-4/5-8/10-4
Item Article no. Description Qty. Item Article no. Description Qty.
18
®
CPV/F
GEAR BOX - Model: CPV/F 10-8/20-4 GEAR BOX - Model: CPV/F 10-8/20-4
Item Article no. Description Qty. Item Article no. Description Qty.
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Yale
CPV/F
®
CHAIN CONTAINERS TO
SUIT ALL MODELS
1 06900003 Chain container, assy. Size 1 1 1 06900006 Chain container, assy. Size 1 1
1 06900004 Chain container, assy. Size 2 1 1 06900007 Chain container, assy. Size 2 1
1 06900005 Chain container, assy. Size 3 1
2 00670432 Fixing kit (part 1). 1
2 00670429 Fixing kit (part 1). Size 1 1
2 00670430 Fixing kit (part 1). Size 1 1 3 00670433 Fixing kit (part 2). 1
20
®
CPV/F
11.1 CPV 400V 3Ph 50Hz - (SINGLE SPEED HOIST, TOP HOOK SUSPENSION)
• TOP HOOK SUSPENSION
• SINGLE SPEED HOIST
• CPV 400V 3Ph 50Hz
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Yale®
CPV/F
Yale Electric Chain Hoist - CPV/F (WIRING DIAGRAMS)
11.2 CPV/F 400V 3Ph 50Hz - (DUAL SPEED HOIST, TOP HOOK SUSPENSION)
• TOP HOOK SUSPENSION
• CPV/F 400V 3Ph 50Hz
• DUAL SPEED HOIST
22
®
CPV/F
11.3 CPV 400V 3Ph 50Hz - (SINGLE SPEED HOIST / SINGLE SPEED TROLLEY)
• SINGLE SPEED TROLLEY
• SINGLE SPEED HOIST
• CPV 400V 3Ph 50Hz
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Yale®
CPV/F
Yale Electric Chain Hoist - CPV/F (WIRING DIAGRAMS)
11.4 CPV/F 400V 3Ph 50Hz - (DUAL SPEED HOIST / SINGLE SPEED TROLLEY)
• SINGLE SPEED TROLLEY
• CPV/F 400V 3Ph 50Hz
• DUAL SPEED HOIST
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®
CPV/F
11.5 CPV 400V 3Ph 50Hz - (SINGLE SPEED HOIST / DUAL SPEED TROLLEY)
• DUAL SPEED TROLLEY
• SINGLE SPEED HOIST
• CPV 400V 3Ph 50Hz
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Yale®
CPV/F
Yale Electric Chain Hoist - CPV/F (WIRING DIAGRAMS)
11.6 CPV/F 400V 3Ph 50Hz - (DUAL SPEED HOIST / DUAL SPEED TROLLEY)
• DUAL SPEED TROLLEY
• CPV/F 400V 3Ph 50Hz
• DUAL SPEED HOIST
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®
EC DECLARATION OF CONFORMITy
hereby, we declare that the construction and commercialised execution of the below lifting Equipment complies with
the essential health and safety requirements of the EC Machinery Directive. the validity of this declaration will cease
in case of any modification not being agreed with us previously.
Furthermore, validity of this declaration will cease in case that the machine will not be operated correctly and in
accordance to the operating instructions and/or not be inspected regularly.
Machinery Directive
transposed standards: iso 12100-1:2003
iso 12100-2:2003
En 349:1993/a1 2008
En 818-1:1996/a1:2008
En 818-7:2002/a1:2008
En 14492-2:2006
En 60204-32:1998
Signature:
Date: 08.01.2010
Chester office:
Yale Industrial Products
A trading division of Columbus McKinnon Corporation Limited
Knutsford Way, Sealand Industrial Estate
Chester, CH1 4NZ
Tel: +44 (0) 1244 375375
Fax: +44 (0) 1244 377403
Email: [email protected]
Web site: www.yaleproducts.com
Belfast office:
Yale Industrial Products
A trading division of Columbus McKinnon Corporation Limited
Unit 12, Loughside Industrial Park
Dargan Crescent, Belfast, BT3 9JP
Tel: +44 (0) 2890 771467
Fax: +44 (0) 2890 771473
Email: [email protected]
Web site: www.yaleproducts.com
Lifting Equipment
Engineers Association
FM20103 003