OPERATING, MAINTENANCE

& PARTS MANUAL

WIRE ROPE ELECTRIC HOISTS

SERIES 80

Before installing hoist, fill in the information below.

Model Number
Serial No.
Purchase Date
Voltage
Rated Load

Please provide Serial Number when ordering parts.

CAPACITIES:
RATED LOADS 1/2 THRU 5 TONS
Follow all instructions and warnings for inspecting,
maintaining and operating this hoist.
The use of any hoist presents some risk of personal injury
or property damage. That risk is greatly increased if proper
instructions and warnings are not followed. Before using
this hoist, each operator should become thoroughly familiar
with all warnings, instructions and recommendations in this
manual. Retain this manual for future reference and use.
Forward this manual to operator. Failure to operate equipment
as directed in manual may cause injury.
Columbus McKinnon Corporation
205 Crosspoint Parkway
Getzville, NY 14068
WEIGHT WATCHER
OVERLOAD CLUTCH
MODELS RATED LOADS
1/2 THRU 5 TONS
Manual No. 117404-10 REV. AB October 2018
 YALE HOIST PARTS AND SERVICES ARE AVAILABLE IN THE
UNITED STATES AND IN CANADA
As a YALE Hoist and Trolley user you are assured of reliable repair and parts services through a
network of Master Parts Depots and Service Centers that are strategically located in the United
States and Canada. These facilities have been selected on the basis of their demonstrated ability to
handle all parts and repair requirements promptly and efficiently. To quickly obtain the name of the
Master Parts Depot or Service Center located nearest you, call (800) 888-0985, Fax: (716) 689-5644,
visit www.cmworks.com.

LAS PIEZAS Y REPARACIONES DE LOS POLIPASTOS DE YALE ESTÁN ASEGURADAS

EN ESTADOS UNIDOS Y CANADÁ
Como usuario de un polipasto y carro de YALE le aseguramos cualquier reparación o la disponibilidad
de cualquier pieza de repuesto a través de una red de almacenes de piezas de repuesto y centros
de servicio situados estratégicamente en Estados Unidos y Canadá. Estas instalaciones se han
seleccionado en base a su capacidad demostrada en la reparación de equipos y suminstro de
piezas de repuesto de forma rápida y eficaz. Para obtener la dirección del almacén de piezas de
repuesto o del centro de servicio más cercano, llame al teléfono (800) 888-0985. Fax: (716) 689-
5644, visita www.cmworks.com. (sólo en Estados Unidos y Canadá).

LE SERVICE DE RÉPARATION ET DE PIÈCES POUR PALANS YALE EST DISPONIBLE

AUX ÉTATS-UNIS ET AU CANADA
Soyez assurés qu'en temps d'utilisateur de palan et treuil YALE, d'un service de réparation et de
pièces fiable par l'entremise d'un réseau de Centres de service et de Dépôts de pièces maîtresses qui
sont stratégiquement situés aux États-Unis et au Canada. Ces établissements ont été sélectionnés
sur une base de leur habileté démontrée à s'occuper promptement et efficacement des besoins de
réparation de pièces. Appelez le (800) 888-0985, Fax: (716) 689-5644, visite www.cmworks.com. pour
obtenir rapidement le nom du dépôt de pièces maîtresses ou du centre de service situé le plus près.

2 Manual No. 117404-10 REV. AB October 2018

FOREWORD
This manual contains important information to help you install, operate, maintain and service your new YALE electric hoist. We recommend
that you study its contents thoroughly before putting the hoist into use. We also recommend that you read ANSI B30.16 safety code and
the applicable performance and safety standards referenced therein. Then, through proper installation, application of correct operating
procedures, and by practicing the recommended maintenance procedures, you can expect maximum lifting service from the hoist.
It will likely be a long time before parts information found in the Parts List is needed. Therefore, after the hoist is installed and you have
completely familiarized yourself with operation and preventative maintenance procedures, we suggest that this book be carefully filed for
future reference.
When ordering replacement parts from this book, it will be necessary that you include with your order: the Hoist Serial Number and Model
Number that are found on the nameplate attached to the hoist as shown in Figure 4-1. For your convenience, a space has been provided
on the front cover of this Manual for entering this information. We recommend that you fill it out immediately so it is readily at hand when
needed.
The contents of this manual are of necessity, general in nature and may cover features not incorporated on your hoist; or, you may have
ordered features not covered by this manual. Therefore, the user must exercise care in applying instructions given in this manual. If specific
information not in this manual is required, contact customer service.
THE INFORMATION CONTAINED IN THIS MANUAL IS FOR INFORMATIONAL PURPOSES ONLY AND YALE DOES NOT WARRANT
OR OTHERWISE GUARANTEE (IMPLIEDLY OR EXPRESSLY) ANYTHING OTHER THAN THE COMPONENTS THAT YALE
MANUFACTURES AND ASSUMES NO LEGAL RESPONSIBILITY (INCLUDING, BUT NOT LIMITED TO CONSEQUENTIAL DAMAGES)
FOR INFORMATION CONTAINED IN THIS MANUAL.

TABLE OF CONTENTS
Master Parts Depots And Service Centers���������������������������������������� 2 TROUBLESHOOTING CHART .............................................. 20
Foreword ������������������������������������������������������������������������������������������� 3
ADJUSTMENTS
GENERAL DESCRIPTION PAGE Mechanical Load Brake.................................................................... 22
General ............................................................................................... 4 Motor Brake...................................................................................... 22
Basic Construction ............................................................................ 4 Block Operated Limit Switch ........................................................... 26
Differences Between Models.............................................................. 4 Screw - Type Limit Switch ............................................................... 26
Overload Clutch Adjustment ........................................................... 26
INSTALLATION
General .............................................................................................. 5 WIRING DIAGRAMS............................................................... 27
Suspending Hoist .............................................................................. 5
Connecting Hoist to Electrical Service .............................................. 5 REPAIR PARTS LIST
Pre-Operation Checks ....................................................................... 6 General ............................................................................................ 28

OPERATION
General .............................................................................................. 7
Push Button Operation ...................................................................... 7
LIST OF ILLUSTRATIONS
Overload Clutch Operation ................................................................ 7 FIG. DESCRIPTION PAGE
Operating Precautions ....................................................................... 7 9-1 Frame, Gearcase and External Parts................................ 29
Safety Precautions����������������������������������������������������������������������������� 2 9-2 Gearing and Load Brake Parts......................................... 31
9-3 Hoist Motor Brake............................................................ 33
LUBRICATION 9-4 Three Phase Motor Assembly........................................... 34
General .............................................................................................. 9 9-5 Upper Limit Switch Parts.................................................. 35
Change Gearcase Oil ........................................................................ 9 9-6 Electrical Control Equipment............................................ 36
Lubricate Hoist Cable ........................................................................ 9 9-7 Push Button Station Assembly and
Lubricate Upper Sheave & Lower Block Assembly ........................... 9 Conductor Cable (Single Speed)...................................... 37
Lubricate Limit Stop Lever ................................................................ 9 9-8 Push Button Station Assembly and
Lubricate Limit Switch ....................................................................... 9 Conductor Cable (Two Speed).......................................... 38
9-9 Lower Block Assembly — 2 parts rope,
INSPECTION AND PREVENTATIVE MAINTENANCE single reeved..................................................................... 39
General ............................................................................................ 10 9-10 Lower Block Assembly — 2 part
Inspect Lower Block ........................................................................ 10 double reeved................................................................... 40
Inspect Upper Block and Hoist Suspension ................................... 11 9-11 Upper and Lower Block Parts (3 & 5 Ton)......................... 41
Inspect Electrical Controls .............................................................. 11 9-12 Screw-Type Limit Switch Parts......................................... 42
Inspect Motor Brake......................................................................... 13
Inspect Mechanical Load Brake, Gearing
and Overload Clutch (Optional)........................................................ 13
Inspect Rope Drum and Shaft ......................................................... 15
Rope Inspection, Maintenance and Replacement .......................... 15
Rope Reeving .................................................................................. 16
Testing Hoist and Overload Clutch (Optional) ................................. 18

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.

3 Manual No. 117404-10 REV. AB October 2018

GENERAL DESCRIPTION
GENERAL
YALE electric hoists are precision built wire rope and drum type
hoists which are made in five rated load sizes (1/2, 1, 2, 3 and 5
tons) with various lifts, lifting speeds and electrical service. Equipped
with an integrally welded mounting lug, they are designed to be
rigidly attached to an overhead structure or mounted on YALE
rigid mount trolleys for operation on runway beams. On certain
models optional base mounting or other supporting methods may
be obtained. For more information, please contact the Customer
Service team.
NOTICE: YALE hoists are available with an optional built-in
mechanical overload clutch. Hoists having this device are
identified with words WEIGHT WATCHER on the hoist.
The WEIGHT WATCHER overload clutch permits operation of your
hoist within its rated load and helps prevent lifting of excessive loads
which could cause permanent deformation of a properly maintained
hoist or trolley.

BASIC CONSTRUCTION
All models are of the same 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 the hoist to a trolley or overhead support, is located on top of
the frame. An aluminum alloy gearcase and cover, attached to one end
of frame, houses a three-reduction gear train and 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, located on the end of the frame (opposite
gearcase end) and enclosed by a steel cover, control operation and
rotating direction of a driving motor. A hoisting rope and an enclosed
lower block assembly are used for lifting loads. An upper limit stop is
used to limit travel of the lower block in the raising direction, to protect
hoist from damage. A push button control station, for operating the
hoist, is suspended from the electrical compartment.

DIFFERENCES BETWEEN MODELS

The main differences between models are in rope reeving and frame
size as described below.
a. R
 ope Reeving. There are four types of rope reeving used:
Two parts of rope single reeved, four parts of rope single
reeved, six parts of rope single reeved and two parts of rope
double reeved. Single reeved hoists have one end of the rope
anchored to the drum, whereas, double reeved hoists have
both ends anchored to the drum. On single reeved models,
the lower block travels sideways as rope winds on drum,
double reeved models offer true vertical lift. For illustrations,
refer to Section V, paragraph 5-9, “Rope Reeving” instructions.
b. F
 rame Size. Length of frame furnished is dependent on hoist
capacity and lift. Four frame lengths are used; short frame,
long frame, first and second extensions. Short frame hoists
have a rope drum flange to flange distance of approximately
9-3/4", whereas this distance on a long frame hoist is
approximately 16-3/4". First extension frame hoists have a
flange to flange distance of 22-15/16" and second extensions
have 35-3/8".
c. M
 otor Brake. Hoists are equipped with a disc brake mounted
on the motor end bell and operated by a short stroke solenoid.
This brake requires periodic adjustment.

4 Manual No. 117404-10 REV. AB October 2018

INSTALLATION Replace side plate and washers if removed for installation.
Replace suspension stud nuts.
GENERAL
YALE electric hoists are lubricated and tested before being shipped
from the factory. To place hoist in service, attach to a suitable
CAUTION
suspension (paragraph 2-2), connect to electrical service (paragraph Recheck spacer washers to make certain that the number of
2-3) and perform pre-operation tests and checks (paragraph 2-4). washers between the side plate and hoist suspension lug are
equal, and also the number on the outside of each side plate are
equal. The suspension stud nuts should only be 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
Before attempting installation of hoist or trolley, the main power will properly seat hoist in the trolley. Tighten suspension stud nuts
switch must be locked in the open position (off). only after hoist has been properly seated in the trolley.

SUSPENDING HOIST
The hoist may be suspended in a fixed location servicing only the
Mounting of the hoist/trolley unit on the monorail and final pre-
area directly below the hoist (Lug Mounted) or the hoist may be
operation inspection shall be performed only by qualified persons
attached to a moveable trolley or trolleys which in turn may be
properly supervised.
mounted on an l-beam attached to a building or crane, servicing a
larger area (Trolley Mounted).

DO NOT use small holes for attaching this hoist unless rated load
on lower block is 1 (one) ton (2000 Ibs.) or less.
a. Lug Mounted hoists attach to adequate supports welded
or bolted to a building or other structure. The supporting
structure must have sufficient strength with appropriate safety
factor, to support the weight of the hoist and rated load as
well as other loads to which the supporting structure may be
subjected.

Design and installation of hoist support shall be performed only

by qualified persons. Figure 2-1. Sectional View of Trolley showing proper wheel and washer spacing

Steel angles or plates used to suspend hoist should be CONNECTING HOIST TO ELECTRICAL SERVICE
spaced as close to the hoist suspension lug as possible. Electrical service to the hoist may be power cable or a guarded
Mounting bolts or threaded studs, attaching hoist to mounting system having sliding shoe collectors.
structure, shall have a diameter not less than recommended
by manufacturer and material equivalent to ASTM A 325.
Make certain that mounting bolts or studs are long enough
so that the threads do not engage the mounting support
and that mounting bolts or studs are secured with nuts and Be certain that electrical power supply is OFF and locked in the
lockwashers, self-locking nuts or cross bolting, if unthreaded. open position before attempting any electrical connections to the
b. T
 rolley Mounted hoists are attached to moveable trolleys. If hoist. This equipment must be effectively grounded according to
the hoist is mounted on an existing trolley, a qualified person the National Electric Code, or other applicable codes. A separate
shall determine that the trolley and its supporting structure are grounding conductor shall be provided.
adequate to support the rated load and weight of the hoist.
Hoist/trolley units may be shipped from the factory with trolley a. Follow National, State and Local Electrical Codes when
packaged separately. If the trolley can be installed directly providing electrical service to the hoist.
over the end of the supporting beam, assemble trolley to
hoist. Be certain that the spacing between wheel flanges, after
assembly, is 1/4" greater than exact width of beam flange.
(See Figure 2-1 below and instruction sheet furnished with
CAUTION
trolley.) Using proper equipment, carefully lift trolley and hoist 230/460V single speed motors are reconnectable at the motor.
and install on end of beam. See motor nameplate. Transformer may be reconnected for
200/230/460/575V. See transformer. Check with wiring diagram to
For trolleys which are to be mounted along the span of a make certain that motor, transformer and brake leads are properly
beam not having open ends, measure exact width of beam connected.
flange and assemble trolley to hoist so that spacing between
wheel flanges is 1/4" (see Figure 2-1) greater than beam width b. Make electrical connections using the appropriate wiring
(3/8" if beam has curves). This is accomplished by rearranging diagrams furnished with the hoist. All electrical connections,
the spacer washers on the bolts connecting trolley side plates including connections to collectors or power cord, shall be
to hoist mounting lug. If trolley is shipped separate from hoist, made only by qualified journeymen electricians.
see instruction sheets furnished with trolley for orientation and
installation.
When proper spacing has been determined, loosen mounting
nuts (item 1, Figure 2-1) to allow trolley wheels to spread
far enough to pass over edges of beam flange. (Some The green wire provided in the power supply cable (when furnished)
installations may require complete removal of one trolley side is a grounding wire and must be connected to a proper ground.
plate.) Using adequate equipment, carefully lift the hoist and
trolley so the wheel treads will rest on the lower beam flange. c. When trolley is shipped separate from hoist, see special

5 Manual No. 117404-10 REV. AB October 2018

 instructions furnished with trolley for orientation and installation. reversing switch is actuated (Figure 2-3). Stop switch stops hoist.
Reversing switch lowers hook block in case of floating rod over-
travel. If limit switch does not function in this manner, refer to trouble
PRE-OPERATION CHECKS shooting chart Section Vl for possible remedy.
a. C
 heck 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 being
expelled through the breather.
b. Check Push Button Operation and Phasing:

Figure 2-3. Electrical Compartment Cover Removed Showing Limit Switch and Reversing
Switch Arrangement
On three phase hoists it is possible to have “Reverse Phasing”
causing the lower block to lower when the  button is depressed. 2. A
 screw-type upper and lower limit switch is provided
When this condition exists, the automatic limit stop switch is optionally when both upper and lower limit stops are
inoperative and hoist operation will be dangerous. required (Figure 7-2). This switch is adjustable and must
be adjusted, at time hoist is installed, to desired high and
To properly check the phase of the hoist, follow steps below: low limits of lower block travel. Refer to Section Vll.
1. With “POWER OFF” operate all the push buttons and d. C
 heck Lower Block and Hoisting Cable. Depress  push
determine that they do not bind or stick in any position. button and run lower block to its lowest position. No less
than two wraps shall remain on the drum with the loaded
hook in its lowest position, unless hoist is equipped with
a lower limit switch in which case no less than one and
one half wraps shall remain on the drum. Also check to
If any push button binds or sticks in any position - DO NOT TURN see that lower block and rope does not twist excessively. If it
POWER ON - determine the cause and correct the malfunction does twist to the extent that two ropes rub against each other,
before operating. disengage rope from the frame anchor and twist rope four
or five turns in a direction opposite to that which the block
2. Temporarily connect hoist to power source. turns. Reconnect rope to anchor (Figure 2-4), holding firmly to
eliminate rope twisting back to its original position. Operate
3. Operate  button briefly to determine direction of hook travel. hoist up and down a few times. If lower block still rotates,
repeat process until twisting is corrected.
4. If hook raises, phase is correct. Turn power off and make
temporary connections permanent. e. L
 ubricate Hoisting Cable. For longer cable life, it is
recommended that the cable be lubricated at time of
5. If hook lowers, hoist is “Reverse Phased.” TURN POWER
installation by applying a Chain and Cable Fluid as outlined in
OFF and correct by interchanging any two leads at power
Section IV, paragraph 4-3.
source connection. Do not change internal wiring of hoist.
c. C
 heck Limit Switch Operation.
 block operated upper limit stop (Figure 2-2) is furnished
1. A
as standard equipment. This limit stop is factory set to
stop lower block in its high position and guard against
over-travel and possible damage to hoist. (Note mounting
position of floating lever for 3 and 5 ton hoists.) No
adjustment can be made. Limit switch operation should be
tested when hoist is installed. Move hook to a low position
by depressing push button marked . Now depress button
marked  to raise hook. While hook is traveling upward,
manually (or with an extension pole) raise limit stop
mechanism (Figure 2-2).
Figure 2-4. Rope End Anchor

Figure 2-2. Limit Stop Mechanism Being Tripped By Lower Block

When floating rod is raised, stop switch is actuated first and then the

6 Manual No. 117404-10 REV. AB October 2018

OPERATION l. DO warn personnel of an approaching load.
m. D
 O protect wire rope from weld splatter or other damaging
GENERAL contaminants.
Operation of Series Y80 YALE electric hoists is controlled by a n. DO promptly report any malfunction, unusual performance, or
convenient pendant push button station. With it, the hoist can be damage of the hoist.
controlled to give fast lifting and lowering; or controlled to lift or
lower load in small increments, providing accurate spotting. The o. DO inspect hoist regularly, replace damaged or worn parts,
pushbutton station has a built-in interlock to prevent depressing and keep appropriate records of maintenance.
opposing buttons simultaneously. p. DO use the hoist manufacturer’s recommended parts when
When first using hoist, break-in by operating under lighter loads to repairing a hoist.
full travel before applying maximum load. q. DO use hook latches.

PUSH BUTTON OPERATION r. DO apply lubricant to wire rope as recommended.

a. Depress push button marked  to raise load. s. DO NOT lift more than rated load.

b. Depress push button marked  to lower load. t. DO NOT use a damaged hoist or a hoist that is not working
correctly.
c. J
 ogging the push button will give “hairline” load movement.
The quickness of the depressing motion will determine the u. DO NOT use the hoist with twisted, kinked, damaged or worn
amount of movement. Excessive use of this “Jogging” wire rope.
feature will cause premature burning of contact tips and v. DO NOT lift a load unless wire rope is properly seated in its
motor overheating. drum groove(s).
d. O
 n two-speed hoists, partial depression of button operates w. DO NOT use wire rope as a sling or wrap rope around the load.
hoist at slow speed; depressing button completely operates
hoist at fast speed. x. D
 O NOT lift a load if any binding prevents equal loading on all
supporting ropes.
OVERLOAD CLUTCH OPERATION (OPTIONAL) y. DO NOT apply the load to the tip of the hook.
The overload clutch, when furnished with the hoist, is factory preset z. DO NOT operate unless load is centered under hoist.
and tested so that the hoist will lift its full rated load but will refuse to
lift overloads which could cause deformation or weakening of your aa. DO NOT allow your attention to be diverted from operating the hoist.
hoist. If the load to be lifted exceeds the clutch setting, the hoist motor
will continue to run when the  button is depressed and rotate the ab. DO NOT operate the hoist beyond limits of wire rope travel.
load brake gear without lifting the load. Whenever this slipping occurs, ac. D
 O NOT use limit switches as routine operating stops unless
immediately release the  button to prevent overheating of the clutch recommended. They are emergency devices only.
friction surfaces and the hoist motor.
ad. DO NOT use hoist to lift, support or transport people.
NOTICE: Always know load to be lifted. Lift-Tech does not
recommend lifting loads greater than the rated capacity of your hoist. ae. DO NOT lift loads over people.
af. D
 O NOT leave a suspended load unattended unless specific
OPERATING PRECAUTIONS precautions have been taken.
ag. D
 O NOT allow sharp contact between two hoists or between
hoist and obstructions.
ah. D
 O NOT allow the rope or hook to be used as a ground for
Equipment covered herein is not designed or suitable as a power welding.
source for lifting or lowering persons.
ai. D
 O NOT allow the rope or hook to be touched by a live
Safe operation of an overhead hoist is the operator’s responsibility. welding electrode.
Listed below are some basic rules that can make an operator aware
of dangerous practices to avoid and precautions to take for his own aj. DO NOT remove or obscure the warnings on the hoist.
safety and the safety of others. Observance of these rules in addition ak. D
 O NOT adjust or repair a hoist unless qualified to perform
to frequent examinations and periodic inspection of the equipment hoist maintenance.
may save injury to personnel and damage to equipment.
al. D
 O NOT attempt to lengthen the wire rope or repair damaged
a. DO read ANSI B30.16 Safety Standard for Overhead Hoists wire rope.
and the Operation, Service and Parts Manual.
am. D
 O NOT allow personnel not physically fit or properly qualified
b. DO be familiar with hoist operating controls, procedures and to operate hoist.
warnings.
an. DO NOT operate hoist unless limit switch is operating properly.
c. DO make sure hook travel is in the same direction as shown
on controls. ao. DO be sure there is no twist in wire rope.
d. DO make sure hoist limit switches function properly. ap. D
 O avoid operating hoist when hook is not centered under
hoist. Avoid side pulls and swinging of load or load hook when
e. DO maintain firm footing when operating a hoist. traveling hoist.
f. DO make sure that load slings or other approved single
attachments are properly sized and seated in the hook saddle.
g. DO make sure that the hook latch is closed and not
supporting any part of the load. DO NOT operate hoist with the hoisting rope out of the drum
h. DO make sure that load is free to move and will clear all grooves. Such operation may result in the rope breaking and
obstructions. dropping the load which can cause damage to equipment and
injury to operator or other personnel. Hoist rope will remain
i. DO take up slack carefully, check load balance, lift a few in the drum grooves during operation under normal operating
inches and check load holding action before continuing. conditions, however, slack or kinked rope, excessive side pulls,
swinging or jerking of load, or similar abuse, may cause the rope
j. DO avoid swinging of load or load hook. to leave the grooves.
k. DO make sure that all persons stay clear of the suspended load.

7 Manual No. 117404-10 REV. AB October 2018

 aq. D
 O operate hoist within recommended duty cycle and do not
“jog’’ unnecessarily.
ar. D
 O conduct regular visual inspections for signs of damage or
wear.
as. D
 O NOT operate hoist with hooks that have opened up. See
Figure 5-1.
at. D
 O provide supporting structure or anchoring means that has
a load rating at least equal to that of the hoist.
au. D
 O NOT use hoists in locations that will not allow operator
movement to be free of the load.
av. D
 O, when starting to lift or pull, move the load a few inches
at which time the hoist should be checked for proper load
holding action. The operation shall be continued only after the
operator is assured that the hoist is operating properly.
aw. D
 O NOT leave a loaded hoist unattended at the end of a work
shift or for extended periods during the work shift. Where
operations are such that this condition cannot be avoided the
operator must be assured that the condition does not create a
hazard to personnel or property.
ax. D
 O NOT use the hoist load limiting device to measure the
load.
ay. D
 O NOT operate hoist unless hook moves in the same
direction as indicated on the pushbutton. If opposite direction
occurs, see pre-operation checks, Paragraph 2-4.b.
az. O
 bserve recommended inspection and maintenance
procedures.
ba. D
 O use common sense and best judgement whenever
operating a hoist. Observe American National Standard Safety
standard, ANSI B30.16, Iatest issue.

SAFETY PRECAUTIONS
Each YALE Wire Rope Hoist is built in accordance with the
specifications contained herein and at the time of manufacture
complies with our interpretation of applicable sections of *American
Society of Mechanical Engineers Code (ASME) B30.16 “Overhead
Hoists,” the National Electrical Code (ANSI/NFPA 70) and the
Occupational Safety and Health Act (OSHA). Since OSHA states the
National Electrical Code applies to all electric hoists, installers are
required to provide current overload protection and grounding on the
branch circuit section in keeping with the code. Check each installation
for compliance with the application, operation and maintenance
sections of these articles.
The safety laws for elevators, lifting of people and for dumbwaiters
specify construction details that are not incorporated into the hoists.
For such applications, refer to the requirements of applicable state
and local codes, and the American National Safety Code for elevators,
dumbwaiters, escalators and moving walks (ASME A17.1). Columbus
McKinnon Corporation cannot be responsible for applications other
than those for which YALE equipment is intended.
*Copies of this standard can be obtained from ASME Order Department,
22 Law Drive, PO Box 2300, Fairfield, NJ 07007- 2300, U.S.A.,
www.asme.org, 800-843-2763.
THIS SYMBOL POINTS OUT IMPORTANT SAFETY
INSTRUCTIONS WHICH IF NOT FOLLOWED COULD
ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY
OF YOURSELF AND OTHERS. READ AND FOLLOW ALL
INSTRUCTIONS IN THIS MANUAL AND ANY PROVIDED
WITH THE EQUIPMENT BEFORE ATTEMPTING TO
OPERATE YOUR YALE HOIST.

8 Manual No. 117404-10 REV. AB October 2018

LUBRICATION LUBRICATE HOISTING CABLE
are shipped from the factory without an exterior coating on hoisting
GENERAL cable. It is recommended, where conditions permit, that the cable
be thoroughly coated at installation and kept well lubricated with
The lubrication services outlined in paragraphs 4-2 through 4-6 LUBRIPLATE Chain and Cable Fluid, or equal, suitable for all
should be performed at regular intervals to maintain top hoist temperature ranges.
performance and ensure long life. Intervals of at least six (6) months,
coinciding with spring and fall seasons, are recommended. The
reason for this is, on hoists installed out-of-doors and in unheated LUBRICATE UPPER SHEAVE AND LOWER
areas, a “cold test” lubricant is required in cold (below freezing) BLOCK ASSEMBLY
climates making seasonal changes necessary.
a. A
 ll hoists have grease fittings located in ends of sheave pins.
Apply (*) NLGI No. 2 grease for operating temperatures from
CHANGE GEARCASE OIL (FIGURE 4-1) +50°F to +125°F. For colder temperatures, (-20°F to +50°F)
a. R
 emove oil drain plug from bottom of gearcase and drain use NLGI No. 1 grease.
out oil. (Two drain plugs, one on front and one on back of b. A
 pply a few drops of S.A.E. No. 50 oil to hook thrust bearings.
gearcase.)
(*) National Lubricating Grease Institute.
b. F
 lush out hoisting using petroleum solvent. Reinstall drain
plug.
LUBRICATE LIMIT STOP LEVER
c. R
 efill through oil hole cover to proper level (bottom of oil level
plug hole) using 10 pints of Automatic Transmission Fluid, a. A
 pply a few drops of S.A.E. No. 50 oil to pivot points of limit
DEXRON III Type, suitable for all temperature ranges. rod.
b. A
 pply a few drops of S.A.E. No. 50 oil to shaft bearing at rear
of electrical compartment.

LUBRICATE LIMIT SWITCH

Provide a light film of NLGI No. 2 grease on bevel gear of limit
switch.

Figure 4-1. View Showing Location of One Oil Drain Plug

9 Manual No. 117404-10 REV. AB October 2018

INSPECTION AND PREVENTIVE corrective action. This will advise the designated person responsible
for hoist operation and safety, who reviews the reports, that
MAINTENANCE deficiencies exist. The designated person will check all deficiencies
as listed and reexamine or otherwise determine whether they
constitute a safety hazard.
GENERAL
YALE, Series Y80, hoists are inspected and tested at the factory.
Regular in service inspection and preventive maintenance programs
not only help reduce overall maintenance costs but may also prevent
serious shutdowns by forewarning of problems that could cause Deficiencies may be hazardous to personnel and equipment.
these shutdowns. Regular inspections, periodic minor adjustments, Do not operate a hoist having deficiencies unless a designated
regular cleaning and lubrication and replacement of worn parts can qualified person has determined that these deficiencies DO NOT
help preserve good performance and operation of your hoist. constitute a safety hazard.
Many factors influence the inspection and preventive maintenance Written, dated and signed inspection reports for many items are
program required for your hoist. Frequency and severity of service mandatory under OSHA regulations, and many state safety codes.
and material handled, local environmental conditions and various It is strongly recommended that the Inspection Schedule and
applicable codes are some of the factors that the user must consider Maintenance Report, shown herein, be completed by a qualified
to adjust inspection and maintenance program outlined in this person designated with the responsibility for hoist operation and
section to meet his specific conditions. safety or an inspector appointed by this person.
The inspection and maintenance services outlined in this section are Inspection records can point out the service life of hoist components
considered minimum. Recommended in the schedule are minimum and help forecast the need for adjustments, repairs and ordering
inspection and maintenance intervals based on average daily of replacement parts. File and review these reports after each
use in a normal environment. Average daily use is based on 1000 inspection.
operational hours per year maximum and intermittent operation of
the hoist eight hours 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 Do not operate a hoist having unusual vibrations, sounds or other
important considerations for the user when adjusting hoist conditions. Danger may be present that the hoist operator cannot
inspection and maintenance programs to local conditions. see. Determine and correct cause of unusual conditions and make
Frequency of inspection and maintenance must be increased if certain the hoist can be operated safely. Be certain to disconnect
hoist is subjected to severe atmospheric environmental conditions, power to the hoist whenever electrical cover is removed.
such as corrosive vapors, extreme heat or cold, cement or dust
and other airborne contaminants. The user should carefully
consider all environmental conditions and adjust frequency and INSPECT LOWER BLOCK
degree of maintenance for his local conditions. Consult Application a. C
 heck lubrication of all parts. If the thrust bearing is not
Engineering for advice for unusual environmental conditions. equipped with a grease fitting, lubricate with SAE No. 50 oil.
Various codes also regulate inspection and maintenance programs. Also lubricate the shank of the hook which passes through the
Attention must be given to applicable Federal Standards, OSHA lower block body.
regulations, National Standards, state and local codes which b. C
 heck each sheave to ensure rope groove is smooth and free
may include mandatory rules relating to hoist inspection and from burrs, or other surface defects.
maintenance. The user should become familiar with all applicable
codes for his area and be guided accordingly. c. C
 heck each sheave for freedom of rotation; replace bearings
if defective.
Listed on the Recommended Inspection and Maintenance Schedule
are inspection frequencies and requirements. Perform these d. M
 ake certain that dowel pin, holding the hook nut to the hook,
inspections regularly as scheduled and additional inspections as is securely in position.
may be required for activity, service and environment of your hoist.
The hoist operator must be responsible for determining the operating e. If hook is equipped with a safety latch or rotational lock, check
conditions and severity of service. to determine that they are in good operating condition.

Inspection Schedule and Maintenance Report Form. f. C

 heck throat opening of hook. (Refer to Figure 5-1.) It is
recommended that upon receipt of the hoist a measurement
Shown on page 10 of this manual is a recommended Inspection be made and recorded of the hook throat opening. OSHA
Schedule and Maintenance Report form which lists various Standards require that the hook be replaced if the throat
components of the hoist. The form also includes trolley components, opening exceeds 15 percent of the original opening, or if the
runway components, and miscellaneous items. This form is hook is twisted more than 10 degrees from the unbent plane.
suggested as a guide for written inspection reports. Inspections are A gage block, properly identified to the hoist, similar to the
recommended each month and should be performed thoroughly one shown in Figure 5-1, is suggested to be made for each
enough to inform the hoist user of deficiencies for any item listed. hook for use in these measurements. For hooks with certain
This form does not supersede the Inspection and Maintenance kinds of safety latches it may be necessary to remove latch to
Schedule listed below but may be used to record scheduled measure hook opening.
inspection and maintenance services required.
g. H
 ooks showing signs of cracks must be replaced. Hooks
The user should revise the inspection interval, add additional units should be inspected at least once per year using dye
or provide a similar form to suit particular conditions which may penetrants, magnetic particle or other suitable crack detecting
exist. However, written, dated and signed inspection reports should methods.
be maintained particularly on critical items, such as hoist hooks,
hoisting ropes, sheaves, drums and brakes. Periodic review of old
inspection reports can point out service life of hoist components,
forecasting need for adjustment, repair or replacement of these
components.
As a matter of expedience, appointed maintenance personnel
inspecting the hoist can also take care of minor adjustments, repairs
and cleaning, where required. Note the column on Inspection
Schedule and Maintenance Report form headed Corrective Action
and Notes. When corrective action is made during inspection, note
condition of part or unit as inspected in appropriate Condition
column with a check mark (). Note “during inspection” corrective
action taken and date in space provided. In this manner, items
requiring further attention will be checked () without showing

10 Manual No. 117404-10 REV. AB October 2018

 b. M
 ake 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.
c. M
 ake certain that rope guide pins are not bent, loose or
otherwise distorted; guide pins must have close clearance to
sheave flange to keep rope in sheave grooves.
d. C
 heck hoist suspension bolts on lug suspended hoists; make
certain that bolts are secure, properly tightened and free from
damage.
e. Inspect suspension lug at top of hoist frame for damage,
cracks, hole elongation or other signs of wear. On all hoists,
the suspension lug is integral with hoist frame and the entire
frame must be replaced when suspension lug is damaged and
requires replacement.

Do not operate hoists having worn or damaged suspension bolts.

f. If disassembly is required reinstall reinstall all parts following
Figure 5-1. Method of measuring hook throat opening procedure in reverse of disassembly.
h. C
 heck wear of the hook, especially at the saddle and replace
if badly worn. INSPECT ELECTRICAL CONTROLS
Arrangement of electrical control equipment varies with the type of
INSPECT UPPER BLOCK AND HOIST control, physical space and the optional control features ordered
with the hoist.
SUSPENSION
a. C
 heck upper block sheaves (when hoist is so equipped) for a. D
 isconnect electrical power to hoist, remove electrical
wear, damage and freedom of rotation. If sheaves do not compartment cover (Figure 9-1, Ref. No. 29) and inspect
rotate freely, disassemble block and inspect bearings. Replace wiring and terminals. Terminals should be securely crimped
worn or damaged bearings, washers, pins or sheaves. to wires and electrical insulation should be sound. Terminal
screws should be tight.
b. C
 heck condition of contactor assembly, transformer, and limit
stop and reverse switches.

11 Manual No. 117404-10 REV. AB October 2018

 INSPECTION SCHEDULE AND MAINTENANCE REPORT
HOIST SERIAL NO. (MFGRS) CUSTOMER CRANE IDENTITY NO.
RATED LOAD LOCATION IN PLANT
THIS INSPECTION IS: MONTHLY  ANNUAL 
TYPE SEMI-ANNUAL 
VOLTAGE INSPECTED BY DATE

CONDITION
*Recommended
COMPONENT, UNIT OR PART (Check column best indicating condition when part
Inspection CORRECTIVE ACTION NOTES
and location or unit is inspected. Use note column to the right if
Interval
condition is not listed below.)
(Indicate corrective action taken during inspection and note

LUBRICATION REQ.
(Loose Parts or Wires)
REPAIR REQUIRED

REPLACEMENT

(Worn or Damaged)
date. For corrective action to be done after inspection, a

(Low Oil or Grease

SEMI-ANNUAL

Rust or Corrosion)

CLEANING OR
ADJUSTMENT
LOCATION

REQUIRED

REQUIRED

REQUIRED
MONTHLY

PAINTING
designated person must determine that the existing deficiency

ANNUAL

GOOD
COMPONENT, UNIT does not constitute a safety hazard before allowing unit to
OR PART operate. When corrective action is completed, describe and
note date in this column.)
DATE
Motor ¡
Motor Brake ¡
Mechanical Load Brake ¡
Overload Clutch ¡
Couplings ¡
Gears, Shafts & Bearings ¡
HOIST

Upper Block ¡
Lower Block ¡
Hook & Throat Opening l X Record Hook Throat Opening
Hoist Rope l
Rope Drum ¡
Guards ¡
Limit Switch ¡
PUSHBUTTON
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 Attach. Chains l
MISC.

Rope Slings & Connect. l

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. For recommended inspection intervals, see figure 5-2.
User must adjust inspection interval and components to suit his individual conditions and usage. 12375B

12 Manual No. 117404-10 REV. AB October 2018

RECOMMENDED INSPECTION AND MAINTENANCE SCHEDULE
TIME INTERVAL INSPECTION OR MAINTENANCE
Daily or start * Check operation of all functional mechanisms including limit switch operation, brakes and control. Check hoist cable for kinks, abrasions,
of each shift corrosion or broken wires or evidence of improper spooling on drum. Inspect hooks, upper and lower blocks, and all load bearing components
(visual) for damage.
1 Month * HOIST CABLE - Inspect and lubricate per Paragraph 5-8.
* ELECTRICAL CONTROLS - Inspect per Paragraph 5-4. Check hoist gearcase oil level - add oil as required per
1-3 Months
Paragraph 4-2.
* LOWER BLOCK - Inspect per Paragraph 5-2.
6 Months
UPPER BLOCK - Inspect per Paragraph 5-3.
* Motor brake and actuating mechanisms. Inspect and adjust per Paragraph 5-5. Inspect hooks with crack detecting
Annually
procedures per Paragraph 5-2. Drain and refill hoist gearcase per Paragraph 4-2. See note 1.
6 Months or * Inspect electrical controls per Paragraph 5-4. Change hoist gearcase oil - Fill with oil per Paragraph 4-2.d. Lubricate hoist cable per Paragraph
500-750 hours 4-3. Lubricate upper and lower hook block per Paragraph 4-4. Lubricate limit stop lever per Paragraph 4-5. If a screw type limit switch is
“on” time 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 that your YALE Repair Station be contacted for
time or 5000
this service.
hours “on” time
*Perform services described by paragraph indicated.
Figure 5-2. Inspection and Maintenance Schedule

INSPECT MOTOR BRAKE (SEE NOTE 1) NOTE 1: Load brake, motor brake, gearing, overload clutch, rope
drum, and shaft inspection procedures: The detailed inspection
See Figure 9-3.
procedures in this manual are not intended to require periodic
a. C
 heck braking surfaces for wear and scoring. Replace disassembly and inspection of these components but to provide
badly worn or scored parts. Check spring studs and guide this procedure when inspection and functional testing indicates
pins to make sure they are not bent or loose. Check coil that the mechanism is not functioning properly. Per ASME B30.16
shock mounts for deterioration and damage. Check air gap Section 16-2.1.4 (c) Periodic inspection – “A qualified person shall
adjustment. (See 7-2). determine whether conditions found during inspection constitute a
hazard and whether disassembly is required”. In keeping with this
requirement, when the qualified person determines disassembly is
INSPECT MECHANICAL LOAD BRAKE required the inspection procedures in this manual should be used.
GEARING AND OVERLOAD CLUTCH (OPTIONAL)
(SEE NOTE 1)
a. T
 he mechanical load brake and gearing may be inspected and
serviced with hoist suspended. To do so, remove lower block
and wire rope, drain oil from gearcase, remove 12 hex head
bolts and lockwashers holding gearcase cover, and pull cover
from gearcase (Figure 5-3).

Figure 5-4. Removing Intermediate Gear and Pinion Assembly

Figure 5-3. View of Gearcase – Cover Removed

b. T
 o inspect gearing, pull out intermediate gear and pinion
assembly and roller thrust bearings (Figure 5-4), and load
brake assembly (Figure 5-5). Do not remove drum gear unless
visual inspection indicates replacement is necessary.
c. Inspect gears and pinions for signs of tooth wear and 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.
Figure 5-5. Removed Load Brake Assembly

13 Manual No. 117404-10 REV. AB October 2018

 d. T
 o disassemble drum gear, remove external snap ring from
splined shaft, using heavy-duty snap ring pliers, and pull off
gear.
e. T
 o 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 YALE Repair Station for inspection and repair. If
it is necessary that you make your own inspection and repair,
instructions below must be followed:
1. P
 lace 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).

Figure 5-8. Removing Pawl and Ratchet Assembly From Load Brake Shaft
g. R
 eassemble gearing and load brake parts following reverse
procedure of disassembly. In assembling load brake, observe
assembly steps (1) through (4).
1. Before installing spring in its retainer (Figure 5-9), apply
a good grade of ball bearing grease to inside of retainer.
Spring must be positioned exactly as illustrated, butted
Figure 5-6. Remove Snap Ring From Load Brake Shaft
against pin at side of cam.
2. U
 sing 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).

10024

Load Brake - Standard

Figure 5-7. View Showing Load Brake Flange Removed

3. R
 emove load brake gear. If replacement of spring, spring
retainer or cam is necessary, press off shaft (Figure 5-9).
4. T
 he load brake pawl and ratchet is a riveted assembly and
is not to be disassembled.
5. C
 lean all parts thoroughly and inspect for wear and
damage. Replace all parts that are excessively worn or
damaged. Hard surface or glazed friction discs should be
replaced. Load Brake - Overload Clutch
Figure 5-9. Load Brake Gear Removed From Load Brake Showing Load Brake Spring
2. W
 hen installing pawl and ratchet assembly on load brake
shaft, be certain that teeth on ratchet face are in the same
direction as shown in Figure 5-8. The ratchet assembly
should rotate freely when turned counterclockwise and
the pawl should engage ratchet teeth when unit is turned
clockwise.
3. W
 hen installing brake flange, position it with chamfer
facing friction disc (Figure 5-7).

14 Manual No. 117404-10 REV. AB October 2018

 end of frame through 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
4. T
 he brake spring must be pre-loaded at assembly to a
torque of 10 to 14 lb.-ft. This is accomplished using a c. C
 heck parts for wear and damage. Replace drum if there are
plumber’s strap wrench to wind (rotate) load brake gear any signs of cracks or other damage.
to 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. ROPE INSPECTION, MAINTENANCE AND
Use brass or copper jaw plates on vise to protect pinion REPLACEMENT
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 Wire rope improperly handled or abused can create a SAFETY
install snap ring in groove. HAZARD. Read and comply with inspection, maintenance and
replacement information given herein.
h. Install gearing and load brake assembly in gearcase in reverse
order of disassembly. Be certain roller thrust bearings are a. Inspection. Wire rope on your hoist is one of the most
installed at both ends of intermediate gear shaft as shown in important components requiring frequent inspection and
Figure 5-4 and that thrust washers are properly installed at maintenance. All wire ropes will eventually deteriorate to a
both ends of load brake shaft as noted below: point where they are not safe and will require replacement.
WIRE ROPE SHOULD BE THOROUGHLY INSPECTED AT
1. A
 steel thrust washer with 5/8" I.D. must be installed on REGULAR MONTHLY INTERVALS BY AN AUTHORIZED
the brake flange end (end opposite pinion) of load brake PERSON AND A DETERMINATION MADE WHEN FURTHER
as shown in Figure 5-5. USE OF THE ROPE WOULD CONSTITUTE A SAFETY
HAZARD. Each inspection should include a written, dated
2. A
 bronze thrust washer with a lug on one side goes on and signed report of rope condition. Reports should be filed
pinion end of load brake shaft and it must be installed and reviewed each month and any rope deterioration carefully
so that its lug engages the special slot located on the noted.
spot face surrounding the load brake bearing bore inside
gearcase cover. Use heavy grease to hold it in place on Inspections revealing rope deterioration, including, but
cover as cover is installed. not limited to the following conditions should cause the
inspector to question remaining strength of rope and consider
On hoists with 18 or 20 tooth load brake pinion, an 11/ replacement:
16" I.D. steel thrust washer is installed between pinion and
bronze thrust washer. 1. T
 welve randomly distributed broken wires in one rope lay
or four broken wires in one strand.
i. A
 t completion of reassembly of gearing and load brake in
gearcase, refill gearcase to proper level using correct grade of 2. W
 ear of one-third of the original diameter of outside
oil, as outlined in Section IV - LUBRICATION. individual wires.
j. F
 or hoists equipped with an overload clutch (optional) which 3. K
 inking, crushing or bird caging.
has been functioning properly, visually inspect clutch adjusting
nut and spring washer for signs of damage or looseness. 4. H
 eat damage from any cause.
With a small hex allen wrench, make certain two set screws 5. R
 eductions from nominal diameter of more than 1/64" for
in adjusting nut are tight. DO NOT TURN ADJUSTING NUT 3/16", 1/4", and 5/16" diameter rope.
OR DISASSEMBLE CLUTCH. If spring washer, adjusting nut
or gear is loose or damaged, or the clutch did not function 6. R
 ope corrosion, internal or external.
properly before disassembly of hoist for inspection, consult
the nearest YALE Authorized Repair Station for repair or 7. E
 ffects from improper lubrication. 
adjustment. 8. R
 ope idle for month or more due to shutdown.

INSPECT ROPE DRUM AND SHAFT (SEE NOTE 1) Special attention should be exercised when inspecting
rope normally hidden during inspecting procedures.
a. T
 o remove drum, remove wire rope, electrical compartment
cover and electrical panel assembly (Figure 9-1) and gearing b. Maintenance. Keep rope well lubricated to help reduce
and load brake assembly (paragraph 5-6). internal friction and prevent corrosion. Lubricant, as described
in paragraph 4-3, should be applied as a part of the regular
b. R
 emove four hex socket head bolts securing gearcase to maintenance program. Special attention is required to
cover. Three bolts are accessible from inside frame (Figure lubricate sections of rope over equalizing sheaves and other
2-2, Section II) and the fourth is accessible from electrical hidden areas.

15 Manual No. 117404-10 REV. AB October 2018

 Avoid dragging ropes in dirt or around sharp objects which will SINGLE REEVED HOISTS
scrape, nick, crush or induce sharp bends in the rope.
Stretch new cable on floor in one continuous length. Make certain
c. R
 eplacement. When recommended by an authorized there is no twist in rope.
inspector, the rope should be replaced. Replacement rope
1. P
 lace one end of rope in rope drum anchor slot. Be sure end
assemblies are shipped from the factory carefully coiled to
fitting is properly seated.
prevent damage by kinking. Care must be taken to avoid
twisting or kinking when uncoiling and handling during reeving. 2. W
 ith all personnel clear of hoist - TURN ON POWER.
Before replacing rope, check condition of grooves in sheaves 3. O
 perate hoist  guiding new rope into drum grooves with
and drums to determine if they are excessively worn. 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. P
 roceed with reeving as described in appropriate paragraph
Use only factory approved rope with swagged wire rope sockets. below and the reeving diagram for your hoist.
When first using the hoist after rope replacement, break-in rope by
operating under lighter loads to full travel before applying maximum DOUBLE REEVED HOISTS
load. Stretch new cable on floor in one continuous length. Make certain
there are no twists in rope.
ROPE REEVING
1. P
 ull far end of rope toward end of rope nearest hoist, until both
a. G
 eneral. Before unreeling rope from a coil or reel, be sure ends are even and a loop is formed. Place fittings on both ends
floor is clean. Dirt picked up by the rope can cause excessive of rope in anchor slots on rope drum. Be sure end fittings are
wear and abrasion. Uncoil the rope by rolling the coil or reel properly seated.
along the floor; or, place reel on a stand with a shaft through
the center of reel so rope can be pulled straight out with the 2. With all personnel clear of hoist - TURN ON POWER.
reel rotating. 3. Operate hoist  guiding rope into grooves at both ends of drum,
until the distance from the drum to the loop is about 28' for 2
part double reeved.
CAUTION 4. Proceed with reeving as described in appropriate paragraph
It is imperative that the rope reel or coil rotates as rope unwinds. below and the reeving diagram for your hoist.
If coil or reel does not rotate, the wire will be twisted as it is d. Reeving - 2 part single.
uncoiled and kinking will result. A kinked rope may be damaged
and unsafe for maximum service. See Figure 5-12, for diagram.
Before removing the old rope, refer to reeving diagrams, (Figures See Figure 9-11 for block parts.
5-12, 5-14, 5-15 and 5-17). Face the rope drum on your hoist from
the side which the rope comes off drum. To assist with rereeving With new rope installed on drum as described in Paragraph
your hoist, select the reeving diagram for your hoist. Note the 5-9c, single reeved above, proceed with rereeving following
description (such as 2 part double reeved, Figure 5-17) and refer steps below:
to the paragraph below with the same description which describes 1. P
 ass other end of rope through bottom opening of hoist,
rereeving procedure. between floating limit rod and motor, and attach rope to
b. Removing old rope - for all reevings. cast dead end anchor fitting. A slot is located at top of
fitting to accept cable. Reinstall bolt and lockwasher in end
1. L
 ower the bottom block to a scaffold located 6 to 7 feet of anchor fitting to lock rope compression fitting in place.
below hoist to relieve tension on wire rope. (Bottom block
may be lowered to floor if desired; however, to handle less 2. G
 rasp loop, formed after installing end anchor, and place
weight and for ease of rereeving adequate scaffold below bottom block sheave in loop. Lower sheave into bottom
the hoist is recommended.) block and insert sheave pin. Replace key plates and bolts
holding sheave pin in place.
2. R
 emove bottom block sheave guard.
 eplace sheave guard. Make certain rope is not twisted.
3. R
3. R
 emove key plates from both sides of sheave pin and Should the two parts of rope tend to wind around each
slide sheave pin from bottom block. other, remove cable from anchor slot and untwist cable.
Reattach the cable anchor.
4. L
 ift out sheaves from the top of the bottom block and
remove wire rope. 4. L
 ubricate cable per Paragraph 4-3.
5. R
 emove key plates or snap rings from upper block
sheave(s) and slide out upper block sheave pins, releasing
upper block sheaves. Remove wire rope from sheaves.
6. M
 ake certain all personnel are clear of hoist and operate
hoist  to completely unwind all wire rope from drum. Stop
hoist so drum anchor slot(s) is accessible. Remove live
rope and socket(s) from drum.
7. T
 URN OFF POWER TO HOIST
8. R
 emove the bolt and lockwasher in the end of the rope
anchor fitting. Remove rope from slot in top of anchor.
c. Installing new rope.

Winding rope on rope drums with power can be hazardous. Keep

hands safe distance from drum, wear gloves and use extreme
care when winding rope.

Figure 5-12. Hoist Reeving - Two Part Single

16 Manual No. 117404-10 REV. AB October 2018

 e. Reeving - 4 part single. f. Reeving - 6 part single.
See Figure 5-14 for diagram. See Figure 5-15 for diagram.
See Figure 9-13 for block parts. See Figure 9-13 for block parts.
With new rope installed on the drum as described in With new rope installed on the drum as described in
paragraph 5-9c single reeved above, proceed with rereeving paragraph 5-9c single reeved above, proceed with rereeving
following steps below: following steps below:
1. G
 rasp the cable near the middle (about 14'-0") of the 1. G
 rasp cable at a point one-third (approx. 14’0") the
unwound end and form a loop. Place upper sheave in this distance hanging below the rope drum and form a loop.
loop. Slide upper sheave with cable into sheave pocket. Place one upper sheave in this loop. Slide upper sheave
with cable into sheave pocket; partially insert sheave pin
2. Insert sheave pin into sheave. Replace key plates and to hold sheave in place.
bolts to hold sheave pin in place.
2. R
 epeat (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. P
 ass free end of rope through 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.

Figure 5-15. Hoist Reeving - Six Part Single

3. P
 ass free end of rope through 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. P
 lace 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.
5. R
 epeat step 4 for remaining bottom block sheaves. Install
sheave pin through sheaves. Replace key plates and bolts
securing sheave pin.
6. Replace sheave guard.
7. Lubricate cable per paragraph 4-3.
g. Reeving - 2 part double.

See Figure 5-17 for diagram.

Figure 5-14. Hoist Reeving - Four Part Single See Figure 9-10 for block parts.
4. P
 lace one sheave in each loop. Install one sheave with
cable in bottom block, partially insert sheave pin to hold With new rope installed on the drum as described in
sheave in place. Note: Some blocks have spacer washers paragraph 5-9c double reeved above, proceed with rereeving
between sheaves. Be certain that washers are installed following steps:
between sheaves, when shown on parts illustration. Install
1. F
 orm loops in the two ropes coming from rope drum.
second sheave with cable into bottom block. Slide sheave
Place these loops into bottom block pockets and slide
pin through sheave. Replace key plates and bolts securing
pipe or rod through sheave pin holes. Note position of
sheave pin.
ropes passing limit stop bar.
5. Replace sheave guard.
2. P
 artially insert upper block sheave pin in opening and
6. Lubricate cable per paragraph 4-3. install one spacer washer. Raise remaining rope up to
hoist, form a loop and place upper sheave in this loop.

17 Manual No. 117404-10 REV. AB October 2018

 Note: If load drifts downward slowly in step 2 or 3
above, motor brake requires adjustment - see MOTOR
BRAKE ADJUSTMENT - Section Vll - paragraph 7-2.
4. Insert lower sheave pin into bottom block removing 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.
5. Replace sheave guard.
6. Lubricate rope per paragraph 4-3.
d. O
 verload Clutch. The overload clutch (optional) must be
tested for proper operation before placing hoist in service or
after disassembly and reassembly of hoist. For test procedure
Figure 5-16. Upper Sheave Installed (Typical) follow instructions listed below.
3. P
 lace sheave with rope into upper sheave pocket and
slide pin partially through sheave. Install remaining washer
and push pin through side plates. Install snap ring on each
end of pin to secure pin in place.
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. U
 sing 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).
Figure 5-17. Hoist Reeving - Two Part Double
h. Checking for and removal of rope twisting. 2. Increase load in steps from rated load, TO A MAXIMUM
OF 200% of the rated load, attempting to lift load with
Although rereeving of hoist may have been done carefully, each increase in weight. Hoist Overload Clutch should slip
sometimes after new rope has been installed twisting may and refuse to lift load before 200% of the rated load is
occur. With new rope installed, the hoist block should be reached. Should hoist lift 200% of the rated load - STOP
raised and lowered several times with gradually increasing TEST - A CLUTCH ADJUSTMENT IS REQUIRED. (See
loads, through full lift. If the block still rotates excessively at no paragraph 7-5 - “OVERLOAD CLUTCH ADJUSTMENT”.)
load, the rope may have twists which should be removed. 3. R
 un hoist with load causing clutch to slip (hoist refusing
load) five cycles of approximately 1 second each.
TESTING HOIST AND OVERLOAD CLUTCH
(OPTIONAL) (SEE NOTE 1)
a. General. Before placing hoist in service or after disassembly
and reassembly, hoist should be tested. To test suspend hoist
CAUTION
from an overhead supporting member of sufficient strength To prevent overheating, release the hoist control button at once
to support the weight of the hoist and the rated load. Hoists when the hoist refuses to lift the load.
having overload clutches, require an overhead supporting
structure capable of supporting with appropriate safety factor, 4. R
 emove weights added in step (2) and return to hoist rated
a load equal to 200 percent rated load and the weight of load. Lift rated load one final time. Clutch should not slip.
the hoist. Connect hoist to power supply as shown on hoist
nameplate and perform the checks listed in b and c below.
b. C
 heck hoist as outlined in PRE-OPERATION CHECKS,
Section II, paragraph 2-4. Do not lift more than rated load except for test purposes.
c. Check hoist with capacity load. NOTICE: ALWAYS KNOW LOAD TO BE LIFTED, LIFT-TECH
1. Attach rated load to lower hook. DOES NOT RECOMMEND LIFTING LOADS GREATER THAN THE
RATED LOAD OF YOUR HOIST.
2. D
 epress push button and raise load. When push button is
released, hoist should immediately stop and hold load at
that level.
3. D
 epress push button, lower load a short distance and
release button. Hoist should stop immediately and hold
load at that level.

18 Manual No. 117404-10 REV. AB October 2018

TROUBLESHOOTING
Problem Probable Cause Remedy
A. No No Power to hoist A. Check switches, circuit breakers or fuses and connections in power supply
lines.
B. Wrong voltage or frequency B. Check current rating on motor data plate against power supply
C. Loose or broken wire connections in hoist electrical system C. Shut off power supply, open hinged cover on hoist and check wiring connec-
tions. Also check connections in push button station and limit switches.
1. Hoist Will Not D. Contactor assembly not funtioning D. Check contact points. Replace if excessively burned or pitted. Check for burned
Operate. out contactor coils. See that necessary jumper wires are properly installed.
E. No control voltage E. Check transformer fuse. If blown, check for grounding and/or shorts in the
push button station. Check the transformer 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.

2. Hook moves in A. Reverse phasing on three-phase hoists A. Interchange any two power supply line leads. Refer to SECTION II.
wrong direction. B. Hoist or push button wired wrong. B. Check wiring connections with appropriate wiring diagram.
A. Lower electrical circuit open. A. Check for loose connections. See that necessary jumper wires are properly
3. Hook will raise installed on contactor.
but not lower.
B. Contactor not functioning. B. Check for burned or pitted contact points or burned out contactor coil.
A. Excessive load A. Reduce loading to rated load of hoist, as shown on nameplate.
4. Hook will
B. Hoist circuit open B. Check for loose connections. See that necessary jumper wires are properly
lower but not
installed on contactor.
raise.
B. Contactor not funtioning B. Check for burned or pitted contact points or burned out contactor coil.
A. Low voltage. A. See that power supply current is same voltage listed on motor data plate.
5. Hoist will not Check size of power supply lines.
lift rated load.
B. Overload Clutch not properly adjusted B. See SECTION VII, Paragraph 7-5.
A. Excessive load. A. Reduce loading to rated load, as shown on nameplate
B. Motor brake not holding. B. With No Load, check hoist for drift. If drifting is excessive, inspect mo-
tor brake (SECTION V, paragraph 5-5) and adjust as outlined in SECTION VII,
Paragraph 7-2.
6. Load drifts
excessively when C. Load brake not holding. C. (1) After determining that the motor brake is working properly, attach rated
hoist Is stopped. 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).
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
7. Hoist motor C. Wrong voltage or frequency C. Check current rating on motor data plate against power supply. Check hoist
overheats. motor connections.
D. Defective motor or worn bearings in hoist frame D. Disassemble hoist and inspect for defective, worn or damaged parts
E. Overload clutch slipping without lifting load. E. See SECTION VII, Paragraph 7-5
A. Collectors make poor contact. A. Check collectors for free movement of spring arm, weak spring or electrical
8. Hoist operates connections.
intermittently.
B. Loose connections B. Check all wiring for loose connections.

19 Manual No. 117404-10 REV. AB October 2018

20 Manual No. 117404-10 REV. AB October 2018
BRAKE TROUBLESHOOTING
Coil Failure Excessive Wear/Overheating
Supply Voltage Cause Supply Voltage Correction Air Gap Cause Air Gap Correction
Line voltage >110% of coil rating Reduce voltage or replace with proper Low solenoid air gap Reset air gap
rated coil (refer to Air Gap Adjustment)
Excessive voltage drop during inrush Increase current rating of power Cycle Rate Cause Cycle Rate Correction
time supply Brake "jogging" exceeding coil cycle Reduce cycle rate or consider
Wiring Cause Wiring Correction rate alternate control method
Leadwires interfering with plunger Reroute wiring away from plunger and Thermal capacity is being exceeded Reduce cycle rate, use alternate
pull-in other moving components control method or increase brake size
Coil leadwire shorted to ground Replace coil or leadwire and protect Alignment Cause Alignment Correction
with wire sleeving Brake endplate not concentric to "Motor resister must be within
Solenoid Assembly Cause Solenoid Assembly Correction motor C-Face
Plunger not seating flush against Loosen solenoid mounting nuts and .004"" on concentricity"
solenoid frame reposition frame to allow full face
Motor shaft runout is excessive Must be within .002"; runout; consult
contact
motor manufacturer
Excessive solenoid/plunger wear at Replace solenoid assembly Worn Parts Cause Worn Parts Correction
mating surface
Friction disc excessively worn Replace friction discs
Broken shading coils Replace solenoid assembly (disc can wear to 1/2 original
Worn Parts Cause Worn Parts Correction thickness or .093")
Excessive wear of solenoid link bolt Replace link bolt; also inspect plunger Endplate, stationary disc or pressure Replaced warped or worn component
thru-hole for elongation plate warped
Plunger guide worn down and interfer- Replace guide Linkages worn Replace all worn components
ing with plunger movement
Motor shaft endfloat excessive Endfloat must not exceed .020";
Application Cause Application Correction consult motor manufacturer
Machinery cycle rate is exceeding Reduce brake cycle rate or use alter- Hub Cause Hub Correction
brake rating nate control method
Burr on hub interfering with disc File off burr
High ambient temperature (>110%) Use Class H rated coil and/or find "float"
and thermal load exceeding coil alternate method of cooling brake
Set screw backed out and interfering Retighten set screw; use Loctite® 680
insulation rating
with disc to help secure
Brake coil wired with windings of an Wire coil to dedicated power source Miscellaneous Miscellaneous
inverter motor or other voltage/current with instantaneous coil rated voltage
limiting device Wiring is restricting disc pack Reroute wiring
movement
Miscellaneous Cause Miscellaneous Correction
Excessive stop time (2 seconds Increase brake size/torque or use
Wrong or over tightened torque Replace with proper spring or refer to
or greater) alternate control method
springs installation section for proper spring
height High Ambient termperature (in excess Reduce cycle rate or use alternate
of 110°F) method of cooling
Excessive air gap Reset, refer to Airgap Adjustment

21 Manual No. 117404-10 REV. AB October 2018

ADJUSTMENTS 3. Be certain power source conforms to the requirements
specified on the brake nameplate.
MECHANICAL LOAD BRAKE 4. Be careful when touching the exterior of an operating brake.
Allow sufficient time for brake to cool before disassembly.
The mechanical load brake on Series Y80 YALE hoists is a pawl and Surfaces may be hot enough to be painful or cause injury.
ratchet “Weston” type automatic brake. The brake is not adjustable
and requires only periodic inspection and occasional replacement of 5. Do not operate brake with housing removed. All moving parts
the friction washers. should be guarded.
6. After usage, the brake interior will contain burnt and degraded
MOTOR BRAKE friction material dust. This dust must be removed before
Check brake adjustment after first 30 days of service and regularly servicing or adjusting the brake.
thereafter during the six-month inspection procedure.
DO NOT BLOW OFF DUST using an air hose. It is important to
Installation and Service Instructions for 54,000 Series (rev. A) avoid dispersing dust into the air or inhaling it, as this may be
Manual Adjust Brakes. dangerous to your health.
a. W
 ear a filtered mask or a respirator while removing dust from
the inside of a brake.
b. U
 se a vacuum cleaner or a soft brush to remove dust from
the brake. When brushing, avoid causing the dust to become
airborne. Collect the dust in a container, such as a bag, which
can be sealed off.

GENERAL DESCRIPTION
This series brake is spring set, electrically released. These brakes
will contain one or two friction discs driven by a hub mounted on the
motor.

OPERATING PRINCIPLE
When the brake coil is energized the lever arm retracts the spring
force from the disc pack, allowing the friction disc to rotate with the
IMPORTANT hub and motor shaft. When power is removed the lever arm pushes
down on the stationary disc and friction discs. The hub is held from
Please read these instructions carefully before installing, operating, rotating, and the load is held in place.
or servicing. Failure to comply with these instructions could cause
injury to personnel and/or damage to property if the brake is
installed or operated incorrectly.

CAUTION Do not release brake if there is a suspended load on the hoist

1. Installation and servicing must be made in compliance with all hook.
local safety codes including Occupational Safety and Health Manually releasing the brake may allow a suspended load to fall,
Act (OSHA). All wiring and electrical connections must comply possibly causing damage, injury or death.
with the National Electric Code (NEC) and local electric codes
in effect. Always be certain any suspended load (which includes below
the hook devices or attachments) are removed before servicing,
2. To prevent an electrical hazard, disconnect power source adjusting or removing brake.
before working on the brake. Lock disconnect in the off position
and tag to prevent accidental application of power.

22 Manual No. 117404-10 REV. AB October 2018

23 Manual No. 117404-10 REV. AB October 2018
AIR GAP ADJUSTMENT Note: Air gap readjustment will be required after disc
replacment.
Brake air gaps are factory adjusted to .100”. As friction discs wear
the air gap will increase. When the gap reaches .200” it will need to
be readjusted to .100”.
1. Loosen jam nut (10N).
2. Turn adjusting screw (10) CW until .100” gap is reached (see Fig. 1).
3. Retighten jamb nut.
4
4. Check air gap again... 3
35
Air Gap

17

COIL REPLACEMENT 5
1. Remove the two support bracket screws (3s), and lift the
bracket and solenoid assembly (3) off the brake.
Adjust Screw 2. Remove the plunger guide (140) from the inside of the coil.
Jam Nut (10N) Fig. 1 3. Remove the through-bolt (160) from the leadwire side of the coil
by backing off the lock-nut (210). Slide the bolt, shock mount
TORQUE ADJUSTMENT pads and flat washer out of the way.
The brake is factory set for nominal rated torque. No further adjustment 4. Remove the coil (12) from the solenoid frame (79) by pushing
to increase torque may be made. The approximate compressed torque down on the coil locking tab on the side opposite the leadwires.
spring height is shown below. Torque reduction may not exceed 1 full Push the coil out of the frame.
turn in the CCW direction. Note that the spring measurement for the 6
and 9 lb-ft spring is from inside the shoulder washer. 5. Insert the new coil into the solenoid frame in reverse of the
steps of removal. Insert the new plunger guide (140) into the
coil, locking tabs first.
Brake Torque Length "L" Max Torque %
(lb-ft) (in.) Reduction Reduction 6. Position a shock mount pad (150) on both sides of the solenoid
(ccw turn of mounting bracket, and reinsert the through-bolt (160) through
torque nut) the shock pads and bracket.
6 1.286 1 25 7. Slide a flat washer (170) over the bolt, and tighten the locknut
9 1.188 1 15 down until the shock pads begin to flatten.
8. Position the solenoid and bracket assembly (3) over the plunger
(29) and slide into place. Tighten the bracket mounting screws
(3s) to 52 in-lb.
6 and 9 lb-ft. 9. Reassemble brake motor by following steps 4-7 of the brake
mounting procedure.

FRICTION DISC REPLACEMENT

Friction disc(s) should be replaced when the wear area is 3/32" thick
or less.
1. Remove the two brake mounting screws and lift the brake
assembly from the hub / motor.
2. Remove the two support bracket screws (3s), and lift the brake
and solenoid assembly (3) off the brake.
3. Lift the lever arm (17) forward and slide the friction disc(s) out of
the brake assembly.
4. Insert new friction disc(s) under the stationary disc (5). If brake has
two friction discs align the center spline holes with each other.
5. Align the brake and friction disc assembly on the hub (16) and
slide onto the motor. Insert and tighten the two brake mounting
screws (15-20 lb-ft).
6. Reposition the support bracket assembly (3) on the brake, and
retighten the two support bracket screws (3s), (52 lbin).

24 Manual No. 117404-10 REV. AB October 2018

SOLENOID REPLACEMENT 9. Position the solenoid and bracket assembly (3) over the plunger
(29) and slide into place. Tighten the bracket mounting screws
1. Remove the two support bracket screws (3s), and lift the (3s) to 50 in-lb.
bracket assembly (3) off the brake.
10. Reassemble brake to motor by following steps 4-7 of the brake
2. Remove the plunger guide (140) from the inside of the coil. mounting procedure.
3. Remove both through-bolts (160) from the solenoid assembly
(79).
4. Remove the coil (12) from the solenoid frame (79) by pushing
down on the coil locking tab on the side opposite the leadwires.
Push the coil out of the frame.
5. Insert the coil into the new solenoid frame in reverse of the
steps of removal. Insert the new plunger guide (140) into the
coil, locking tab first.
6. Position the new shock mount pad (150) on both sides of the
solenoid mounting bracket, and reinsert the tap-bolts (160)
through the shock pads and bracket.
7. Slide the flat washers (170) over the bolt, and tighten the
locknut down until the shock pads begin to flatten.
8. Remove the plunger nut (29N) and screw (29S), and lift plunger
(29) from lever arm (17). Install the new plunger to the lever arm
using the new screw and nut provided. Tighten to 40 in-lb.

25 Manual No. 117404-10 REV. AB October 2018

BLOCK OPERATED LIMIT SWITCH a. Remove four screws and lift off switch cover.
The block operated upper limit stop, furnished as standard b. L
 oosen locking plate screws. Slide locking plate away from
equipment, is nonadjustable and designed to stop lower block at adjustment discs.
its high point of travel to guard against over-travel with possible
damage to hoist. When high point is reached, limit stop switch c. T
 urn proper adjustment disc (right for up, left for down) toward
automatically stops hook travel. If hook drifts upward slightly stitch to reduce hook travel or away from switch to increase
after stop switch is actuated, a reversing switch will close and hook travel.
automatically reverse direction of hook travel. d. S
 lide locking plate back into position ensuring slots on
adjustment discs are fully engaged, tighten locking plate
SCREW-TYPE LIMIT SWITCH screws to 4 in-lbs.
This limit switch has a rotary screw driven by a gear reduction e. Replace cover.
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 accordance with the appropriate wiring diagram, which
is packaged with hoist. Adjustment of this screw-type limit switch is Check limit switch operation carefully, without load, before placing
accomplished as follows: (Refer to Figure 7-2). hoist in service. If misadjusted, SEVERE DAMAGE AND/OR A
DROPPED LOAD COULD RESULT. Allow 6" for hook drift in
both directions. Never allow less than 1-1/2 complete wraps of
rope on drum with hook in lowest position.

Before attempting actual adjustments, be certain main power Provide a light film of NLGI No. 2 grease on bevel gear of limit
switch is OFF and locked in the open position. switch.

OVERLOAD CLUTCH ADJUSTMENT

When properly adjusted, the overload device is designed so that
the hoist will 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
YALE Authorized Repair Station be contacted. Consult your YALE
Distributor for nearest Repair Station.

Switch
Adjustment Switch
Locking Plate Discs

Figure 7-2. Screw-Type Limit Switch Adjustment (Wires not Shown for Clarity.)

26 Manual No. 117404-10 REV. AB October 2018

WIRING DIAGRAMS
Wiring diagrams for YALE electric hoists have been omitted from
this book because of many possible variations. This is due to
different currents and types of electrical components used in
their construction. A print of the correct wiring diagram for each
hoist is furnished as a separate insert and shipped with hoist. We
suggest you carefully file the wiring diagram with this book for future
reference.
WHEN ORDERING PARTS OR INFORMATION ON THIS
EQUIPMENT, ALWAYS INCLUDE MODEL AND SERIAL NUMBER
ON ORDER.

27 Manual No. 117404-10 REV. AB October 2018

REPAIR PARTS LIST

Using “Commercial” or other manufacturer’s parts to repair the

YALE Hoists may cause load loss.
TO AVOID INJURY:
Use only YALE supplied replacement parts. Parts may look alike
but YALE parts are made of specific materials or processed to
achieve specific properties

ORDERING INSTRUCTIONS
The following information must accompany all correspondence
orders for replacement parts:
1. Hoist Model Number from identification plate.
2. Serial number of the hoist stamped below identification plate.
3. Voltage, phase, hertz from the identification plate.
4. Length of lift.
5. Part number of part from parts list.
6. Number of parts required.
7. Part name from parts list.
NOTE: When ordering replacement parts, it is recommended
that consideration be given to the need for also ordering such
items as gaskets, fasteners, insulators, etc. These items may be
damaged or lost during disassembly or just unfit for future use
because of deterioration from age or service.

GENERAL
The parts lists and illustrations in this section of the manual, cover
parts for all standard 800 YALE Electric Hoists. A typical hoist is
shown as the basis for the exploded parts illustrations; therefore,
certain variations may occur from the information given. For this
reason, always give the Hoist Serial Number, Catalog Number, Motor
Horsepower, Voltage, Phase, Frequency and Rated Load of Hoist
when ordering parts.
Certain parts of your hoist will, in time, require replacement
under normal wear conditions. It is suggested that these parts be
purchased for your hoist as spares for future use. These
parts are indicated by a (†) symbol at the right side of the parts
reference numbers.
The numbers assigned to the parts of our various assemblies
in our parts list 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.

28 Manual No. 117404-10 REV. AB October 2018

 11455C

Figure 9-1. Frame, Gearcase and External Parts

Ref. Quantity Ref. Quantity

Item Number Part Name Item Number Part Name
No. Required No. Required

1 800-197 Plug - Oil Level 2 Frame Assembly (Single Reeved Models) 1

9
1/2, 1 & 2 Ton
2 800-192 Cover & Bearing Assembly - Gearcase 1
800-117 Short Frame
3 800-105 Dowel 2
800-118 Long Frame
4† 800-106 Gasket - Gearcase 1
800-2106 3 Ton
5 800-107 Gearcase & Bearing Assembly 1
800-2107 First Extension Second Extension
Drum & Hub Assembly (Double Reeved
6 800-2108 5 Ton
Models) 1 1/2 & 1 Ton (3/6" Dia. Rope)
800-109 18' Lift 800-2109 First Extension Second Extension
800-111 34' Lift Frame Assembly (Double Reeved Models)
9A 1
1/2, 1 & 2 Ton
800-2100 47' Lift
800-2110 Short Frame
800-108 2 Ton (1/4" Dia. Rope) 14' Lift
800-2111 Long Frame
800-110 25' Lift
800-2112 First Extension
800-2101 36' Lift
12 800-121 Closure - 1/2" Plug 3
Drum & Hub Assembly (Single Reeved
7 14 800-124 Nut - Hex (Double Reeved Models) 4
Models) 1 1/2 & 1 Ton (1/4" Dia. Rope)
800-113 25' Lift 15 800-125 Lockwasher (Double Reeved Models) 4
800-115 50' Lift 19 Shaft - Extension, Drum 1
800-112 2 Ton (5/16" Dia. Rope) 20' Lift 800-130 Short Frame
800-114 40' Lift 800-131 Long Frame
800-2102 3 Ton (5/16" Dia. Rope) 30' Lift 800-2113 First Extension
800-2103 45' Lift 800-2114 Second Extension
800-2104 5 Ton (5/16" Dia. Rope) 20' Lift 20 800-132 Key - Woodruff (“Hi-Pro” Type) 1
800-2105 30' Lift 21 800-133 Ring - Retaining, Hub (Internal) 1
Screw - Hex, Socket Button Head - Self- 22† 800-134 Bearing - Drum Shaft 1
8 800-116
Locking 4 23 800-135 Ring - Retaining, External 1

29 Manual No. 117404-10 REV. AB October 2018

 Ref. Quantity Ref. Quantity
Item Number Part Name Item Number Part Name
No. Required No. Required
24 800-136 Ring - Retaining, Beveled Hub (Internal) 1 800-2118 30' Lift
25 800-137a Plate Assembly - Base 1 47 800-164 Screw - Hex Socket 4
26 800-138 Lockwasher 16 48 800-165 Head Roll Pin 2
27 800-139 Screw - Hex Socket Head Cap 4 49 800-166 Lockwasher 2
29 800-194c Cover Assembly - Electrical 1 50 800-167 Screw - Hex Head Cap 2
30 800-2121 Screw - Self-Tapping 2 51 800-168 Key Plate 1
32 800-146a Plate Assembly - Base (Short Frame) 1 52 800-169 Shaft - Sheave (Double Reeved Models) 1
34 800-2122 Shell - Brake, Short Frame 1 53 800-170 Bracket, Sheave (Double Reeved Models) 1
35 800-149 Screw - Self-Tapping 2 54† 800-171 Bearing, Sheave (Double Reeved Models) 1
See Fig. 9-3 Sheave Assembly, Upper (Double Reeved
41 Motor & Brake 1 55† 800-172 1
& Fig. 9-4 Models) Includes Bearing
43 800-155 Screw - Hex Socket Head 1 Rope & Thimble Assembly (Double Reeved
56†
Models) 1/2 & 1 Ton (3/16"" Dia. Rope)
44 800-156 Lockwasher 1
800-174 18' Lift
Rope & Thimble Assembly (Single Reeved
45† 1
Models) 1/2 & 1 Ton (1/4" Dia. Rope) 800-176 34' Lift
800-158 25' Lift 800-2119 47' Lift
800-161 50' Lift 2 Ton (1/4"" Dia. Rope)
2 Ton (5/16" Dia. Rope) 800-173 14' Lift
800-157 20' Lift 800-175 25' Lift
800-160 40' Lift 800-2120 36' Lift
3 Ton (5/16" Dia. Rope) 57 800-177 Plug, Pin
800-2115 30' Lift 58 800-178 Bolt, Hex Head
800-2116 45' Lift 61 800-196 Label, Capacity (Specify Capacity)
5 Ton (5/16" Dia. Rope)
800-2117 20' Lift

† Recommended spares

30 Manual No. 117404-10 REV. AB October 2018

 11456LC

Figure 9-2. Gearing and Load Brake Parts

Ref. Quantity Ref. Quantity

Item Number Part Name Item Number Part Name
No. Required No. Required

Bearing Assembly - Needle, Intermediate & 19 800-269 Cover - Oil Hole 1

1† 800-201 2
Drum Gear Shaft 20 800-224 Pipe Plug - Hex Socket 1
2† 800-202 Race - Thrust Bearing 4 21† 800-225 Oil Seal - Motor Shaft 1
3† 800-203 Bearing Assembly - Needle Thrust 2 22† 800-226 Bearing Assembly - Ball, Motor Shaft 1
4 Gear - Intermediate 1 Bearing Assembly - Needle, Load Brake
23† 800-227 1
800-204 104 Teeth Shaft
800-205 109 Teeth 24 800-228 Ring - Retaining, Motor Shaft Bearing 1
800-266 103 Teeth 25 800-229 Washer - Thrust (Steel) 1
800-206 90 Teeth Brake Assembly - Load, Complete (Includes
1
Items 26 thru 37)
800-2205A 107 Teeth
800-230 23 Teeth
5 800-207 Key - Woodruff 1
800-231 36 Teeth
7 Gear - Drum 1
800-267 24 Teeth
800-209 71 Teeth
800-232 18 Teeth
800-210 61 Teeth
800-2232A 20 Teeth
800-2209 71 Teeth
26 800-233 Ring - Retaining, Brake Flange 1
8 Shaft - Intermediate Gear 1
27 800-234 Flange - Load Brake 1
800-211 14 Teeth
28* 800-235 Washer - Friction 2
800-212 24 Teeth
Pawl & Ratchet Assembly - Load Brake
800-2211 14 Teeth 29 800-236 1
(Available Only As An Assembly)
15 800-219 Ring - Retaining, Drum Shaft Bearing 1 30 800-237 Bushing - Ratchet 1
17 800-221 Ring - Retaining 1 31 800-238 Gear & Center Assembly 1
Bearing Assembly - Roller, Intermediate 32 800-239 Pin - Groove 2
18† 800-222 1
Shaft

31 Manual No. 117404-10 REV. AB October 2018

 Ref. Quantity
Item Number Part Name
No. Required
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
Bearing Assembly - Needle, Load Brake
40† 800-249 1
Shaft
Load Brake - Clutch Assembly With Bear-
* 800-250 1
ings (Complete)
Load Brake - Clutch Assembly (Includes
** 800-251 Items 26 thru 30, 34, 36 thru 38 and 43 1
thru 45)
43 800-254 Spring Retainer
Available only as
44 800-253 Brake Gear, Center part of 0-250 or
800-251 above
45 800-252 Clutch Assembly 80
46 800-260 Ring - Retaining 3
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.

32 Manual No. 117404-10 REV. AB October 2018

Figure 9-3. Hoist Motor Brake

Part No. Motor HP Motor RPM Voltage Coil Kit Brake Torque ft. - lbs.

800-4047 208-230/460 800-5001

1 1800 6
800-4048 575 800-5002
800-2425 208-230/460 800-2427
2 1800 9
800-2426 575 800-2428
800-2425 208-230/460 800-2427
3&4 3600 9
800-2426 575 800-2428

Ref.
Item Number Part Name
No.
800-5004 Soleniod Kit
4 800-5005 Friction Disc
800-5006 Brake Hub (not shown)
Brake Cover - Partial Cover
800-5007
(short frame only)
Brake Cover - Primer
800-5008
(not shown - except short frame)

33 Manual No. 117404-10 REV. AB October 2018

 12724

Figure 9-4. Three Phase Motor Assembly

Ref. Item Quantity Ref. Item Quantity

Part Name Part Name
No. Number Required No. Number Required
Motor Assembly (Includes Ref. Nos. 1 thru 8) 3 - 1 Horsepower (2 Speed)
1
1 Horsepower (1 Speed)
800-1318 200 Volt
800-1301 200 Volt
800-1319 230 Volt
800-1302 230/460 Volt
800-1320 460 Volt
800-1303 575 Volt
800-1321 575 Volt
2 Horsepower (1 Speed)
4 - 2 Horsepower (2 Speed)
800-1304 200 Volt
800-1322 200 Volt
800-1305 230/460 Volt
800-1323 230 Volt
800-1306 575 Volt
800-1324 460 Volt
4 Horsepower (1 Speed)
800-1325 575 Volt
800-1307 200 Volt
1 * Bell - End 1
800-1308 230/460 Volt
2 * Ring - Retaining 1
800-1309 575 Volt
3 * Bearing - Ball 1
1 - 1/3 Horsepower (2 Speed)
4 * Ring - Retaining 1
800-1310 200 Volt
5 * Key - Brake 1
800-1311 230 Volt
6 * Rotor and Shaft Assembly 1
800-1312 460 Volt
7 * Stator Assembly 1
800-1313 575 Volt
8 * Bolt - Motor 4
2 - 2/3 Horsepower (2 Speed)
800-1314 200 Volt
800-1315 230 Volt
800-1316 460 Volt
800-1317 575 Volt

* Furnished only as part of motor assemblyer.

34 Manual No. 117404-10 REV. AB October 2018

 11460

Figure 9-5. Upper Limit Switch Parts

Ref. Item Quantity Ref. Item Quantity

Part Name Part Name
No. Number Required No. Number Required

1 800-501 Pin - Pivot 2 Switch Assembly - Limit, Reversing (Includes

8† 800-510 1
Wire Leads)
2 Arm - Lever 1
9 800-511 Connector - Wire 3
800-502 Short Frame
Switch Assembly - Limit, Stop (Includes Wire
800-503 Long Frame 10† 800-512 1
Leads)
800-526 First Extension 11 800-513 Screw - Round Head 4
800-527 Second Extension 12 800-514 Screw - Socket Head Shoulder 1
3 Lever - Floating 1 13 800-515 Shaft & Cam Assembly 1
800-504 Short Frame 14 800-516 Insulator - Limit Switch 1
800-505 Long Frame 15 800-517 Bearing - Nylon 2
800-528 First Extension 16 800-518 Screw - Socket Head Cap 2
800-529 Second Extension 17 800-519 Lockwasher 2
4 800-506 Washer 2 18 800-520 Nut - Lock 1
5 800-507 Pin - Cotter 2 19 800-521 Bracket Assembly - Mounting 1
6 800-525 Coupling 1 20 800-522 Nut - Hex 2
7 800-509 Pin - Roll 2

† Recommended spares

35 Manual No. 117404-10 REV. AB October 2018

 12748A

Figure 9-6. Electrical Control Equipment

Ref. Item Quantity

Part Name
No. Number Required
3 800-670 Cord Grip - Conductor 2
5 800-654 Screw - Self-Tapping 4
6† 800-655 Contactor - Two Speed 1
7† 800-656 Contactor 1
8 800-657 Screw - Self-Tapping 2
9† 800-671 Transformer 1
10 800-663 Screw - Self-Tapping 4
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

† Recommended spares

36 Manual No. 117404-10 REV. AB October 2018

 12763

Figure 9-7. Push Button Station and Conductor Cable Assembly. Single Speed Hoists

Ref. Item Quantity Ref. Item Quantity

Part Name Part Name
No. Number Required No. Number Required

Push Button Station and Conductor Cable Type 1 Pan Head Machine Screw (M 6 x 1 x
800-2701 1 8 * 1
Assembly (Includes Ref. Nos. 1 thru 17) 12 Pltd.)

Push Button Station 9 * Lockwasher (M 6 Pltd.) 1

800-2702 1
(Includes Ref. Nos. 1 thru 15) 10 * Plain Washer (M 6 Pltd.) 1
Type 1 Pan Head Machine Screw (M 3.5 x 0.6 Type 1 Pan Head Machine Screw (M 3.5 x 1 x
1 * 7 11 * 2
x 12 Pltd.) 14 Pltd.)
2 * Lockwasher (M 3.5 Pltd.) 7 12 * Lockwasher (M 3.5 Pltd.) 2
3 * Rear Cover 1 13 * Housing Cap 1
4 800-2703 Gasket 1 14 800-2706 Grommet 1
Type 1 Pan Head Thread Cutting Screw (M 4 15 * Housing 1
5 * 2
x 15 Pltd.)
16 800-2707 Conductor Cable Assembly 1
6 800-2704 Contact Assembly 1
17 800-2708 Plastic Warning Tag 1
7 800-2705 Button Assembly 1

* Not available separately. Order Push Button Station

37 Manual No. 117404-10 REV. AB October 2018

 12721A

Figure 9-8. Push Button Station and Conductor Cable Assembly. (Two Speed Hoists Only)

Ref. Item Quantity

Part Name
No. Number Required
Push Button Station and Conductor Cable
BH-4027 1
Assembly (Includes Ref. Nos. 1 thru 30)
1 BH-1981 Grommet 1
2 BH-1982 Conductor Cable 1
3 BH-1971 Operator Warning Label 1
Push Button Station
BH-4029 1
(Includes Ref. Nos. 12 thru 30)
4 BH-4030 Control Station Grommet 1
5 * Control Station Hardware 4
6 * Control Station Housing 4
7 BH-3403 Gasket 1
8 BH-4028 Button and Control Assembly 1
Contact Block 2
Contact Block 2

* Not available separately. Order Push Button Station.

** Not available separately. Order Push Button Assembly.

38 Manual No. 117404-10 REV. AB October 2018

 11464

Figure 9-9. Lower Block Assembly - Two Parts Rope, Single Reeved

Ref. Item Quantity Ref. Item Quantity

Part Name Part Name
No. Number Required No. Number Required
800-801 Block Assembly - Lower, Complete, 2 Ton 1 Sheave Assembly - 1/2 & 1 Ton
† 800-818 1
(Consists of Items 7 and 8)
800-802 Block Assembly - Lower, Complete, 1 Ton 1
7 800-819 Bearing 1
800-803 Block Assembly - Lower, Complete, 1/2 Ton 1
8 800-820 Sheave 1
1 800-804 Screw - Flat Head, Self-Threading 2
9 800-821 Cover - Lower Block, 2 Ton 1
2 800-805 Cover - 2 Ton 1
800-822 Cover - Lower Block, 1 Ton 1
800-806 Cover - 1 Ton 1
800-823 Cover - Lower Block, 1/2 Ton 1
800-807 Cover - 1/2 Ton 1
Hook Assembly - (Consists of Hook, Nut &
3 800-808 Ring - Retaining, 2 Ton 2 10† 800-824 1
Grooved Pin), 2 Ton
800-809 Ring - Retaining, 1/2 & 1 Ton 2
Hook Assembly - (Consists of Hook, Nut &
† 800-825 1
4 800-810 Lube Fitting 1 Grooved Pin), 1/2 & 1 Ton
5 800-811 Pin - Sheave, 2 Ton 1 11 800-826 Shroud - Thrust Bearing, 2 Ton 1
800-812 Pin - Sheave, 1/2 & 1 Ton 1 800-827 Shroud - Thrust Bearing, 1/2 & 1 Ton 1
6 800-813 Spacers - 2 Ton 2 12† 800-828 Bearing Washer - Thrust, 2 Ton 1
800-814 Spacers - 1/2 Ton & 1 Ton 2 † 800-829 Bearing Washer - Thrust, 1/2 & 1 Ton 1
Sheave Assembly - 2 Ton (Consists of Items 13 800-830 Body - Lower Block, 2 Ton 1
† 800-815 1
7 and 8)
800-831 Body - Lower Block, 1/2 & 1 Ton 1
7 800-816 Bearing 1
14 800-832 *Safety Hook Latch Kit - 2 Ton 1
8 800-817 Sheave 1
800-833 *Safety Hook Latch Kit - 1/2 & 1 Ton 1

† Recommended Spares 15 800-834 Screw - Flat Head, Self-Threading 2

* Furnished as standard with hook

39 Manual No. 117404-10 REV. AB October 2018

 11465

Figure 9-10. Lower Block Assembly—Two Parts Double Reeved

Ref. Item Quantity Ref. Item Quantity

Part Name Part Name
No. Number Required No. Number Required
800-851 Block Assembly - Lower, Complete, 2 Ton 1 8 800-820 Sheave 2
800-852 Block Assembly - Lower, Complete, 1 Ton 1 9 800-856 Cover - Intermediate 1
800-853 Block Assembly - Lower, Complete, 1/2 Ton 1 10 800-834 Screw - Flat Head, Self-Threading 4
1 800-804 Screw - Flat Heads Self-Threading 4 Hook Assembly - (Consists of Hook, Nut &
11† 800-824 1
Grooved Pin), 2 Ton
2 800-854 Cover - Lower Block, 2 Ton 2
Hook Assembly - (Consists of Hook, Nut &
800-806 Cover - Lower Block, 1 Ton 2 † 800-825 1
Grooved Pin), 1/2 & 1 Ton
800-807 Cover - Lower Block, 1/2 Ton 2
12 800-826 Shroud - Thrust Bearing, 2 Ton 1
3 800-809 Ring - Retaining 2
800-827 Shroud - Thrust Bearing, 1/2 & 1 Ton 1
4 800-810 Fitting - Lube 1
13† 800-828 Bearing - Thrust, 2 Ton 1
5 800-855 Pin - Sheave 1
† 800-829 Bearing - Thrust, 1/2 & 1 Ton 1
6 800-814 Spacer 4
14 800-857 Body - Lower Block, 2 Ton 1
Sheave Assembly - (Consists of Items 7 and
† 800-818 2 800-858 Body - Lower Block, 1/2 & 1 Ton 1
8)
15 800-832 *Safety Hook Latch Assembly - 2 Ton 1
7 800-819 Bearing 2
800-833 *Safety Hook Latch Assembly - 1/2 & 1 Ton 1

† Recommended Spares
* Furnished as standard with hook

40 Manual No. 117404-10 REV. AB October 2018

 12197LA

Figure 9-11 . Upper and Lower Block Parts (3 & 5 Ton - Typical)

QTY. Required QTY. Required

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

† Recommended Spares
* Hook Nuts with roll pins are not interchangeable - Available only as an assembly

41 Manual No. 117404-10 REV. AB October 2018

 12757A

Figure 9-12. Screw-Type Limit Switch Parts

Ref. Item Quantity

Part Name
No. Number Required
Limit Switch Assembly
1 800-1655 1
(Includes Ref. Nos. 2, 3 and 4)
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

42 Manual No. 117404-10 REV. AB October 2018

 RECOMMENDED SPARE PARTS
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 AND SERVICES ARE AVAILABLE IN THE UNITED STATES AND IN CANADA
Parts for your hoist or trolley are available from your local authorized repair station. For the name of the nearest parts or service
center, visit our website www.cmworks.com or call the Columbus McKinnon customer service department at (800) 888-0985.

43 Manual No. 117404-10 REV. AB October 2018

Notes

44 Manual No. 117404-10 REV. AB October 2018

 WARRANTY
LIMITATION OF WARRANTIES, REMEDIES AND DAMAGES

INDEMNIFICATION AND SAFE OPERATION

Buyer shall comply with and require its employees to comply with directions C. IN NO EVENT SHALL SELLER BE LIABLE TO BUYER OR ANY THIRD
set forth in instructions and manuals furnished by Seller and shall use PARTY WITH RESPECT TO ANY GOOD OR REPLACEMENT PART,
and require its employees to follow such instructions and manuals and to WHETHER IN CONTRACT, TORT OR OTHER THEORY OF LAW, FOR
use reasonable care in the use and maintenance of the Goods and any LOSS OF PROFITS OR LOSS OF USE, OR FOR ANY INCIDENTAL,
Replacement Parts. Buyer shall not remove or permit anyone to remove any CONSEQUENTIAL, SPECIAL, DIRECT OR INDIRECT DAMAGES,
warning or instruction signs on the Goods or Replacement Parts. In the event HOWSOEVER CAUSED. SELLER’S MAXIMUM LIABILITY TO BUYER
of personal injury or damage to property or business arising from the use of WITH RESPECT TO THE GOODS OR ANY REPLACEMENT PART
the Goods or Replacement Parts, Buyer shall within 48 hours thereafter give SHALL IN NO EVENT EXCEED THE PRICE PAID BY BUYER FOR THE
Seller written notice of such injury or damage. Buyer shall cooperate with GOODS OR REPLACEMENT PART THAT ARE THE SUBJECT OF THE
Seller in investigating any such injury or damage and in the defense of any APPLICABLE CLAIM.
claims arising therefrom.
D. Seller shall not be liable for any damage, injury or loss arising out of the
If Buyer fails to comply with this section or if any injury or damage is caused, use of the Goods or any Replacement Part if, prior to such damage, injury
in whole or in part, by Buyer’s failure to comply with applicable federal or or loss, such Goods or Replacement Parts are: (1) damaged or misused
state laws, rules or regulations safety requirements, Buyer shall indemnify and following Seller’s delivery to the carrier; (2) not maintained, inspected, or
hold Seller harmless against any claims, loss or expense for injury or damage used in compliance with applicable law and Seller’s written instructions
arising from the use of the Goods and/or Replacement Parts. and recommendations; or (3) installed, repaired, altered or modified (a) with
any part or accessory other than those supplied by Seller or (b) without
CMCO Warranty (HOISTS) compliance with such laws, instructions or recommendations.
A. Columbus McKinnon Corporation (“Seller”) warrants to the original end E. This warranty is limited and provided only to the original end user. Each
user (“Buyer”) that, for a period of one (1) year from the date of Seller’s Good and Replacement Part must be registered within sixty (60) days
delivery of the goods (collectively, the “Goods”) to the carrier, the Goods of receipt of each product to establish eligibility. Please register at
will be free from defects in workmanship and materials. . In addition, www.cmworks.com/hoist-warranty-registration or submit registration card
Seller warrants to Buyer that, for a period of one (1) year from the date via US mail.
of their delivery by Seller to the carrier, any aftermarket or replacement
parts, accessories or components purchased by Buyer with respect to F. Any action against Seller for breach of warranty, negligence or otherwise
any Goods (collectively, “Replacement Parts”) will be free from defects in in connection with the electrical components of any Good must be
workmanship and materials. commenced by Buyer within one (1) year after: (a) the date any alleged
claim accrues; or (b) the date of delivery of the Goods to Buyer, whichever
B. IN THE EVENT OF ANY BREACH OF ANY SUCH WARRANTY, SELLER’S is earlier. Any action against Seller for breach of warranty, negligence or
SOLE OBLIGATION SHALL BE EXCLUSIVELY LIMITED TO, AT THE otherwise in connection with the mechanical components of any Good
OPTION OF SELLER, REPAIR OR REPLACEMENT, F.O.B. SELLER’S must be commenced by Buyer within one (1) year after the date any
POINT OF SHIPMENT, OF ANY GOODS OR REPLACEMENT PARTS alleged claim accrues. . Any action against Seller for breach of warranty,
THAT SELLER DETERMINES TO HAVE BEEN DEFECTIVE OR, IF negligence or otherwise in connection with any Replacement Part must
SELLER DETERMINES THAT SUCH REPAIR OR REPLACEMENT IS be commenced by Buyer within one (1) year after: (y) the date any alleged
NOT FEASIBLE, TO A REFUND OF THE PURCHASE PRICE UPON claim accrues; or (z) the date of delivery of the Replacement Part to Buyer,
RETURN OF THE OR REPLACEMENT PARTS TO SELLER. NO CLAIM whichever is earlier.
AGAINST SELLER FOR ANY BREACH OF (i) SUCH WARRANTY WITH
RESPECT TO THE ELECTRICAL COMPONENTS OF ANY GOOD OR G. This warranty is contingent upon Buyer’s proper maintenance and care
ANY REPLACEMENT PARTS, SHALL BE VALID OR ENFORCEABLE of the Goods and/or Replacement Parts, and does not extend to normal
UNLESS BUYER’S WRITTEN NOTICE THEREOF IS RECEIVED BY wear and tear. Seller reserves the right, at its option, to void this warranty
SELLER WITHIN ONE (1) YEAR FROM THE DATE OF SELLER’S in the event of Buyer’s use with the Goods and/or Replacement Parts of
DELIVERY TO THE CARRIER AND (ii) SUCH WARRANTY WITH RESPECT parts or accessories other than those supplied by Seller.
TO THE MECHANICAL COMPONENTS OF ANY GOOD SHALL BE
VALID OR ENFORCEABLE UNLESS BUYER’S WRITTEN NOTICE
THEREOF IS RECEIVED BY SELLER WITHIN ONE (1) YEAR FROM
THE DATE THE DATE ANY ALLEGED CLAIM ACCRUES. EXCEPT FOR
THE WARRANTIES SET FORTH ABOVE, SELLER MAKES NO OTHER
WARRANTIES WITH RESPECT TO THE GOODS OR ANY REPLACEMENT Alterations or modifications of equipment and use of non-Seller
PARTS, WHETHER EXPRESSED OR IMPLIED, INCLUDING ANY replacement parts can lead to dangerous operation and injury.
WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR
PURPOSE, QUALITY AND/OR THOSE ARISING BY STATUTE OR TO AVOID INJURY:
OTHERWISE BY LAW OR FROM ANY COURSE OF DEALING OR USE OF • Do not alter or modify equipment.
TRADE, ALL OF WHICH ARE HEREBY EXPRESSLY DISCLAIMED. • Do use only replacement parts manufactured by Seller.

USA: Ph: (800) 888.0985 • (716) 689.5400 • Fax: (716) 689.5644 • www.cmworks.com
CANADA: Ph: (877) 264.6478 • Fax: (877) 264.6477 • www.cmworks.com
UK: Ph: +44 1244 375375 • Fax: +44 1244 377403 • www.cmco.eu
© 2018 Columbus McKinnon Corporation. All Rights Reserved. Manual No. 117404-10 REV. AB October 2018