Operation, Service & Parts Manual: Wire Rope Electric Hoists

OPERATION, SERVICE & PARTS MANUAL
Before installing hoist, fill in the

information below. Refer to the
Hoist and Motor data plates.
Model No. _________________
Serial No. _________________
SERIES Y80 Purchase Date _____________

Voltage ___________________
YALE
Rated Load _______________
WIRE ROPE ELECTRIC HOISTS

INCLUDING
WEIGHT WATCHER OVERLOAD CLUTCH MODELS

RATED LOADS 1/2 THRU 5 TONS
Printed in U.S.A.
May, 2003 Copyright 2003, Yale•Lift-Tech, division of Columbus McKinnon Corporation Part No. 117404-10
Page 1
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FOREWORD
This manual contains important information to help you install, operate, provided on the front cover of this Manual for entering this information.
maintain and service your new YALE electric hoist. We recommend We recommend that you fill it out immediately so it is readily at hand
that you study its contents thoroughly before putting the hoist into use. when needed.
Read ANSI B30.16 safety code for hoists. Then, thru proper installation,
application of correct operating procedures and by practicing the The contents of this manual are of necessity, general in nature and
recommended maintenance suggestions you can expect maximum may cover features not incorporated on your hoist; therefore, the user
lifting service from the hoist. must exercise care in applying instructions given in this manual. If
specific information not in this manual is required, contact the factory
It will likely be a long time before parts information found in Section IX at Muskegon, Michigan 49443.
is needed; therefore, after the hoist is installed and you have completely
familiarized yourself with operation and preventive maintenance THE INFORMATION CONTAINED IN THIS MANUAL IS FOR
procedures, we suggest that this book be carefully filed for future INFORMATIONAL PURPOSES ONLY AND YALE•LIFT-TECH DOES
reference. NOT WARRANT OR OTHERWISE GUARANTEE (IMPLIEDLY OR
EXPRESSLY) ANYTHING OTHER THAN THE COMPONENTS THAT
When ordering replacement parts from this book, it will be necessary YALE•LIFT-TECH MANUFACTURES AND ASSUMES NO LEGAL
that you include, with your order, the Hoist Serial Number, Model RESPONSIBILITY (INCLUDING, BUT NOT LIMITED TO
Number and Catalog Number which is found on the nameplate attached CONSEQUENTIAL DAMAGES) FOR INFORMATION CONTAINED IN
to the hoist electrical cover. For your convenience, a space has been THIS MANUAL.
NOTICE: Information contained in this book is subject to change without notice.
INDEX
SECTION I GENERAL DESCRIPTION Page
Paragraph 1-1 General ................................................................................................................................................................. 3
Paragraph 1-2 Basic Construction ............................................................................................................................................... 3
Paragraph 1-3 Differences Between Models ............................................................................................................................... 3
SECTION II INSTALLATION
Paragraph 2-2 Suspending Hoist ................................................................................................................................................. 3
Paragraph 2-3 Connecting Hoist to Electrical Service ................................................................................................................ 4
Paragraph 2-4 Pre-Operation Checks .......................................................................................................................................... 4
SECTION III OPERATION
Paragraph 3-2 Push Button Operation ......................................................................................................................................... 6
Paragraph 3-3 Overload Clutch Operation (Optional) ................................................................................................................. 6
Paragraph 3-4 Operating Precautions .......................................................................................................................................... 6
SECTION IV LUBRICATION
Paragraph 4-2 Change Gear Case Oil ......................................................................................................................................... 7
Paragraph 4-3 Lubricate Hoist Cable ........................................................................................................................................... 7
Paragraph 4-4 Lubricate Upper Sheave and Lower Block Assembly ......................................................................................... 7
Paragraph 4-5 Lubricate Limit Stop Lever .................................................................................................................................... 8
Paragraph 4-6 Lubricate Limit Switch .......................................................................................................................................... 8
SECTION V INSPECTION AND PREVENTIVE MAINTENANCE
Paragraph 5-2 Inspect Lower Block ............................................................................................................................................. 9
Paragraph 5-3 Inspect Upper Block and Hoist Suspension ........................................................................................................ 9
Paragraph 5-4 Inspect Electrical Controls .................................................................................................................................... 9
Paragraph 5-5 Inspect Motor Brake ........................................................................................................................................... 11
Paragraph 5-6 Inspect Mechanical Load Brake, Gearing and Overload Clutch (Optional) ..................................................... 11
Paragraph 5-7 Inspect Rope Drum and Shaft ............................................................................................................................ 13
Paragraph 5-8 Rope Inspection, Maintenance and Replacement ............................................................................................ 14
Paragraph 5-9 Rope Reeving ..................................................................................................................................................... 14
Paragraph 5-10 Testing Hoist and Overload Clutch (Optional) ................................................................................................... 17
SECTION Vl TROUBLE SHOOTING CHART ............................................................................................................................ 19-20
SECTION Vll ADJUSTMENTS
Paragraph 7-1 Mechanical Load Brake ...................................................................................................................................... 21
Paragraph 7-2 Motor Brake ......................................................................................................................................................... 21
Paragraph 7-3 Block Operated Limit Switch .............................................................................................................................. 21
Paragraph 7-4 Screw- Type Limit Switch .................................................................................................................................... 21
Paragraph 7-5 Overload Clutch Adjustment .............................................................................................................................. 22
SECTION VIII WIRING DIAGRAMS
SECTION IX PARTS LIST
Paragraph 9-1 General ............................................................................................................................................................... 22
Paragraph 9-2 List of Parts Illustrations ..................................................................................................................................... 22
No part of this document may be reproduced in any form, in an electronic retrieval system or otherwise, without prior written permission of the publisher.
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SECTION I — GENERAL DESCRIPTION This brake requires periodic adjustment.
1-1. GENERAL. YALE electric hoists are precision built wire

rope and drum type hoists which are made in five rated load SECTION II — INSTALLATION
sizes (1/2, 1, 2, 3 and 5 tons) with various lifts, lifting speeds
and electrical service. Equipped with an integrally welded 2-1. GENERAL. YALE electric hoists are lubricated and tested
mounting lug, they are designed to be rigidly attached to an before being shipped from the factory. To place hoist in service,
overhead structure or mounted on YALE rigid mount trolleys attach to a suitable suspension (paragraph 2-2), connect to
for operation on runway beams. On certain models optional electrical service (paragraph 2-3) and perform pre-operation
base mounting or other supporting methods may be obtained. tests and checks (paragraph 2-4).
For full information apply to factory at Muskegon, Michigan
49443.
WARNING
NOTICE
Before attempting installation of hoist or trolley, the
YALE hoists are available with an optional built-in
main power switch must be locked in the open position
mechanical overload clutch. Hoists having this device
(off).
are identified with words WEIGHT WATCHER on the
hoist.
2-2. SUSPENDING HOIST. The hoist may be suspended in a
The WEIGHT WATCHER overload clutch permits operation of fixed location servicing only the area directly below the hoist
your hoist within its rated load and helps prevent lifting of (Lug Mounted) or the hoist may be attached to a moveable
excessive loads which could cause permanent deformation trolley or trolleys which in turn may be mounted on an l-beam
of a properly maintained hoist or trolley. attached to a building or crane, servicing a larger area (Trolley
1-2. BASIC CONSTRUCTION. All models are of the same Mounted).
basic construction and consist of a rugged welded steel frame
which houses a lifting drum and serves as the suspension for
carrying the entire hoist load. A mounting lug, for attaching WARNING
the hoist to a trolley or overhead support, is located on top of DO NOT use small holes for attaching this hoist unless
the frame. An aluminum alloy gearcase and cover, attached rated load on lower block is 1 (one) ton (2000 Ibs.) or
to one end of frame, houses a three-reduction gear train and less.
a mechanical load brake. An electric driving motor with disc-
type motor brake is located beside the frame, face mounted
on the back of the gearcase. Electrical system components, a. Lug Mounted hoists attach to adequate supports welded
located on the end of the frame (opposite gearcase end) and or bolted to a building or other structure. The supporting
enclosed by a steel cover, control operation and rotating structure must have sufficient strength with appropriate safety
direction of a driving motor. A hoisting rope and an enclosed factor, to support the weight of the hoist and rated load as
lower block assembly are used for lifting loads. An upper limit well as other loads to which the supporting structure may be
stop is used to limit travel of the lower block in the raising subjected.
direction, to protect hoist from damage. A push button control
station, for operating the hoist, is suspended from the electrical
compartment.
WARNING
Design and installation of hoist support shall be
1-3. DIFFERENCES BETWEEN MODELS. The main
performed only by qualified persons.
differences between models are in rope reeving and frame
size as described below.
Steel angles or plates used to suspend hoist should be spaced
a. Rope Reeving. There are four types of rope reeving used: as close to the hoist suspension lug as possible. Mounting
Two parts of rope single reeved, four parts of rope single bolts or threaded studs, attaching hoist to mounting structure,
reeved, six parts of rope single reeved and two parts of rope shall have a diameter not less than recommended by
double reeved. Single reeved hoists have one end of the manufacturer and material equivalent to ASTM A 325. Make
rope anchored to the drum, whereas, double reeved hoists certain that mounting bolts or studs are long enough so that
have both ends anchored to the drum. On single reeved the threads do not engage the mounting support and that
models, the lower block travels sideways as rope winds on mounting bolts or studs are secured with nuts and
drum, double reeved models offer true ver tical lift. For lockwashers, self-locking nuts or cross bolting, if unthreaded.
illustrations, refer to Section V, paragraph 5-9, “Rope Reeving”
instructions. b. Trolley Mounted hoists are attached to moveable trolleys. If
the hoist is mounted on an existing trolley, a qualified person
b. Frame Size. Length of frame furnished is dependent on shall determine that the trolley and its supporting structure
hoist capacity and lift. Four frame lengths are used; short are adequate to support the rated load and weight of the
frame, long frame, first and second extensions. Short frame hoist. Hoist/trolley units may be shipped from the factory with
hoists have a rope drum flange to flange distance of trolley packaged separately. If the trolley can be installed
approximately 9-3/4", whereas this distance on a long frame directly over the end of the supporting beam, assemble trolley
hoist is approximately 16-3/4". First extension frame hoists to hoist. Be certain that the spacing between wheel flanges,
have a flange to flange distance of 22-15/16" and second after assembly, is 1/4" greater than exact width of beam
extensions have 35-3/8". flange. (See Figure 2-1 below and instruction sheet furnished
c. Motor Brake. Hoists are equipped with a disc brake mounted with trolley.) Using proper equipment, carefully lift trolley and
on the motor end bell and operated by a short stroke solenoid. hoist and install on end of beam.
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For trolleys which are to be mounted along the span of a
beam not having open ends, measure exact width of beam WARNING
flange and assemble trolley to hoist so that spacing between
wheel flanges is 1/4" (see Figure 2-1) greater than beam Be certain that electrical power supply is off and locked
width (3/8" if beam has curves). This is accomplished by in the open position before attempting any electrical
rearranging the spacer washers on the bolts connecting trolley connections to the hoist. This equipment must be
side plates to hoist mounting lug. If trolley is shipped separate effectively grounded according to the National Electric
from hoist, see instruction sheets furnished with trolley for Code, or other applicable codes. If the grounding
orientation and installation. method used is through the trolley wheels, then each
section of track must be grounded by metal-to-metal
When proper spacing has been determined, loosen mounting connection to the building ground. Certain
nuts (item 1, Figure 2-1) to allow trolley wheels to spread far environments may prevent proper grounding by this
enough to pass over edges of beam flange. (Some installations means. In this case a separate grounding conductor
may require complete removal of one trolley side plate.) Using should be provided.
adequate equipment, carefully lift the hoist and trolley so the
wheel treads will rest on the lower beam flange. Replace side a. Follow National, State and Local Electrical Codes
plate and washers if removed for installation. Replace when providing electrical service to the hoist.
suspension stud nuts.
CAUTION
CAUTION
208/230/460V single speed motors are reconnectable at
Recheck spacer washers to make certain that the number the motor. See motor nameplate. Transformer may be
of washers between the side plate and hoist suspension lug reconnected for 200/230/460/575V. See transformer. Check
are equal, and also the number on the outside of each side with wiring diagram to make certain that motor, transformer
plate are equal. The suspension stud nuts should only be and brake leads are properly connected.
snugged up on the lockwashers until a load has been
applied on the hook. A partial load (approx. 25% rated hoist
load) placed on the hook will properly seat hoist in the b. Make electrical connections using the appropriate wiring
trolley. Tighten suspension stud nuts only after hoist has diagrams furnished with the hoist. All electrical connections,
been properly seated in the trolley. including connections to collectors or power cord, shall be
made only by qualified journeymen electricians.
WARNING WARNING
The green wire provided in the power supply cable
Mounting of the hoist-trolley unit on the monorail and
(when furnished) is a grounding wire and must be
final pre-operation inspection shall be performed only
connected to a proper ground.
by qualified persons properly supervised.
c. When trolley is shipped separate from hoist, see special
instructions fur nished with trolley for orientation and
installation.
2-4. PRE-OPERATION CHECKS.

11207A
a. Check Oil Level and Grease Fittings. The gearcase has
been filled with oil to the proper level and grease points for
lower and upper sheaves have been lubricated at the factory.
However, this should be checked before operating hoist. Check
oil level by removing oil level plug with hoist in a level position.
Oil level should be at the bottom edge of the plug hole. If not,
add oil as specified in Section IV. Grease fittings in lower and
upper sheave pins should show evidence of grease.
CAUTION
Overfilling of the gearcase may result in the excess fluid
Figure 2-1. Sectional View of Trolley showing proper wheel being expelled through the breather.
and washer spacing.
2-3. CONNECTING HOIST TO ELECTRICAL SERVICE.

Electrical service to the hoist may be power cable or a guarded
system having sliding shoe collectors.
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b. Check Push Button Operation and Phasing. When floating rod is raised, stop switch is actuated first and
then the reversing switch is actuated (Figure 2-3). Stop switch
stops hoist. Reversing switch lowers hook block in case of
WARNING floating rod over-travel. If limit switch does not function in this
manner, refer to trouble shooting chart Section Vl for possible
On three phase hoists it is possible to have “Reverse remedy.
Phasing” causing the lower block to lower when the
á button is depressed. When this condition exists,
the automatic limit stop switch is inoperative and
hoist operation will be dangerous.
To properly check the phase of the hoist, follow the steps

below:
(1) With “POWER OFF” operate all the push buttons

and determine that they do not bind or stick in any position
WARNING
If any push button binds or sticks in any position —
DO NOT TURN POWER ON — determine the cause Figure 2-3. Electrical Compartment Cover Removed
and correct the malfunction before operating. Showing Limit Switch and Reversing Switch Arrangement.
(2) Temporarily connect hoist to power source. WARNING

(3) Operate á button briefly to determine direction of Do not attempt to make above test with hook in a
hook travel. high position near hoist.
(4) If hook raises, phase is correct. Turn power off and (2) A screw-type upper and lower limit switch is provided
make temporary connections permanent. optionally when both upper and lower limit stops are required
(5) If hook lowers, hoist is “Reverse Phased”. TURN (Figure 7-2). This switch is adjustable and must be adjusted,
POWER OFF and correct by interchanging any two leads at at time hoist is installed, to desired high and low limits of
power source connection. Do not change internal wiring of lower block travel. Refer to Section Vll.
hoist.
d. Check Lower Block and Hoisting Cable. Depress â push
c. Check Limit Switch Operation. button and run lower block to its lowest position. No less than
two wraps shall remain on the drum with the loaded hook in
(1) A block operated upper limit stop (Figure 2-2) is its lowest position, unless hoist is equipped with a lower limit
furnished as standard equipment. This limit stop is factory switch in which case no less than one and one half wraps
set to stop lower block in its high position and guard against shall remain on the drum. Also check to see that lower block
over-travel and possible damage to hoist. (Note mounting and rope does not twist excessively. If it does twist to the
position of floating lever for 3 and 5 ton hoists.) No adjustment extent that two ropes rub against each other, disengage rope
can be made. Limit switch operation should be tested when from the frame anchor and twist rope four or five turns in a
hoist is installed. Move hook to a low position by depressing direction opposite to that which the block turns. Reconnect
push button marked â. Now depress button marked á to rope to anchor (Figure 2-4), holding firmly to eliminate rope
raise hook. While hook is traveling upward, manually (or with twisting back to its original position. Operate hoist up and
an extension pole) raise limit stop mechanism (Figure 2-2). down a few times. If lower block still rotates, repeat process
until twisting is corrected.
e. Lubricate Hoisting Cable. For longer cable life, it is

recommended that the cable be lubricated at time of
installation by applying a Chain and Cable Fluid as outlined
in Section IV, paragraph 4-3.
11403
Figure 2-2. Limit Stop Mechanism

Being Tripped By Lower Block. Figure 2-4. Rope End Anchor.
Page 5

SECTION III — OPERATION d. DO make sure hoist limit switches function properly.
e. DO maintain firm footing when operating a hoist.
3-1. GENERAL. Operation of Series 800 YALE electric hoists
is controlled by a convenient pendant push button station. f. DO make sure that load slings or other approved
With it, the hoist can be controlled to give fast lifting and single attachments are properly sized and seated in the
lowering; or controlled to lift or lower load in small increments, hook saddle.
providing accurate spotting. The push button station has a g. DO make sure that the hook latch, is closed and not
built-in interlock to prevent depressing opposing buttons supporting any part of the load.
simultaneously. h. DO make sure that load is free to move and will clear
When first using hoist, break-in by operating under lighter all obstructions.
loads to full travel before applying maximum load. i. DO take up slack carefully, check load balance, lift a
few inches and check load holding action before
3-2. PUSH BUTTON OPERATION. continuing.
a. Depress push button marked á to raise load. j. DO avoid swinging of load or load hook.
k. DO make sure that all persons stay clear of the
b. Depress push button marked â to lower load.
suspended load.
c. Jogging the push button will give “hairline” load movement. l. DO warn personnel of an approaching load.
The quickness of the depressing motion will determine the m. DO protect wire rope from weld splatter or other
amount of movement. Excessive use of this “Jogging” feature
damaging contaminants.
will cause premature burning of contact tips and motor
overheating. n. DO promptly repor t any malfunction, unusual
performance, or damage of the hoist.
d. On two-speed hoists, partial depression of button operates o. DO inspect hoist regularly, replace damaged or worn
the hoist at slow speed; depressing button completely operates parts, and keep appropriate records of maintenance.
the hoist at fast speed.
p. DO use the hoist manufacturer’s recommended parts
3-3. OVERLOAD CLUTCH OPERATION (Optional). The when repairing a hoist.
overload clutch, when furnished with the hoist, is factory q. DO use hook latches.
preset and tested so that the hoist will lift its full rated load r. DO apply lubricant to wire rope as recommended.
but will refuse to lift overloads which could cause deformation
s. DO NOT lift more than rated load.
or weakening of your hoist. If the load to be lifted exceeds
the clutch setting, the hoist motor will continue to run when t. DO NOT use a damaged hoist or a hoist that is not
the á button is depressed and rotate the load brake gear working correctly.
without lifting the load. Whenever this slipping occurs, u. DO NOT use the hoist with twisted, kinked, damaged
immediately release the á push button to prevent overheating or worn wire rope.
of the clutch friction surfaces and the hoist motor. v. DO NOT lift a load unless wire rope is properly seated
in its drum groove(s).
NOTICE
Always know load to be lifted. Lift-Tech does not w. DO NOT use wire rope as a sling or wrap rope around
recommend lifting loads greater than the rated load of the load.
your hoist. x. DO NOT lift a load if any binding prevents equal
loading on all supporting ropes.
3-4. OPERATING PRECAUTIONS. y. DO NOT apply the load to the tip of the hook.
z. DO NOT operate unless load is centered under hoist.
aa. DO NOT allow your attention to be diverted from
WARNING operating the hoist.
Equipment covered herein is not designed or suitable ab. DO NOT operate the hoist beyond limits of wire rope
as a power source for lifting or lowering persons. travel.
ac. DO NOT use limit switches as routine operating stops
unless recommended. They are emergency devices only.
Safe operation of an overhead hoist is the operator’s
responsibility. Listed below are some basic rules that can ad. DO NOT use hoist to lift, support or transport people.
make an operator aware of dangerous practices to avoid and ae. DO NOT lift loads over people.
precautions to take for his own safety and the safety of others. af. DO NOT leave a suspended load unattended unless
Observance of these rules in addition to frequent examinations specific precautions have been taken.
and periodic inspection of the equipment may save injury to ag. DO NOT allow sharp contact between two hoists or
personnel and damage to equipment. between hoist and obstructions.
a. DO read ANSI B30.16 Safety Standard for Overhead ah. DO NOT allow the rope or hook to be used as a
Hoists and the Operation, Service and Parts Manual. ground for welding.
b. DO be familiar with hoist operating controls, ai. DO NOT allow the rope or hook to be touched by a
procedures and warnings. live welding electrode.
c. DO make sure hook travel is in the same direction as aj. DO NOT remove or obscure the warnings on the hoist.
shown on controls.
Page 6

ak. DO NOT adjust or repair a hoist unless qualified to SECTION IV — LUBRICATION
perform hoist maintenance.
4-1. GENERAL. The lubr ication ser vices outlined in
al. DO NOT attempt to lengthen the wire rope or repair
paragraphs 4-2 thru 4-6 should be performed at regular
damaged wire rope.
intervals to maintain top hoist performance and ensure long
am. DO NOT allow personnel not physically fit or properly life. Intervals of at least six (6) months, coinciding with spring
qualified to operate hoist. and fall seasons, are recommended. The reason for this is,
an. DO NOT operate hoist unless limit switch is operating on hoists installed out-of-doors and in unheated areas, a
properly. “cold test” lubricant is required in cold (below freezing)
ao. DO be sure there is no twist in wire rope. climates making seasonal changes necessary.
ap. DO avoid operating hoist when hook is not centered 4-2. CHANGE GEARCASE OIL. (Figure 4-1)
under hoist. Avoid side pulls and swinging of load or
load hook when traveling hoist. a. Remove oil drain plug from bottom of gearcase and drain
out oil. (Two drain plugs, one on front and one on back of
gearcase.)
WARNING b. Flush out housing using petroleum solvent. Reinstall drain
DO NOT operate hoist with the hoisting rope out of the plug.
drum groves. Such operation may result in the rope
breaking and dropping the load which can cause c. Refill thru oil hole cover to proper level (bottom of oil
damage to equipment and injury to operator and other level plug hole) using 10 pints of Automatic Transmission
personnel. Hoist rope will remain in the drum groves Fluid, DEXRON III Type, suitable for all temperature ranges.
during operation under normal operating conditions,
however, slack or kinked rope, excessive side pulls,
swinging or jerking of load, or similar abuse, may cause
the rope to leave the groves.
aq. DO operate hoist within recommended duty cycle and

do not “jog’’ unnecessarily.
ar. DO conduct regular visual inspections for signs of
damage or wear.
as. DO NOT operate hoist with hooks that have opened
up. See Figure 5-1.
at. DO provide supporting structure or anchoring means
that has a load rating at least equal to that of the hoist. 11413A
au. DO NOT use hoists in locations that will not allow
operator movement to be free of the load. Figure 4-1. View Showing Location of
av. DO, when starting to lift or pull, move the load a few One Oil Drain Plug.
inches at which time the hoist should be checked for
proper load holding action. The operation shall be 4-3. LUBRICATE HOISTING CABLE. Hoists are shipped from
continued only after the operator is assured that the hoist the factory without an exterior coating on hoisting cable. It is
recommended, where conditions permit, that the cable be
is operating properly.
thoroughly coated at installation and kept well lubricated with
aw. DO NOT leave a loaded hoist unattended at the end LUBRIPLATE Chain and Cable Fluid, or equal, suitable for all
of a work shift or for extended periods during the work temperature ranges.
shift. Where operations are such that this condition cannot
be avoided the operator must be assured that the 4-4. LUBRICATE UPPER SHEAVE AND LOWER BLOCK
condition does not create a hazard to personnel or ASSEMBLY.
property.
a. All hoists have grease fittings located in ends of sheave
ax. DO NOT use the hoist load limiting device to measure pins. Apply (*) NLGI No. 2 grease for operating temperatures
the load. from +50°F to +125°F. For colder temperatures, (-20°F to
ay. DO NOT operate hoist unless hook moves in the same +50°F) use NLGI No. 1 grease.
direction as indicated on the pushbutton. If opposite
direction occurs, see pre-operation checks, Paragraph 2- b. Apply a few drops of S.A.E. No. 50 oil to hook thrust
bearings.
4.b.
az. Observe recommended inspection and maintenance (*) National Lubricating Grease Institute.
procedures.
4-5. LUBRICATE LIMIT STOP LEVER.
ba. DO use common sense and best judgement whenever
operating a hoist. Observe American National Standard a. Apply a few drops of S.A.E. No. 50 oil to pivot points of
Safety standard, ANSI B30.16, Iatest issue. limit rod.
b. Apply a few drops of S.A.E. No. 50 oil to shaft bearing at

rear of electrical compartment.
Page 7

4-6. LUBRICATE LIMIT SWITCH. Provide a light film of reports. Inspections are recommended each month and should
NLGI No. 2 grease on bevel gear of limit switch. be performed thoroughly enough to inform the hoist user of
deficiencies for any item listed. This form does not supersede
the Inspection and Maintenance Schedule listed below but
SECTION V may be used to record scheduled inspection and maintenance
INSPECTION AND PREVENTIVE services required.
MAINTENANCE The user should revise the inspection interval, add additional
5-1. GENERAL. YALE, Series 800, hoists are inspected units or provide a similar form to suit particular conditions
and tested at the factory. Regular in service inspection and which may exist. However, written, dated and signed inspection
preventive maintenance programs not only help reduce overall reports should be maintained particularly on critical items,
maintenance costs but may also prevent serious shutdowns such as hoist hooks, hoisting ropes, sheaves, drums and
by forewarning of problems that could cause these shutdowns. brakes. Periodic review of old inspection reports can point
Regular inspections, periodic minor adjustments, regular out service life of hoist components, forecasting need for
cleaning and lubrication and replacement of worn parts can adjustment, repair or replacement of these components.
help preserve good performance and operation of your hoist. As a matter of expedience, appointed maintenance personnel
Many factors influence the inspection and preventive inspecting the hoist can also take care of minor adjustments,
maintenance program required for your hoist. Frequency and repairs and cleaning, where required. Note the column on
severity of service and material handled, local environmental Inspection Schedule and Maintenance Report form headed
conditions and various applicable codes are some of the Corrective Action and Notes. When corrective action is made
factors that the user must consider to adjust inspection and during inspection, note condition of part or unit as inspected
maintenance program outlined in this section to meet his in appropriate Condition column with a check mark (ü). Note
specific conditions. “during inspection” corrective action taken and date in space
provided. In this manner, items requiring further attention will
The inspection and maintenance services outlined in this be checked (ü) without showing corrective action. This will
section are considered minimum. Recommended in the advise the designated person responsible for hoist operation
schedule are minimum inspection and maintenance intervals
and safety, who reviews the reports, that deficiencies exist.
based on average daily use in a normal environment. Average
The designated person will check all deficiencies as listed
daily use is based on 1000 operational hours per year
and reexamine or otherwise determine whether they constitute
maximum and intermittent operation of the hoist eight hours
a safety
per day, five days per week with a maximum 40% “on” time
and the average loading not exceeding 65% of rated load.
Environmental conditions in which the hoist operates are

also important considerations for the user when adjusting
WARNING
hoist inspection and maintenance programs to local conditions. Deficiencies may be hazardous to personnel and
Frequency of inspection and maintenance must be increased equipment. Do not operate a hoist having deficiencies
if hoist is subjected to severe atmospheric environmental unless a designated qualified person has determined
conditions, such as corrosive vapors, extreme heat or cold, that these deficiencies DO NOT constitute a safety
cement or dust and other airborne contaminants. The user hazard.
should carefully consider all environmental conditions and
adjust frequency and degree of maintenance for his local
conditions. Consult Lift-Tech Field Service Department for Written, dated and signed inspection reports for many items
advice for unusual environmental conditions. are mandatory under OSHA regulations, and many state safety
codes. It is strongly recommended that the Inspection
Various codes also regulate inspection and maintenance
Schedule and Maintenance Repor t, shown herein, be
programs. Attention must be given to applicable Federal
completed by a qualified person designated with the
Standards, OSHA regulations, National Standards, state and
responsibility for hoist operation and safety or an inspector
local codes which may include mandatory rules relating to
hoist inspection and maintenance. The user should become appointed by this person.
familiar with all applicable codes for his area and be guided Inspection records can point out the service life of hoist
accordingly. components and help forecast the need for adjustments,
Listed on the Recommended Inspection and Maintenance repairs and ordering of replacement parts. File and review
Schedule are inspection frequencies and requirements. these reports after each inspection.
Perform these inspections regularly as scheduled and
additional inspections as may be required for activity, service
and environment of your hoist. The hoist operator must be WARNING
responsible for determining the operating conditions and
severity of service. Do not operate a hoist having unusual vibrations,
sounds or other conditions. Danger may be present
Inspection Schedule and Maintenance Report Form. that the hoist operator cannot see. Determine and
correct cause of unusual conditions and make
Shown on page 10 of this manual is a recommended certain the hoist can be operated safely. Be certain
Inspection Schedule and Maintenance Report form which to disconnect power to the hoist whenever electrical
lists various components of the hoist. The form also includes cover is removed.
trolley components, runway components, and miscellaneous
items. This form is suggested as a guide for written inspection
Page 8

5-2. INSPECT LOWER BLOCK. c. Make certain that rope guide pins are not bent, loose or
otherwise distorted; guide pins must have close clearance to
a. Check lubrication of all parts. If the thrust bearing is not sheave flange to keep rope in sheave grooves.
equipped with a grease fitting, lubricate with SAE No. 50 oil.
Also lubricate the shank of the hook which passes through d. Check hoist suspension bolts on lug suspended hoists;
the lower block body. make certain that bolts are secure, properly tightened and
free from damage.
b. Check each sheave to ensure rope groove is smooth and
free from burrs, or other surface defects. e. Inspect suspension lug at top of hoist frame for damage,
cracks, hole elongation or other signs of wear. On all hoists,
c. Check each sheave for freedom of rotation; replace the suspension lug is integral with hoist frame and the entire
bearings if defective. frame must be replaced when suspension lug is damaged
and requires replacement.
d. Make certain that dowel pin, holding the hook nut to the
hook, is securely in position.
e. If hook is equipped with a safety latch or rotational lock, WARNING

check to determine that they are in good operating condition.
Do not operate a hoist having worn or damages
f. Check throat opening of hook. (Refer to Figure 5-1.) It is suspension bolts.
recommended that upon receipt of the hoist a measurement
be made and recorded of the hook throat opening. OSHA
f. Reinstall all parts following procedure in reverse of
Standards require that the hook be replaced if the throat
disassembly.
opening exceeds 15 percent of the original opening, or if the
hook is twisted more than 10 degrees from the unbent plane. 5-4. INSPECT ELECTRICAL CONTROLS. Arrangement of
A gage block, properly identified to the hoist, similar to the electrical control equipment varies with the type of control,
one shown in Figure 5-1, is suggested to be made for each physical space and the optional control features ordered with
hook for use in these measurements. the hoist.
NOTE: Hooks and hook openings shown are based on a. Disconnect electrical power to hoist, remove electrical
hooks normally furnished with standard hoists. For compartment cover (Figure 9-1, Ref. No. 29) and inspect
dimensions of hooks having a special size, shape or wiring and terminals. Terminals should be securely crimped
material, consult the Muskegon, Michigan factory. For to wires and electrical insulation should be sound. Terminal
hooks with certain kinds of safety latches it may be screws should be tight.
necessary to remove latch to measure hook opening.
b. Check condition of contactor assembly, transformer, and
g. Hooks showing signs of cracks must be replaced. Hooks limit stop and reverse switches.
should be inspected at least once per year using dye
penetrants, magnetic particle or other suitable crack detecting
methods.
HOIST
RATED HOOK CORRECT "L"
LOAD SIZE DIMENSION
(IN TONS) (STANDARD) (NEW HOOK)
1/2 G 1-1/8"
1 G 1-1/8"
2 H 1-1/4"
3 I 1-1/2"
11202A 5 J 1-3/4"
Figure 5-1. Proper Hook Opening.

(Shown with latch removed for clarity.)
h. Check wear of the hook, especially at the saddle and

replace if badly worn.
5-3. INSPECT UPPER BLOCK AND HOIST SUSPENSION.
a. Check upper block sheaves (when hoist is so equipped)

for wear, damage and freedom of rotation. If sheaves do not
rotate freely, disassemble block and inspect bearings. Replace
worn or damaged bearings, washers, pins or sheaves.
b. Make certain that all sheaves, bearings and hanger pins

are free of foreign material and properly lubricated. Bearings
without grease fittings are lubricated for the life of the bearing
and require no further lubrication. After inspection, lubricate
all upper block lubrication fittings.
Page 9

INSPECTION SCHEDULE AND MAINTENANCE REPORT
HOIST SERIAL NO. (MFGRS) _______________________ CUSTOMER CRANE IDENTITY NO. _______________________
RATED LOAD _________________ LOCATION IN PLANT __________________________________
TYPE ________________________ THIS INSPECTION IS MONTHLY o ANNUAL o
VOLTAGE _____________________ SEMI-ANNUAL o
INSPECTED BY: ________________ DATE _____________
Recom- * CONDITION
COMPONENT, UNIT OR PART mended (Check column best indicating condition when CORRECTIVE ACTION
and location Inspection part or unit is inspected. Use note column to NOTES
Interval the right if condition is not listed below.)
REPAIR REQUIRED
(Worn or Damaged)
(Low Oil or Grease,

Rust or Corrosion)
(Indicate corrective action taken during inspection and note date. For corrective
REPLACEMENT
(Loose Parts or
CLEANING OR
SEMI-ANNUAL
ADJUSTMENT
LUBRICATION
action to be done after inspection, a designated person must determine that
REQUIRED
REQUIRED
REQUIRED
REQUIRED
LOCATION
MONTHLY
PAINTING
COMPONENT,
ANNUAL
GOOD
Wires)
the existing deficiency does not constitute a safety hazard before allowing
UNIT OR
unit to operate. When corrective action is completed, describe and note date
PART in this column.)
DATE
Motor
Motor Brake
Mechanical Load Brake
Overload Clutch
Couplings
Gears, Shafts & Bearings
HOIST
Upper Block
Lower Block
Hook & Throat Opening X Record Hook Throat Opening
Hoist Rope
Rope Drum
Guards
Limit Switch
PUSH BUTTON
STATION OR
Pushbutton
CONTROL
Wiring
Motor
Brake (when so equipped)
Couplings
Gears, Shafts & Bearings
TROLLEY
Frame
Wheels
Bumpers
Guards
Conductors
Collectors
Hoist
RESISTORS
Trolley
Monorail Joints
RUNWAYS
Monorail
Main Conductors
Main Collectors
General Condition
Load Attachment Chains
MISC.
Rope Slings & Connections

Change Gearcase Lub.
Grounding Faults
* See text for DAILY & WEEKLY REQUIREMENTS. SIGNED & DATED REPORT REQUIRED – OSHA.
INSPECTION INTERVAL. X MAGNETIC PARTICLE OR EQUIVALENT EXAMINATION REQUIRED.
Typical Inspection Schedule and Maintenance Report form.
User must adjust inspection interval and components to suit his individual conditions and usage. 12375B
Page 10

TIME INTERVAL INSPECTION OR MAINTENANCE
Daily or start Check operation of all functional mechanisms including limit switch operation,
of each shift brakes and control. Check hoist cable for kinks, abrasions, corrosion or broken
(\/isual) wires or evidence of improper spooling on drum. Inspect hooks, upper and lower
blocks, and all load bearing components for damage.
1 Month * HOIST CABLE — Inspect and lubricate per paragraph 5-8.
* ELECTRICAL CONTROLS — Inspect per paragraph 5-4.

1 - 3 Months
Check hoist gearcase oil level — add oil as required per paragraph 4-2.
6 Months * LOWER BLOCK — Inspect per paragraph 5-2.

UPPER BLOCK — Inspect per paragraph 5-3.
Motor brake and actuating mechanisms. Inspect and adjust per paragraph 5-5.
Annually * Inspect hooks with suitable crack detecting procedures per paragraph 5-2.
Drain and refill hoist gearcase per paragraph 4-2.
Inspect electrical controls per paragraph 5-4. Change hoist gearcase oil — Fill
6 Months or with oil per paragraph 4-2. Lubricate hoist cable per paragraph 4-3. Lubricate
500 - 750 hours * upper and lower hook block per paragraph 4-4. Lubricate limit stop lever per
“on” time paragraph 4-5. If a screw type limit switch is furnished, add a light film of
NLGI No. 2 grease to bevel gear.
5 Years elapsed Complete inspection, disassembly, and maintenance required. It is recommended

time or 5000 * that your YALE Repair Station be contacted for this service.
hours “on” time
*Perform services described by paragraph indicated.
Figure 5-2. Inspection and Maintenance Schedule.
5-5. INSPECT MOTOR BRAKE. See Figure 9-4.
a. Remove acorn nuts holding brake cover and remove
brake cover.
b. Remove brake mounting plate screws and lift brake
assembly off.
c. Check braking surfaces for wear and scoring. Replace

badly worn or scored parts.
d. Reinstall parts in reverse of disassembly. 11404A
e. Adjust brake as explained in Section Vll.

Figure 5-3. View of Gearcase – Cover Removed.
5-6. INSPECT MECHANICAL LOAD BRAKE, GEARING AND
OVERLOAD CLUTCH (Optional). b. To inspect gearing, pull out intermediate gear and pinion
assembly and roller thrust bearings (Figure 5-4), and load
a. The mechanical load brake and gearing may be inspected
brake assembly (Figure 5-5). Do not remove drum gear unless
and serviced with hoist suspended. To do so, remove lower
visual inspection indicates replacement is necessary.
block and wire rope, drain oil from gearcase, remove 12 hex
head bolts and lockwashers holding gearcase cover, and pull c. Inspect gears and pinions for signs of tooth wear and
cover from gearcase (Figure 5-3). damage. If replacement of any parts appears necessary,
disassemble drum gear, intermediate gear and pinion
assembly, and load brake assembly as directed on following
page.
Page 11

(2) Using a puller tool, remove brake flange from shaft.
A groove is provided around outer diameter for this purpose.
See Figure 5-7. Remove key from shaft and lift off 2 friction
discs, and the pawl and ratchet assembly (Figure 5-8).
11421
Figure 5-4. Removing Intermediate Gear and

Pinion Assembly.
10334
Figure 5-7. View Showing Load Brake

Flange Removed.
(3) Remove load brake gear. If replacement of spring,

spring retainer or cam is necessary, press off shaft (Figure
5-9).
11422 (4) The load brake pawl and ratchet is a riveted

assembly and is not to be disassembled.
Figure 5-5. Removed Load Brake Assembly. (5) Clean all parts thoroughly and inspect for wear and
damage. Replace all parts that are excessively worn or
d. To disassemble drum gear, remove external snap ring damaged. Hard surface or glazed friction discs should be
from splined shaft, using heavy-duty snap ring pliers, and replaced.
pull off gear.
e. To disassemble intermediate gear and pinion, press

pinion shaft from gear using an arbor press.
f. It is recommended that load brake assembly be returned
to an Authorized Repair Station for inspection and repair. If it
is necessary that you make your own inspection and repair,
instructions below must be followed:
(1) Place load brake assembly, flange up, in a vise

equipped with brass or copper jaw plates to protect pinion
gear teeth. Remove snap ring from end of load brake shaft
(Figure 5-6).
10335A
Figure 5-8. Removing Pawl and Ratchet Assembly

From Load Brake Shaft.
10333
g. Reassemble gearing and load brake parts following
Figure 5-6. Remove Snap Ring From Load Brake Shaft. reverse procedure of disassembly. In assembling load brake,
observe assembly steps (1) through (4) below:
Page 12

(1) Before installing spring in its retainer (Figure 5-9), apply (4) The brake spring must be pre-loaded at assembly to
a good grade of ball bearing grease to inside of retainer. a torque of from 10 to 14 lb.-ft. This is accomplished using a
Spring must be positioned exactly as illustrated, butted against plumber’s strap wrench to wind (rotate) load brake gear to
pin at side of cam. set up spring (Figure 5-10) while pressing brake flange into
place using an arbor press. Clamp pinion end of shaft into a
portable vise to keep brake from rotating in press. Use brass
or copper jaw plates on vise to protect pinion gear teeth.
Wind gear counterclockwise (viewing brake from flange end)
with strap wrench and press down on flange until snap ring
groove in shaft is exposed allowing snap ring to be installed.
Use extreme care not to over wind spring as yield will result
and final spring torque will be reduced. Do not wind gear
beyond point necessary to install snap ring in groove.
h. Install gearing and load brake assembly in gearcase in

reverse order of disassembly. Be certain roller thrust bearings
are installed at both ends of intermediate gear shaft as shown
LOAD BRAKE — OVERLOAD CLUTCH in Figure 5-4 and that thrust washers are properly installed at
both ends of load brake shaft as noted below:
(1) A steel thrust washer with 5/8" I.D. must be installed

on the brake flange end (end opposite pinion) of load brake
as shown in Figure 5-5.
(2) A bronze thrust washer with a lug on one side goes

on pinion end of load brake shaft and it must be installed so
that its lug engages the special slot located on the spot face
surrounding the load brake bearing bore inside gearcase
cover. Use heavy grease to hold it in place on cover as cover
is installed.
On hoists with 18 or 20 tooth load brake pinion, an 11/

16" I.D. steel thrust washer is installed between pinion
and bronze thrust washer.
LOAD BRAKE — STANDARD j. At completion of reassembly of gearing and load brake in
Figure 5-9. Load Brake Gear Removed From gearcase, refill gearcase to proper level using correct grade
Load Brake Showing Load Brake Spring. of oil, as outlined in Section IV — LUBRICATION.
k. For hoists equipped with an overload clutch (optional)

(2) When installing pawl and ratchet assembly on load which has been functioning properly, visually inspect clutch
brake shaft, be certain that teeth on ratchet face are in the adjusting nut and spring washer for signs of damage or
same direction as shown in Figure 5-8. The ratchet assembly looseness. With a small hex allen wrench, make certain two
should rotate freely when turned counterclockwise and the set screws in adjusting nut are tight. DO NOT TURN
pawl should engage ratchet teeth when unit is turned ADJUSTING NUT OR DISASSEMBLE CLUTCH. If spring
clockwise. washer, adjusting nut or gear is loose or damaged, or the
clutch did not function properly before disassembly of hoist
(3) When installing brake flange, position it with chamfer
for inspection, consult the nearest YALE Authorized Repair
facing friction disc (Figure 5-7).
Station for repair or adjustment.
5-7. INSPECT ROPE DRUM AND SHAFT.
a. To remove dr um, remove wire rope, electr ical

compartment cover and electrical panel assembly (Figure
9-1) and gearing and load brake assembly (paragraph 5-6).
b. Remove four hex socket head bolts securing gearcase to

cover. Three bolts are accessible from inside frame (Figure
2-2, Section II) and the fourth is accessible from electrical
end of frame thru special access hole using a socket hex key
wrench with an extension (Figure 5-11). With bolts removed,
pry assembled gearcase and motor from frame. Exercise
caution so that gearcase and motor assembly does not fall
as it comes free of frame. This disassembly operation is not
recommended with hoist suspended. Drum will remain in frame
and can be lifted from drum shaft. To remove shaft, remove
internal retaining ring from bearing bore in frame.
Figure 5-10. Winding Load Brake Gear Using a Strap

Wrench to Set Up Load Brake Spring.
Page 13

b. Maintenance. Keep rope well lubricated to help reduce
internal friction and prevent corrosion. Lubricant, as described
in paragraph 4-3, should be applied as a part of the regular
maintenance program. Special attention is required to lubricate
sections of rope over equalizing sheaves and other hidden
areas.
Avoid dragging ropes in dirt or around sharp objects which

will scrape, nick, crush or induce sharp bends in the rope.
c. Replacement. When recommended by an authorized

inspector, the rope should be replaced. Replacement rope
assemblies are shipped from the factory carefully coiled to
prevent damage by kinking. Care must be taken to avoid
twisting or kinking when uncoiling and handling during reeving.
Figure 5-11. Removing Bolt Before replacing rope, check condition of grooves in sheaves
Securing Gearcase to Frame. and drums to determine if they are excessively worn.
c. Check parts for wear and damage. Replace drum if there

are any signs of cracks or other damage.
WARNING
5-8. ROPE INSPECTION, MAINTENANCE AND
REPLACEMENT. Use only factory approved rope with swagged wire
rope sockets.
WARNING When first using the hoist after rope replacement, break-in
Wire rope improperly handled or abused can create a rope by operating under lighter loads to full travel before
SAFETY HAZARD. Read and comply with inspection, applying maximum load.
maintenance and replacement information given herein.
5-9. ROPE REEVING.
a. General. Before unreeling rope from a coil or reel, be

a. Inspection. Wire rope on your hoist is one of the most sure floor is clean. Dirt picked up by the rope can cause
important components requiring frequent inspection and excessive wear and abrasion. Uncoil the rope by rolling the
maintenance. All wire ropes will eventually deteriorate to a coil or reel along the floor; or, place reel on a stand with a
point where they are not safe and will require replacement. shaft thru the center of reel so rope can be pulled straight out
WIRE ROPE SHOULD BE THOROUGHLY INSPECTED AT with the reel rotating.
REGULAR MONTHLY INTERVALS BY AN AUTHORIZED
PERSON AND A DETERMINATION MADE WHEN FURTHER
USE OF THE ROPE WOULD CONSTITUTE A SAFETY
CAUTION
HAZARD. Each inspection should include a written, dated It is imperative that the rope reel or coil rotates as rope
and signed report of rope condition. Reports should be filed unwinds. If coil or reel does not rotate, the wire will be
and reviewed each month and any rope deterioration carefully twisted as it is uncoiled and kinking will result. A kinked
noted. Inspections revealing but not limited to the following rope may be damaged and unsafe.
conditions should cause the inspector to question remaining
strength of rope and consider replacement: Before removing the old rope, refer to reeving diagrams,
(1) Twelve randomly distributed broken wires in one rope (Figures 5-12, 5-14, 5-15 and 5-17). Face the rope drum on
lay or four broken wires in one strand. your hoist from the side which the rope comes off drum. To
assist with rereeving your hoist, select the reeving diagram
(2) Wear of one-third of the original diameter of outside for your hoist. Note the description (such as 2 part double
individual wires. reeved, Figure 5-17) and refer to the paragraph below with
the same description which describes rereeving procedure.
(3) Kinking, crushing or bird caging.
b. Removing old rope — for all reevings.
(4) Heat damage from any cause.
(1) Lower the bottom block to a scaffold located 6 to 7
(5) Reductions from nominal diameter of more than feet below hoist to relieve tension on wire rope. (Bottom block
1/64" for 3/16", 1/4", and 5/16" diameter rope. may be lowered to floor if desired; however, to handle less
(6) Rope corrosion, internal or external. weight and for ease of rereeving adequate scaffold below the
hoist is recommended.)
(7) Effects from improper lubrication.
(2) Remove bottom block sheave guard.
(8) Rope idle for month or more due to shutdown.
(3) Remove key plates from both sides of sheave pin
Special attention should be exercised when inspecting rope and slide sheave pin from bottom block.
normally hidden during inspecting procedures.
(4) Lift out sheaves from the top of the bottom block and
remove wire rope.
Page 14

(5) Remove key plates or snap rings from upper block With new rope installed on the drum as described in paragraph
sheave(s) and slide out upper block sheave pins, releasing 5-9c single reeved above, proceed with rereeving following
upper block sheaves. Remove wire rope from sheaves. steps below:
(6) Make certain all personnel are clear of hoist and (1) Pass other end of rope thru bottom opening of hoist,
operate hoist â to completely unwind all wire rope from between floating limit rod and motor, and attach rope to cast
drum. Stop hoist so drum anchor slot(s) is accessible. Remove dead end anchor fitting. A slot is located at top of fitting to
live rope and socket(s) from drum. accept cable. Reinstall bolt and lockwasher in end of anchor
fitting to lock rope compression fitting in place.
(7) TURN OFF POWER TO HOIST.
(2) Grasp loop, formed after installing end anchor, and
(8) Remove the bolt and lockwasher in the end of the place bottom block sheave in loop. Lower sheave into bottom
rope anchor fitting. Remove rope from slot in top of anchor. block and insert sheave pin. Replace key plates and bolts
c. Installing new rope. holding sheave pin in place.
(3) Replace sheave guard. Make certain rope is not

twisted. Should the two parts of rope tend to wind around
WARNING each other, remove cable from anchor slot and untwist cable.
Reattach the cable anchor.
Winding rope on rope drums with power can be
hazardous. Keep hands safe distance from drum, wear (4) Lubricate cable per paragraph 4-3.
gloves and use extreme care when handling rope.
SINGLE REEVED HOISTS
Stretch new cable on floor in one continuous length. Make

certain there is no twist in rope.
(1) Place one end of rope in rope drum anchor slot. Be

sure end fitting is properly seated.
(2) With all personnel clear of hoist — TURN ON

POWER.
(3) Operate hoist á, guiding new rope into drum grooves

with gloved hand, until the following lengths remain unwound:
(a) 2 part single reeved — about 14'-0".

(b) 4 part single reeved — about 28'-0".
(c) 6 part single reeved — about 42'-0".
(4) Proceed with reeving as described in appropriate

paragraph below and the reeving diagram for your hoist.
12203A
DOUBLE REEVED HOISTS
Stretch new cable on floor in one continuous length. Make Figure 5-12. Hoist Reeving — Two Part Single.
certain there are no twists in rope.
e. Reeving — 4 part single.
(1) Pull far end of rope toward end of rope nearest hoist,
until both ends are even and a loop is formed. Place fittings See Figure 5-14 for diagram.
on both ends of rope in anchor slots on rope drum. Be sure
end fittings are properly seated. See Figure 9-13 for block parts.
(2) With all personnel clear of hoist — TURN ON With new rope installed on the drum as described in
POWER. paragraph 5-9c single reeved above, proceed with rereeving
following steps below:
(3) Operate hoist á guiding rope into grooves at both
ends of drum, until the distance from the drum to the loop is (1) Grasp the cable near the middle (about 14'-0") of
— about 28' for 2 part double reeved. the unwound end and form a loop. Place upper sheave in
this loop. Slide upper sheave with cable into sheave pocket.
(4) Proceed with reeving as described in appropriate
paragraph below and the reeving diagram for your hoist. (2) Insert sheave pin into sheave. Replace key plates
and bolts to hold sheave pin in place.
d. Reeving — 2 part single.
See Figure 5-12 for diagram.
See Figure 9-11 for block parts.
Page 15

(1) Grasp cable at a point one-third (approx. 14’0") the
distance hanging below the rope drum and form a loop. Place
one upper sheave in this loop. Slide upper sheave with cable
into sheave pocket; partially insert sheave pin to hold sheave
in place.
(2) Repeat (1) above and install second upper sheave

with rope. Insert sheave pin and install key plates and bolts
to secure sheave pin.
Figure 5-13. Upper Sheave Installed.

(Typical 3 and 5 Ton)
(3) Pass free end of rope thru bottom opening of hoist

between floating limit rod and motor, and insert rope in anchor
fitting at hoist frame. Be certain power is off before attempting
to place rope in anchor fitting. With end fitting properly seated
in anchor, replace bolt and lockwasher in end of socket. Two
loops have now been formed for bottom block sheaves.
12205A
Figure 5-15. Hoist Reeving — Six Part Single.
(3) Pass free end of rope thru bottom opening of hoist

between floating limit rod and motor and insert in rope anchor
fitting at hoist frame. Be certain power is off before attempting
to place rope in anchor fitting. With end fitting properly seated
in anchor, replace bolt and lockwasher in end of socket.
Three loops have now been formed for bottom block sheaves.
(4) Place sheave in each loop. Install one sheave with

cable in bottom block; partially insert sheave pin to hold
sheave in place. NOTE: Be certain that washers are installed
between sheaves, as shown on parts illustration.
12204A
(5) Repeat step 4 for remaining bottom block sheaves.
Figure 5-14. Hoist Reeving — Four Part Single. Install sheave pin through sheaves. Replace key plates and
bolts securing sheave pin.
(4) Place one sheave in each loop. Install one sheave (6) Replace sheave guard.
with cable in bottom block, partially insert sheave pin to hold
sheave in place. NOTE: Some blocks have spacer washers (7) Lubricate cable per paragraph 4-3.
between sheaves. Be certain that washers are installed
between sheaves, when shown on parts illustration. Install g. Reeving — 2 part double.
second sheave with cable into bottom block. Slide sheave pin See Figure 5-17 for diagram.
through sheave. Replace key plates and bolts securing sheave
pin. See Figure 9-12 for block parts.
(5) Replace sheave guard. With new rope installed on the drum as described in paragraph
5-9c double reeved above, proceed with rereeving following
(6) Lubricate cable per paragraph 4-3. steps below:
f. Reeving — 6 part single. (1) Form loops in the two ropes coming from rope drum.
See Figure 5-15 for diagram. Place these loops into bottom block pockets and slide pipe or
rod through sheave pin holes. Note position of ropes passing
See Figure 9-13 for block parts. limit stop bar.
With new rope installed on the drum as described in paragraph (2) Partially insert upper block sheave pin in opening
5-9c single reeved above, proceed with rereeving following and install one spacer washer. Raise remaining rope up to
steps below: hoist, form a loop and place upper sheave in this loop.
Page 16

(d) Tur n on power ; raise and lower the block
several times to feed the correcting twist in the rope
through the reeving.
(e) If block still tends to twist, repeat the above

procedure until block rotation is corrected.
(2) To remove rope twist in double reeved hoists.
(a) Observe direction block tends to rotate.
(b) Lower the bottom block unspooling rope from rope

drum until only one quarter (1/4) turn remains to
rope end anchors in drum.
Figure 5-16. Upper Sheave Installed (Typical).
(c) Rotate rope near ends entering drum in a direction
tending to correct block rotation. This rotates rope
(3) Place sheave with rope into upper sheave pocket end fittings in the drum.
and slide pin partially thru sheave. Install remaining washer
and push pin thru side plates. Install snap ring on each end (d) Turn on power; raise and lower the block several
of pin to secure pin in place. times to feed the correcting twist in the rope through
the reeving.
(e) If block still tends to twist, repeat the above

procedure until block rotation is corrected.
5-10. TESTING HOIST AND OVERLOAD CLUTCH
(Optional).
a. General. Before placing hoist in service or after disas-

sembly and reassembly, hoist should be tested. To test sus-
pend hoist from an overhead supporting member of sufficient
strength to support the weight of the hoist and the rated load.
Hoists having overload clutches, require an overhead sup-
porting structure capable of supporting with appropriate safety
factor, a load equal to 200 percent rated load and the weight
of the hoist. Connect hoist to power supply as shown on hoist
nameplate and perform the checks listed in b and c below.
b. Check hoist as outlined in PRE-OPERATION CHECKS,

12206A Section II, paragraph 2-4.
Figure 5-17. Hoist Reeving — Two Part Double.
c. Check hoist with capacity load.
(4) Insert lower sheave pin into bottom block removing
(1) Attach rated load to lower hook.
pipe as sheave pin is inserted. Be certain washers are
replaced as shown on parts illustration. With sheave pin
installed, replace key plates and bolts to secure sheave pin. (2) Depress á push button and raise load. When push
button is released, hoist should immediately stop and hold
(5) Replace sheave guard. load at that level.
(6) Lubricate rope per paragraph 4-3.
(3) Depress â push button, lower load a short distance
h. Checking for and removal of rope twisting. and release button. Hoist should stop immediately and hold
load at that level.
Although rereeving of hoist may have been done carefully,
sometimes after new rope has been installed twisting may NOTE: If load drifts downward slowly in step 2 or
occur. With new rope installed, the hoist block should be 3 above, motor brake requires adjustment — see
raised and lowered several times with gradually increasing MOTOR BRAKE ADJUSTMENT — Section Vll —
loads, through full lift. If the block still rotates excessively at paragraph 7-2.
no load, the rope may have twists which should be removed.
(1) To remove rope twist in single reeved hoists. d. Overload Clutch. The overload clutch (optional) must
be tested for proper operation before placing hoist in service
(a) Observe direction block tends to rotate. or after disassembly and reassembly of hoist. For test
procedure follow instructions listed below.
(b) Lower the block to a low position and turn off
power.
(c) Rotate rope near the anchor end several turns in

a direction tending to correct block rotation. This
rotates rope end fitting in the anchor.
Page 17

WARNING
BEFORE ATTEMPTING TO TEST THE OVERLOAD
CLUTCH, MAKE CERTAIN THE FOLLOWING
PREREQUISITES ARE STRICTLY OBSERVED:
a. An appointed person must determine, before

starting, that all structures supporting the hoist are
adequately strong to withstand the test load of 200%
of the rated load, plus the weight of the hoist, whether
hoist is tested in installed position or moved to a
designated test facility.
b. Loads used for testing must be accurately known.
c. Test must be made ONLY by a qualified operator,

thoroughly familiar with the hoist and the purpose of
the test.
d. Adequate and proper rigging must be provided to

ensure that test loads are securely attached, properly
balanced, and lifted level. Failure to provide adequate
support could cause injury to personnel and/or damage
to equipment.
(1) Using a known load, equal to the hoist rated load,

energize hoist to lift the load. Raise this load just high enough
to be certain hoist is lifting the entire load. Clutch should not
slip with the rated load. Lower load to rest position. If clutch
slips with rated load, adjustment is required. (See paragraph
7-5. — “OVERLOAD CLUTCH ADJUSTMENT”.) If hoist will lift
rated load, proceed to step (2).
(2) Increase load in steps from rated load, TO A MAXIMUM

OF 200% of the rated load, attempting to lift load with each
increase in weight. Hoist Overload Clutch should slip and refuse
to lift load before 200% of the rated load is reached. Should
hoist lift 200% of the rated load — STOP TEST — A CLUTCH
ADJUSTMENT IS REQUIRED. (See paragraph 7-5 —
“OVERLOAD CLUTCH ADJUSTMENT”.)
(3) Run hoist with load causing clutch to slip (hoist refusing
load) five cycles of approximately 1 second each.
CAUTION
To prevent overheating, release the hoist control button at
once when the hoist refuses to lift the load.
(4) Remove weights added in step (2) and return to hoist rated
load. Lift rated load one final time. Clutch should not slip.
WARNING
Do not lift more than rated load except for test
purposes.
NOTICE
ALWAYS KNOW LOAD TO BE LIFTED, LIFT-TECH

DOES NOT RECOMMEND LIFTING LOADS GREATER
THAN THE RATED LOAD OF YOUR HOIST.
Page 18

SECTION Vl - TROUBLE SHOOTING
Trouble Probable Cause Remedy
6-1. Hoist Will Not Operate. a. No power to hoist. a. Check switches, circuit breakers or fuses and
connections in power supply lines. Check power
collectors.
b. Wrong voltage. b. Check voltage required on motor data plate

against power supply.
c. Loose or broken wire c. Shut off power supply, remove electrical cover on
connections in hoist electrical hoist and check wiring connections. Also check
system. connections in push button station and limit
switches.
d. Contactor assembly not d. See that necessary jumper wires are properly
functioning. installed. Verify that the contactor armatures are
free to move. If binding occurs, replace contactor.
Check for burned out contactor coils.
e. No control voltage. e. Check transformer fuse. If blown, check for

grounding and/or shorts in the push button station.
Check the transfor mer coil for signs of
overheating. Replace transformer if burned out.
Verify the transformer secondary is the same
voltage as the coils to which it is connected.
f. Motor burned out. f. Replace motor. Check input power supply. Check
hoist motor connections.
6-2. Hook Moves in Wrong a. Reverse phasing on three- a. Interchange any two power supply line leads.
Direction. phase hoists. Refer to Section II, paragraph 2-4 b.
b. Hoist wired wrong. b. Check wiring connections with appropriate wiring

diagram.
6-3. Hook Will Raise But a. Lower electrical circuit open. a. Check for loose connections. See that necessary
Not Lower. jumper wires are properly installed on contactor.
b. Contactor assembly not b. See that necessary jumper wires are properly
c. Down, push button inoperative. c. Check push button contacts and wires.
6-4. Hook Will Lower But a. Excessive load. a. Reduce loading to rated load of hoist, as shown
Not Raise. on nameplate.
b. Hoist electrical circuit open. b. Check for loose connections. See that necessary
jumper wires are properly installed on contactor.
Check limit switch mounting and connections.
c. Contactor assembly not c. See that necessary jumper wires are properly
d. Up, push button inoperative. d. Check push button contacts and wires.
Page 19

SECTION Vl - TROUBLE SHOOTING (Continued)
Trouble Probable Cause Remedy
6-5. Hoist Will Not Lift Rated a. Low voltage a. See that power supply current is same voltage
Load. Iisted on motor data plate. Check hoist motor
connections. Check size of power supply lines.
b. Overload Clutch not properly b. See Section VII, paragraph 7-5.

adjusted.
6-6. Hoist Motor Overheats. a. Excessive load. a. Reduce loading to rated load of hoist, shown on
nameplate.
b. Excessive duty-cycle. b. Reduce frequency of lifts or amount of jogging.
c. Wrong voltage or frequency. c. Check current rating on motor data plate against
power supply. Check hoist motor connections.
d. Defective motor or worn bear- d. Disassemble hoist and inspect for defective, worn
ings in hoist frame. or damaged parts.
e. Overload Clutch slipping without e. See Section VII, paragraph 7-5.

lifting load.
6-7. Load Drifts Excessively a. Excessive load. a. Reduce loading to rated load, as shown on
When Hoist Is Stopped. nameplate.
b. Motor brake not holding. b. With No Load, check hoist for drift. If drifting is
excessive, inspect motor brake (Section V,
paragraph 5-5) and adjust as outlined in Section
VII, paragraph 7-2.
c. Load brake not holding. c. (1) After determining that the motor brake is working
properly, attach rated load to hook and operate
hoist. If the load accelerates during lowering, the
load brake is not functioning properly. See Section
V, paragraph 5-6 for replacing worn or damaged
parts.
(2) If load brake checks O.K., magnetic motor brake

needs adjustment (see b. above).
6-8. Hoist Operates a. Collectors make poor contact. a. Check collectors for free movement of spring arm,
Intermittently weak spring or electrical connections.
b. Loose connections. b. Check all wiring for loose connections.
Page 20

SECTION Vll — ADJUSTMENTS c. On the early version of the brake (Figure 7-1), if the tang is
below the midway position of the two adjustment points shown
7-1. MECHANICAL LOAD BRAKE. The mechanical load on the brake, the brake should be adjusted to bring the tang
brake on Series 800 YALE hoists is a pawl and ratchet “Weston” back up alongside the NORMAL position on the brake.
type automatic brake. The brake is not adjustable and requires
only periodic inspection and occasional replacement of the d. Remove the hex key (1/8" size) from the holster on the
friction washers. cover mounting stud and carefully turn the ADJUSTING SCREW
(located above the solenoid coil) clockwise. The indicating tang
7-2. MOTOR BRAKE. Instructions for adjusting the brake are will move a large distance for a small turn of the adjusting
inside the brake cover and are repeated below. Check brake screw, therefore turn the screw no more than one quarter turn
adjustment after the first 30 days of service and regularly before checking adjustment.
thereafter during the six-month inspection procedure. Two
versions of the motor brake occur in this manual. e. After adjustment operate the brake by hand to assure brake
disc running clearance. The outboard brake pad should separate
from the brake disc by approximately .010".
f. Replace hex key in holster.
g Replace brake cover.
7-3. BLOCK OPERATED LIMIT SWITCH. The block operated

upper limit stop, furnished as standard equipment, is
nonadjustable and designed to stop lower block at its high
point of travel to guard against over-travel with possible damage
to hoist. When high point is reached, limit stop switch
automatically stops hook travel. If hook drifts upward slightly
after stop switch is actuated, a reversing switch will close and
automatically reverse direction of hook travel.
7-4. SCREW-TYPE LIMIT SWITCH. This limit switch has a

rotary screw driven by a gear reduction which is coupled to the
end of the drum shaft. Adjustment discs operate the contacts of
separate switches; one for the hoisting circuit and one for the
lowering circuit. The switch assembly must be wired in
12759C
accordance with the appropriate wiring diagram, which is
Figure 7-1A. Motor Brake - Later Version. packaged with hoist. Adjustment of this screw-type limit switch
is accomplished as follows: (Refer to Figure 7-2).
WARNING
Before attempting actual adjustments, be certain main
power switch is OFF and locked in the open position.
12759
Figure 7-1. Motor Brake - Early Version. ADJUSTMENT SWITCH

SWITCH DISCS
LOCKING
PLATE
a. Examine position of indicating tang located below the 12758B
solenoid coil (Figure 7-1 or 7-1A).

Figure 7-2. Screw-Type Limit Switch Adjustment.
b. On the later version of the brake (Figure 7-1A), if the tang (Wires not Shown for Clarity.)
is below the line by more than 1/8", the brake should be adjusted
to bring the top of the tang back up alongside the line on the a. Remove four screws and lift off switch cover.
adjust label. b. Loosen locking plate screws. Slide locking plate away from
adjustment discs.
Page 21

c. Turn proper adjustment disc (right for up, left for down) hoist is furnished as a separate insert and shipped with hoist.
toward stitch to reduce hook travel or away from switch to We suggest you carefully file the wiring diagram with this book
increase hook travel. for future reference.
d. Slide locking plate back into position ensuring slots on WHEN ORDERING PARTS OR INFORMATION ON THIS
adjustment discs are fully engaged, tighten locking plate screws EQUIPMENT, ALWAYS INCLUDE MODEL AND SERIAL
to 4 in-lbs. NUMBER ON ORDER.
e. Replace cover.
SECTION IX — PARTS LIST
WARNING 9-1. GENERAL. The parts lists and illustrations in this section
of the manual, cover parts for all standard 800 SHAWBOX
Check limit switch operation carefully, without load, Electric Hoists. A typical hoist is shown as the basis for the
before placing hoist in service. If misadjusted, SEVERE exploded parts illustrations; therefore, certain variations may
DAMAGE AND/OR A DROPPED LOAD COULD RESULT. occur from the information given. For this reason, always give
Allow 6" for hook drift in both directions. Never allow the Hoist Serial Number, Catalog Number, Motor Horsepower,
less than 1-1/2 complete wraps of rope on drum with Voltage, Phase, Frequency and Rated Load of Hoist when
hook in lowest position. ordering parts.
Provide a light film of NLGI No. 2 grease on bevel gear of limit Certain parts of your hoist will, in time, require replacement
switch. under normal wear conditions. It is suggested that these parts
be purchased for your hoist as spares for future use. These
7-5. OVERLOAD CLUTCH ADJUSTMENT. When properly parts are indicated by a (†) symbol at the right side of the parts
adjusted, the overload device is designed so that the hoist will reference numbers.
lift its full rated load but will refuse to lift an excessive overload.
The overload clutch is not externally adjustable. It is necessary
to remove the overload clutch assembly from the hoist for proper
adjustment. Therefore, it is strongly recommended that when
adjustment and/or replacement parts are required, a SHAWBOX
WARNING
Authorized Repair Station be contacted. Consult your SHAWBOX NON-FACTORY AUTHORIZATIONS OR MODIFICATION
Distributor for nearest Repair Station. OF EQUIPMENT AND USE OF NON-FACTORY REPAIR
PARTS CAN LEAD TO DANGEROUS OPERATION AND
INJURY.
SECTION VIII — WIRING DIAGRAMS
TO AVOID INJURY:
Wiring diagrams for SHAWBOX electric hoists have been omitted • Do not alter or modify equipment without factory
from this book because of many possible variations. This is due authorization.
to different currents and types of electrical components used in • Do use only factory provided replacement parts.
their construction. A print of the correct wiring diagram for each
The numbers assigned to the parts of our various assemblies in our parts lists are not the part numbers used in
manufacturing the part. They are identification numbers, that when given with the model number, permit us to
identify, select or manufacture, and ship the correct part needed.
9-2. INDEX OF EXPLODED VIEW PARTS ILLUSTRATIONS
Figure No. Title Page No.

9-1 Frame, Gearcase and External Parts ........................................................................................................... 23
9-2 Gearing and Load Brake Parts ..................................................................................................................... 26
9-3 Hoist Motor Brake - Later Version ................................................................................................................. 28
9-4 Hoist Motor Brake - Early Version............................................................................................ .................. 30
9-5 Three Phase Motor Assembly ....................................................................................................................... 32
9-6 Upper Limit Switch Parts ............................................................................................................................... 33
9-7 Electrical Control Equipment ......................................................................................................................... 34
9-8 Push Button Station Assembly and Conductor Cable (Single Speed) ........................................................ 35
9-9 Push Button Station Assembly and Conductor Cable (Two Speed) - Later Version ................................... 36
9-10 Push Button Station Assembly and Conductor Cable (Two Speed) - Early Version ................................... 38
9-11 Lower Block Assembly — 2 parts rope, single reeved ................................................................................ 40
9-12 Lower Block Assembly — 2 part double reeved ........................................................................................... 41
9-13 Upper and Lower Block Parts (3 & 5 Ton) .................................................................................................... 42
9-14 Screw-Type Limit Switch Parts ...................................................................................................................... 43
Page 22

11455C
Figure 9-1. Frame, Gearcase and External Parts.
Ref. Part Qty.

No. Number Description Req’d
1 800-197 Plug — Oil Level 2

2 800-192 Cover & Bearing Assembly — Gearcase 1
3 800-105 Dowel 2
4† 800-106 Gasket — Gearcase 1
5 800-107 Gearcase & Bearing Assembly 1
6 Drum & Hub Assembly (Double Reeved Models) 1
1/2 & 1 Ton (3/6" Dia. Rope)
800-109 18' Lift
800-111 34' Lift
800-2100 47' Lift
2 Ton (1/4" Dia. Rope)
800-108 14' Lift
800-110 25' Lift
800-2101 36' Lift
7 Drum & Hub Assembly (Single Reeved Models) 1
1/2 & 1 Ton (1/4" Dia. Rope)
800-113 25' Lift
800-115 50' Lift
800-112 20' Lift
800-114 40' Lift
800-2102 30' Lift
800-2103 45' Lift
800-2104 20' Lift
800-2105 30' Lift
Page 23

Figure 9-1. Frame, Gearcase & External Parts. (Cont’d.)
Ref. Part Qty.

No. Number Description Req’d.
8 800-116 Screw — Hex, Socket Button Head — Self-Locking 4
9 Frame Assembly (Single Reeved Models) 1
1/2, 1 & 2 Ton
800-117 Short Frame
800-118 Long Frame
3 Ton
800-2106 First Extension
800-2107 Second Extension
5 Ton
9A Frame Assembly (Double Reeved Models) 1
1/2, 1 & 2 Ton
800-2110 Short Frame
800-2111 Long Frame
12 800-121 Closure — 1/2" Plug 3
14 800-124 Nut — Hex (Double Reeved Models) 4
15 800-125 Lockwasher (Double Reeved Models) 4
19 Shaft — Extension, Drum 1
800-130 Short Frame
800-131 Long Frame
20 800-132 Key — Woodruff (“Hi-Pro” Type) 1
21 800-133 Ring — Retaining, Hub (Internal) 1
22† 800-134 Bearing — Drum Shaft 1
23 800-135 Ring — Retaining, External 1
24 800-136 Ring — Retaining, Beveled Hub (Internal) 1
25 800-137a Plate Assembly — Base 1
26 800-138 Lockwasher 16
27 800-139 Screw — Hex Socket Head Cap 4
29 800-194c Cover Assembly — Electrical 1
30 800-2121 Screw — Self-Tapping 2
32 800-146a Plate Assembly — Base (Short Frame) 1
34 800-2122 Shell — Brake, Short Frame 1
41 See Fig. 9-3 Motor & Brake 1
& Fig. 9-4
43 800-155 Screw — Hex Socket Head 1
45† Rope & Thimble Assembly (Single Reeved Models) 1
1/2 & 1 Ton (1/4" Dia. Rope)
800-158 25' Lift
800-161 50' Lift
800-157 20' Lift
800-160 40' Lift
800-2115 30' Lift
800-2116 45' Lift
800-2117 20' Lift
800-2118 30' Lift
47 800-164 Screw — Hex Socket Head 4
48 800-165 Roll Pin 2
Page 24

Figure 9-1. Frame, Gearcase & External Parts. (Cont’d.)
Ref. Part Qty.

50 800-167 Screw — Hex Head Cap 2
51 800-168 Key Plate 1
52 800-169 Shaft — Sheave (Double Reeved Models) 1
53 800-170 Bracket, Sheave (Double Reeved Models) 1
54† 800-171 Bearing, Sheave (Double Reeved Models) 1
55† 800-172 Sheave Assembly, Upper (Double Reeved Models) Includes Bearing 1
56† Rope & Thimble Assembly (Double Reeved Models) 1
1/2 & 1 Ton (3/16" Dia. Rope)
800-174 18' Lift
800-176 34' Lift
800-2119 47' Lift
800-173 14' Lift
800-175 25' Lift
800-2120 36' Lift
57 800-177 Plug, Pin 2
58 800-178 Bolt, Hex Head 12
61 800-196 Label, Rated Load (Specify Rated Load) 1
†Recommended spares.
NOTES
Page 25

11456LC
Figure 9-2. Gearing and Load Brake Parts.
Ref. Part Qty.

1† 800-201 Bearing Assembly — Needle, Intermediate & Drum Gear Shaft 2
2† 800-202 Race — Thrust Bearing 4
3† 800-203 Bearing Assembly — Needle Thrust 2
4 Gear — Intermediate 1
800-204 104 Teeth
800-205 109 Teeth
800-266 103 Teeth
800-206 90 Teeth
800-2205A 107 Teeth
5 800-207 Key — Woodruff 1
7 Gear — Drum 1
800-209 71 Teeth
800-210 61 Teeth
800-2209 71 Teeth
8 Shaft — Intermediate Gear 1
800-211 14 Teeth
800-212 24 Teeth
800-2211 14 Teeth
Page 26

Figure 9-2. Gearing and Load Brake Parts. (Cont’d.)
Ref. Part Qty.

15 800-219 Ring — Retaining, Drum Shaft Bearing 1
17 800-221 Ring — Retaining 1
18† 800-222 Bearing Assembly — Roller, Intermediate Shaft 1
19 800-269 Cover — Oil Hole 1
20 800-224 Pipe Plug — Hex Socket 1
21† 800-225 Oil Seal — Motor Shaft 1
22† 800-226 Bearing Assembly — Ball, Motor Shaft 1
23† 800-227 Bearing Assembly — Needle, Load Brake Shaft 1
24 800-228 Ring — Retaining, Motor Shaft Bearing 1
25 800-229 Washer — Thrust (Steel) 1
Brake Assembly — Load, Complete (Includes Items 26 thru 37) 1
800-230 23 Teeth
800-231 36 Teeth
800-267 24 Teeth
800-232 18 Teeth
800-2232A 20 Teeth
26 800-233 Ring — Retaining, Brake Flange 1
27 800-234 Flange — Load Brake 1
28* 800-235 Washer — Friction 2
29 800-236 Pawl & Ratchet Assembly — Load Brake (Available Only As An Assembly) 1
30 800-237 Bushing — Ratchet 1
31 800-238 Gear & Center Assembly 1
32 800-239 Pin — Groove 2
33† 800-240 Cam — Load Brake 1
34† 800-241 Spring — Load Brake 1
35 800-242 Retainer — Spring, Load Brake 1
36 800-243 Key — Woodruff 2
37 Shaft & Integral Pinion — Load Brake 1
800-244 23 Teeth
800-245 36 Teeth
800-268 24 Teeth
800-246 18 Teeth
800-2246A 20 Teeth
38† 800-247 Washer — Thrust (Used With 800-246 Only) 1
39† 800-248 Washer — Thrust (Bronze) 1
40† 800-249 Bearing Assembly — Needle, Load Brake Shaft 1
* 800-250 Load Brake — Clutch Assembly With Bearings (Complete) 1
** 800-251 Load Brake — Clutch Assembly (Includes Items 26 thru 30, 34, 36 thru 38
and 43 thru 45) 1
}
43 800-254 Spring Retainer
44 800-253 Brake Gear, Center Available only as part of
45 800-252 Clutch Assembly 800-250 or 800-251 above
47 800-263 Oil Seal — Drum Shaft 1
48 800-261 Bearing Assembly — Ball, Drum Shaft 1
49 800-262 Shaft — Drum 1
† Recommended spares.
* Recommended Replacement Kit for Load Brake Clutch (Complete).
** Replacement Complete, Less Bearings and Thrust Washers.
For hoists built prior to March, 1997, gearing part numbers, with four digits (rather than three) after “800-”, must be replaced in sets.
For hoists built between March 1, 1997 and July 1, 1997, contact the factory for gearing requirements.
Page 27

12756H
Figure 9-3. Hoist Motor Brake - Later Version.
Ref. Part Qty.

800-2401 Motor Brake Assembly (Includes Ref. Nos. 1 thru 31) 1
1 * Acorn Nut - Plated (#10-32) 2
2 800-2402 Brake Cover Assembly (Includes Brake Cover and Label Inside Cover) 1
3 * Cover Stud 2
4 * Gasket 1
5 * Phillips Pan Head Self Tapping Screw - Plated (#10-32 x 1-3/4) 4
6 * Solenoid Frame Cover Assembly 1
7 * Hex Key (1/8 - 3/4 x 2) 1
8 800-2410† Solenoid Coil Assembly 1
9 * Tubing 3
10 * Hex Nut - Plated (#10-32) 2
11 800-2411 Solenoid Frame 1
14 * Hex Head Self Locking Nut - Plated (#10-32) 2
15 800-2403 Solenoid Support 1
16 * Hex Washer Head Thread Forming Screw - Plated (#10-32 x 1/4) 2
17 * Solenoid Plunger 1
18 * Hex Socket Head Set Screw - Oval Point (1/4-28 x 1) 1
19 * Hex Socket Shoulder Screw (#10-24 x 1)** 1
20 * Hex Head Self Locking Nut - Plated (#10-24)** 1
21 * Brake Spring (Use Red Spring Only) 1
22 * Brake Lever Assembly 1
23 * Pressure Pad 2
24 Brake Disc (Non-asbestos) 1
25 * Brake Support Stud 2
26 * Separating Spring 2
27 800-2404 Brake Mounting Plate 1
28 * Hex Socket Head Self Locking Set Screw - Cup Point (1/4-20 x 3/8) 2
29 * Brake Hub 1
30 * Hex Socket Head Screw (3/8-16 x 3/4) 2
31 Lock Washer (3/8) 2
Wire Nuts — Not Shown (No. 22 thru 14 AWG) 4
* Not available as individual parts. See replacement kits listed below.
** Later models have a hex socket head screw (1/4-20 x 1-1/2) with a hex head self locking nut - plated (1/4-20).
Kits include quantities shown above.
Page 28

Figure 9-3. Hoist Motor Brake. (Cont’d.)
Kit Description Part Number Reference Numbers Included
Brake Disc 800-2405† 23, 24, 26
Brake Lever 800-2406 6, 15, 17, 18, 19, 20, 21 (Red Color), 22,
Adjusting Screw Label, Brake Adjust Label —
Discard Zinc Colored Spring
Rectifier 800-2407 12, 13, 4 Wire Nuts
Hardware 800-2408 1, 3, 4, 5, 7, 9, 10, 12, 16, 18, 20, 25, 28, 30, 31,
Instruction Label, Power Warning Label
Brake Hub 800-2409 28, 29, Hub Drive Key (Shown Elsewhere)
† Recommended spares.
NOTES
Page 29

12756A
Figure 9-4. Hoist Motor Brake - Early Version.
Ref. Part Qty.

Motor Brake Assembly (Includes Ref. Nos. 1 thru 32) 1
800-1400 Short Frame Models Only
800-1401 Other Models
1 * Acorn Nut (#10-32) 2
2 800-1402 Brake Cover Assembly (Includes Brake Cover and Label Inside Cover) 1
3 * Cover Stud 2
4 * Gasket 1
5 * Hex Washer Head Thread Forming Screw (#10-32 x 1 -3/4) 4
6 * Solenoid Frame Cover Assembly 1
7 * Hex Key (1/8-3/4 x 2-1/4) 1
8 * Solenoid Coil Assembly 1
9 * Tubing 3
10 * Hex Nut (#10-32 Pltd.) 2
11 * Solenoid Frame 1
14 * Hex Head Self-Locking Nut (#10-24) 2
15 800-1403 Solenoid Support 1
16 * Hex Washer Head Thread Forming Screw (#10-32 x 1/4) 2
17 * Solenoid Plunger 1
18 800-1404 Hex Socket Head Self-Locking Set Screw - Oval Point (1/4 - 28 x 1) 1
20 * Clevis Pin (3/16 x 1-1/4) 1
21 * Flat Washer 2
22 * Brake Spring 1
23 * Brake Lever Assembly 1
24 * Pressure Pad 2
25 * Brake Disc (Non-asbestos) 1
26 * Brake Support Stud 2
27 * Separating Spring 2
28 * Hex Socket Head Self-Locking Set Screw - Cup Point (1/4 - 20 x 3/8) 2
29 * Brake Hub 1
30 * Hex Socket Head Screw (3/8 - 16 x 3/4) 2
31 800-1405 Brake Mounting Plate 1
32 * Wire Nuts — Not Shown (No. 22 thru 16 AWG) 4
* Not available as individual parts. See replacement kits listed below. Kits include quantities shown above.
Page 30

Figure 9-4. Hoist Motor Brake. (Cont’d.)
Kit Description Part Number Reference Numbers Included

Brake Disc 800-1406 24, 25, 27
Solenoid 800-1407 5, 6, 8, 11, 17
Brake Lever 800-1408 18, 20, 21, 22, 23
Brake Hub 800-1409 28, 29, Hub Drive Key (Shown Elsewhere)
Special Hardware 800-1410 3, 4, 9, 26, Instruction Label inside cover,

Adjust Label, Adjusting Screw Label on
brake lever assembly, Power Warning Label
on cover
Hardware 800-1411 1, 5, 7, 10, 12, 14, 16, 18, 20, 21, 28, 30
NOTES
Page 31

12724
Figure 9-5. Three Phase Motor Assembly.
Ref. Part Qty.

Motor Assembly (Includes Ref. Nos. 1 thru 8) 1
1 Horsepower (1 Speed)
800-1301 200 Volt
800-1302 230/460 Volt
800-1303 575 Volt
800-1304 200 Volt
800-1305 230/460 Volt
800-1306 575 Volt
800-1307 200 Volt
800-1308 230/460 Volt
800-1309 575 Volt
1 - 1/3 Horsepower (2 Speed)
800-1310 200 Volt
800-1311 230 Volt
800-1312 460 Volt
800-1313 575 Volt
2 - 2/3 Horsepower (2 Speed)
800-1314 200 Volt
800-1315 230 Volt
800-1316 460 Volt
800-1317 575 Volt
3 - 1 Horsepower (2 Speed)
800-1318 200 Volt
800-1319 230 Volt
800-1320 460 Volt
800-1321 575 Volt
4 - 2 Horsepower (2 Speed)
800-1322 200 Volt
800-1323 230 Volt
800-1324 460 Volt
800-1325 575 Volt
1 * Bell — End 1
2 * Ring — Retaining 1
3 * Bearing — Ball 1
4 * Ring — Retaining 1
5 * Key — Brake 1
6 * Rotor and Shaft Assembly 1
7 * Stator Assembly 1
8 * Bolt — Motor 4
* Furnished only as part of motor assembly.
Page 32

11460
Figure 9-6. Upper Limit Switch Parts.
Ref. Part Qty.

1 800-501 Pin — Pivot 2
2 Arm — Lever 1
800-502 Short Frame
800-503 Long Frame
3 Lever — Floating 1
800-504 Short Frame
800-505 Long Frame
4 800-506 Washer 2
5 800-507 Pin — Cotter 2
6 800-525 Coupling 1
7 800-509 Pin — Roll 2
8† 800-510 Switch Assembly — Limit, Reversing (Includes Wire Leads) 1
9 800-511 Connector — Wire 3
10† 800-512 Switch Assembly — Limit, Stop (Includes Wire Leads) 1
11 800-513 Screw — Round Head 4
12 800-514 Screw — Socket Head Shoulder 1
13 800-515 Shaft & Cam Assembly 1
14 800-516 Insulator — Limit Switch 1
15 800-517 Bearing — Nylon 2
16 800-518 Screw — Socket Head Cap 2
18 800-520 Nut — Lock 1
19 800-521 Bracket Assembly — Mounting 1
20 800-522 Nut — Hex 2
† Recommended Spares.
Page 33

12748A
Figure 9-7. Electrical Control Equipment.
Ref. Part Qty.

3 800-670 Cord Grip — Conductor 2
6† 800-655 Contactor — Two Speed 1
7† 800-656 Contactor 1
9† 800-671 Transformer 1
11† 800-672 Terminal Board (Reconnectable Hoist Only) 1
12 800-673 Fuse, Fuse Holder and Wire Assembly 1
800-674 Fuse Only (2A, 300V) 1
13 800-675 Brake Module 1
14 800-676 Screw — Self Tapping 2
NOTES
Page 34

12763
Figure 9-8. Push Button Station and Conductor Cable Assembly.

Single Speed Hoists.
Ref. Part Qty.

800-2701 Push Button Station and Conductor Cable Assembly
(Includes Ref. Nos. 1 thru 17) 1
800-2702 Push Button Station (Includes Ref. Nos. 1 thru 15) 1
1 * Type 1 Pan Head Machine Screw (M 3.5 x 0.6 x 12 Pltd.) 7
2 * Lockwasher (M 3.5 Pltd.) 7
3 * Rear Cover 1
4 800-2703 Gasket 1
5 * Type 1 Pan Head Thread Cutting Screw (M 4 x 15 Pltd.) 2
6 800-2704 Contact Assembly 1
7 800-2705 Button Assembly 1
8 * Type 1 Pan Head Machine Screw (M 6 x 1 x 12 Pltd.) 1
9 * Lockwasher (M 6 Pltd.) 1
10 * Plain Washer (M 6 Pltd.) 1
11 * Type 1 Pan Head Machine Screw (M 3.5 x 1 x 14 Pltd.) 2
12 * Lockwasher (M 3.5 Pltd.) 2
13 * Housing Cap 1
14 800-2706 Grommet 1
15 * Housing 1
16 800-2707 Conductor Cable Assembly 1
17 800-2708 Plastic Warning Tag 1
* Not available separately. Order Push Button Station.
Page 35

12721A

Two Speed Hoists Only - Later Version.
Ref. Part Qty.

1 800-1822 Grommet 1
7 800-1823 Conductor Cable As Req’d
11 800-1812 Operator Warning Label 1
12 800-1814 Sleeve — Conductor 1
13 * Support — Strain Cable 1
14 * Screw — Slotted Head 4
15 * Lockwasher 4
16 * Enclosure — Rear 1
17 * Gasket 1
Page 36

Figure 9-9. Push Button Station and Conductor Cable Assembly. (Cont’d.)
Ref. Part Qty.

20 * Clamp — Conductor 1
21 * Contact Block Assembly 1
800-1815 Contact Block (ZB2-BE101) 2
22 * Interlock—Mechanical 1
800-1817 Up Push Button Assembly (Includes 1 Each of Ref. Nos. 23 and
25 thru 29) 1
800-1818 Down Push Button Assembly (Includes 1 Each of Ref. Nos. 23,
25 thru 28 and 30) 1
23 ** Ring — Retaining 2
24 * Enclosure — Front 1
25 ** Seat — Spring 2
26 ** Spring 2
27 ** Seal 2
28 ** Plate — Push Button 2
29 ** Push Button — Up 1
30 ** Push Button — Down 1
** Not available separately. Order Push Button Assembly.
NOTES
Page 37

12721

Two Speed Hoists Only - Early Version.
Ref. Part Qty.

1 800-1802 Anchor Bracket — Strain Cable 1
2 800-1803 Grip Assembly — Conductor 1
3 800-1804 Connector — Strain Cable 1
4 800-1805 Thimble — Strain Cable 2
5 800 1806 Connector — Conductor to Strain Cable 1
6 800-1807 Clamp — Conductor 1
7 800-1808 Conductor Cable 1
8 800-1809 Strain Cable 1
9 800-1810 Sleeve — Pressure 1
10 800-1811 Tie — Conductor As Req’d.
11 800-1812 Operator Warning Label 1
12 800-1814 Sleeve — Conductor 1
Page 38

Figure 9-10. Push Button Station and Conductor Cable Assembly. (Cont’d.)
Ref. Part Qty.

13 * Support — Strain Cable 1
15 * Lockwasher 4
16 * Enclosure — Rear 1
17 * Gasket 1
20 * Clamp — Conductor 1
21 * Contact Block Assembly 1
22 * Interlock — Mechanical 1
800-1817 Up Push Button Assembly (Includes 1 Each of Ref. Nos. 23 and
25 thru 29) 1
800-1818 Down Push Button Assembly (Includes 1 Each of Ref. Nos. 23,
25 thru 28 and 30) 1
23 ** Ring — Retaining 2
24 * Enclosure — Front 1
25 ** Seat — Spring 2
26 ** Spring 2
27 ** Seal 2
28 ** Plate — Push Button 2
29 ** Push Button — Up 1
30 ** Push Button — Down 1
** Not available separately. Order Push Button Assembly.
NOTES
Page 39

11464
Figure 9-11. Lower Block Assembly — Two Parts Rope, Single Reeved.
Ref. Part Qty.

800-801 Block Assembly — Lower, Complete, 2 Ton 1
800-803 Block Assembly — Lower, Complete, 1/2 Ton 1
1 800-804 Screw — Flat Head, Self-Threading 2
2 800-805 Cover — 2 Ton 1
800-806 Cover — 1 Ton 1
800-807 Cover — 1/2 Ton 1
3 800-808 Ring — Retaining, 2 Ton 2
800-809 Ring — Retaining, 1/2 & 1 Ton 2
4 800-810 Lube Fitting 1
5 800-811 Pin — Sheave, 2 Ton 1
800-812 Pin — Sheave, 1/2 & 1 Ton 1
6 800-813 Spacers — 2 Ton 2
800-814 Spacers — 1/2 Ton & 1 Ton 2
† 800-815 Sheave Assembly — 2 Ton (Consists of Items 7 and 8) 1
7 800-816 Bearing 1
8 800-817 Sheave 1
† 800-818 Sheave Assembly — 1/2 & 1 Ton (Consists of Items 7 and 8) 1
7 800-819 Bearing 1
8 800-820 Sheave 1
9 800-821 Cover — Lower Block, 2 Ton 1
800-822 Cover — Lower Block, 1 Ton 1
800-823 Cover — Lower Block, 1/2 Ton 1
10 † 800-824 Hook Assembly — (Consists of Hook, Nut & Grooved Pin), 2 Ton 1
† 800-825 Hook Assembly — (Consists of Hook, Nut & Grooved Pin), 1/2 & 1 Ton 1
11 800-826 Shroud — Thrust Bearing, 2 Ton 1
800-827 Shroud — Thrust Bearing, 1/2 & 1 Ton 1
12 † 800-828 Bearing Washer -— Thrust, 2 Ton 1
† 800-829 Bearing Washer — Thrust, 1/2 & 1 Ton 1
13 800-830 Body — Lower Block, 2 Ton 1
800-831 Body — Lower Block, 1/2 & 1 Ton 1
14 800-832 *Safety Hook Latch Kit — 2 Ton 1
800-833 *Safety Hook Latch Kit — 1/2 & 1 Ton 1
Page 40

11465
Figure 9-12. Lower Block Assembly—Two Parts Double Reeved.
Ref. Part Qty.

800-853 Block Assembly — Lower, Complete, 1/2 Ton 1
1 800-804 Screw — Flat Heads Self-Threading 4
2 800-854 Cover — Lower Block, 2 Ton 2
800-806 Cover — Lower Block, 1 Ton 2
800-807 Cover — Lower Block, 1/2 Ton 2
4 800-810 Fitting — Lube 1
5 800-855 Pin — Sheave 1
6 800-814 Spacer 4
† 800-818 Sheave Assembly — (Consists of Items 7 and 8) 2
7 800-819 Bearing 2
8 800-820 Sheave 2
9 800-856 Cover — Intermediate 1
11 † 800-824 Hook Assembly — (Consists of Hook, Nut & Grooved Pin), 2 Ton 1
† 800-825 Hook Assembly — (Consists of Hook, Nut & Grooved Pin), 1/2 & 1 Ton 1
12 800-826 Shroud — Thrust Bearing, 2 Ton 1
800-827 Shroud — Thrust Bearing, 1/2 & 1 Ton 1
13 † 800-828 Bearing — Thrust, 2 Ton 1
† 800-829 Bearing — Thrust, 1/2 & 1 Ton 1
14 800-857 Body — Lower Block, 2 Ton 1
800-858 Body — Lower Block, 1/2 & 1 Ton 1
15 800-832 *Safety Hook Latch Assembly — 2 Ton 1
800-833 *Safety Hook Latch Assembly — 1/2 & 1 Ton 1
* Furnished as Standard with hook.
Page 41

12197LA
Figure 9-13. Upper and Lower Block Parts (3 & 5 Ton — Typical).
Quantity Required
Ref. Part Reeving
No. Number Description 3-Ton/4 PS 5-Ton/6 PS
800-1501 Block Assembly — Lower, 4 Part Single (Complete) 1 —
800-1502 Block Assembly — Lower, 6 Part Single (Complete) — 1
1 800-1503 Screw — Hex Head Cap 2 2
2 800-1504 Lockwasher 2 2
3 800-1505 Key Plate 1 1
4 800-1506 Fitting — Grease 1 1
5 800-1507 Pin — Upper Sheave 1 1
6 800-1508 Spacer Washer — Upper Sheave 2 4
7† 800-1509 Bearing — Upper Sheave (Includes Outer Race) 1 2
8† 800-1510 Sheave — Upper 1 2
9 800-1535 Pin — Rope Guide 2 2
11 800-1513 Spacer Washer — Lower Sheave 4 6
12† 800-1514 Bearing — Lower Sheave (Includes Outer Race) 2 3
13† 800-1515 Sheave — Lower 2 3
14 800-1516 Pin — Roll, Hook Nut 1 1
15 800-1517 Nut — Hook* 1 1
16† 800-1518 Bearing — Thrust, Hook 1 1
800-1530 Shield — Bearing (Not Shown) 1 —
800-1531 Washer — Thrust (Not Shown) 2 —
17 800-1519 Fitting — Grease 1 1
18† 800-1520 Hook Assembly — (includes Hook, Latch & Nut) 1 1
19 800-1521 Plate — Capacity 2 2
20 800-1522 Screw — Round Head, Self-Tapping (Capacity Plate) 4 4
21 800-1523 Guard — Sheave 1 1
22 800-1524 Body — Lower Block 1 1
23 800-1525 Pin — Lower Sheave 1 1
24 800-1526 Screw — Button Head Cap, Self-Locking (Sheave Guard) 4 4
25 800-1527 Ring — Retaining, External 2 2
26 800-1528 Lockwasher — (Capacity Plate) 4 4
27 800-1529 Spacer — Upper Block, 9/16" 2 —
* Hook Nuts with roll pins are not interchangeable — Available only as an assembly.
Page 42

12757A
Figure 9-14. Screw-Type Limit Switch Parts.

Ref. Part Qty.
1 800-1655 Limit Switch Assembly (Includes Ref. Nos. 2, 3 and 4) 1
2 800-1651 Cap Screw — Hex Socket Head 3
3 800-1652 Sealing Washer 3
4 800-1657 Drum Shaft Insert 1
For switch element replacement order 800-1654.
NOTES
Page 43

Recommended Spare Parts for Your Yale Hoist
Certain parts of your hoist will, in time, require replacement under normal wear conditions.
It is suggested that the following parts be purchased for your hoist as spares for future use.
One Friction Disc Kit

One Motor Brake Solenoid Coil
One Set Of Contactors
One Transformer
One Wire Rope Assembly
One Gearcase Gasket
Note: When ordering parts always furnish Hoist Serial Number, Catalog Number, Motor Horsepower, Voltage,
Phase, Frequency and Rated Load of Hoist on which the parts are to be used.
Parts for your hoist are available from your local authorized SHAW-BOX repair station.
For the location of your nearest repair station, write:
IN USA
YaleLift-Tech
P.O. Box 769
Muskegon, MI 49443-0769
Phone: 800 742-9269
Fax: 800 742-9270
WARRANTY
WARRANTY AND LIMITATION OF REMEDY AND LIABILITY
A. Seller warrants that its products and parts, when shipped, and its B. Upon Buyer’s submission of a claim as provided above and its
work (including installation, construction and start-up), when performed, substantiation, Seller shall at its option either (i) repair or replace its
will meet applicable specifications, will be of good quality and will be product, part or work at either the original f.o.b. point of delivery or at
free from defects in material and workmanship. All claims for defective Seller’s authorized service station nearest Buyer or (ii) refund an
products or parts under this warranty must be made in writing equitable portion of the purchase price.
immediately upon discovery and in any event, within one (1) year from C. This warranty is contingent upon Buyer’s proper maintenance and
shipment of the applicable item unless Seller specifically assumes care of Seller’s products, and does not extend to normal wear and
installation, construction or start-up responsibility. All claims for tear. Seller reserves the right to void warranty in event of Buyer’s use
defective products or parts when Seller specifically assumes of inappropriate materials in the course of repair or maintenance, or
installation, construction or start-up responsibility and all claims for if Seller’s products have been dismantled prior to submission to Seller
defective work must be made in writing immediately upon discovery for warranty inspection.
and in any event, within one (1) year from completion of the applicable
work by Seller, provided; however, all claims for defective products D. The foregoing is Seller’s only obligation and Buyer’s exclusive
and parts made in writing no later than eighteen (18) months after remedy for breach of warranty and is Buyer’s exclusive remedy
shipment. Defective items must be held for Seller’s inspection and hereunder by way of breach of contract, tort, strict liability or otherwise.
returned to the original f.o.b. point upon request. THE ‘FOREGOING In no event shall Buyer be entitled to or Seller liable for incidental or
IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES consequential damages. Any action for breach of this agreement
WHATSOEVER, EXPRESS, IMPLIED AND STATUTORY, must be commenced within one (1) year after the cause of action has
INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES accrued.
OF MERCHANTABILITY AND FITNESS.

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OPERATION, SERVICE & PARTS MANUAL

Before installing hoist, fill in the

SERIES Y80 Purchase Date _____________

WIRE ROPE ELECTRIC HOISTS

WEIGHT WATCHER OVERLOAD CLUTCH MODELS

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NOTICE: Information contained in this book is subject to change without notice.

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1-1. GENERAL. YALE electric hoists are precision built wire

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2-4. PRE-OPERATION CHECKS.

2-3. CONNECTING HOIST TO ELECTRICAL SERVICE.

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To properly check the phase of the hoist, follow the steps

(1) With “POWER OFF” operate all the push buttons

(2) Temporarily connect hoist to power source. WARNING

e. Lubricate Hoisting Cable. For longer cable life, it is

Figure 2-2. Limit Stop Mechanism

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aq. DO operate hoist within recommended duty cycle and

b. Apply a few drops of S.A.E. No. 50 oil to shaft bearing at

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Environmental conditions in which the hoist operates are

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e. If hook is equipped with a safety latch or rotational lock, WARNING

Figure 5-1. Proper Hook Opening.

h. Check wear of the hook, especially at the saddle and

5-3. INSPECT UPPER BLOCK AND HOIST SUSPENSION.

a. Check upper block sheaves (when hoist is so equipped)

b. Make certain that all sheaves, bearings and hanger pins

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(Low Oil or Grease,

Rope Slings & Connections

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1 Month * HOIST CABLE — Inspect and lubricate per paragraph 5-8.

* ELECTRICAL CONTROLS — Inspect per paragraph 5-4.

6 Months * LOWER BLOCK — Inspect per paragraph 5-2.

5 Years elapsed Complete inspection, disassembly, and maintenance required. It is recommended

*Perform services described by paragraph indicated.

Figure 5-2. Inspection and Maintenance Schedule.

5-5. INSPECT MOTOR BRAKE. See Figure 9-4.

a. Remove acorn nuts holding brake cover and remove

b. Remove brake mounting plate screws and lift brake

c. Check braking surfaces for wear and scoring. Replace

d. Reinstall parts in reverse of disassembly. 11404A

e. Adjust brake as explained in Section Vll.

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Figure 5-4. Removing Intermediate Gear and

Figure 5-7. View Showing Load Brake

(3) Remove load brake gear. If replacement of spring,

11422 (4) The load brake pawl and ratchet is a riveted

e. To disassemble intermediate gear and pinion, press

(1) Place load brake assembly, flange up, in a vise

Figure 5-8. Removing Pawl and Ratchet Assembly

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h. Install gearing and load brake assembly in gearcase in

(1) A steel thrust washer with 5/8" I.D. must be installed

(2) A bronze thrust washer with a lug on one side goes