Yale HOISTS YEL Series User manual

Capacities
1/8 Ton
1/4 Ton
1/2 Ton
1 Ton
2 Ton
Operating, Maintenance &
Parts Manual
YJL680-2
YEL Series
Electric Chain
414 Broadway Avenue
P.O.Box 769
Muskegon, Michigan USA
Tel: [phone] •Fax: [phone]
www.yalehoists.net
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 the hoist operator.
Failure to operate the equipment as directed in the manual
may cause injury.
Should you have any questions or have problems with this
product, please callYale Hoists at [phone]
Before using the hoist, fill in the information below:
Model No.
Serial No.
Purchase Date
F ollow all instructions and warnings for
inspecting, maintaining and operating this hoist.

E very hoist is thoroughly inspected and
performance tested prior to shipment from the
factory.If any properly installed, maintained and
operated hoist as outlined in the applicable
accompanying Yale Hoists manual develops a
performance problem due to defective materials or
workmanship as verified byYale Hoists, repair or
replacement of the hoist will be made to the
original purchaser without charge and the hoist
will be returned, transportation prepaid.This
warranty does not apply where deterioration is
caused by normal wear, abuse, improper or
inadequate power supply, improper or inadequate
maintenance, eccentric or side loading,
overloading, chemical or abrasive actions,
excessive heat, unauthorized modifications or
repairs, or use of non-Yale repair parts. EXCEPT
AS STATED HEREIN, YALE HOISTS MAKES NO
OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDINGWARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE.
© 2002Yale Hoists®Printed in USA
WARRANTY
Yale Hoists •414 Broadway Avenue •P.O. Box 769 •
Muskegon, Michigan USA
Tel: [phone] •Fax: [phone]
www.yalehoists.net

2
Country Club Road
P.O. Box 779
Wadesboro, NC 28170 USA
TEL: [phone]
FAX: [phone]
SAFETY PRECAUTIONS
EachYaleYEL Series Electric Chain 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.
*Copies of this Standard can be obtained from ASME Order
Department, 22 Law Drive, Box 2300, Fairfield, NJ 07007-2300,
U.S.A.
1. NOT operate a damaged, malfunctioning or unusually
performing hoist.
2. NOT operate the hoist until you have thoroughly read and
understood the manufacturer’s Operating and Maintenance
Instructions or Manuals.
3. NOT operate a hoist which has been modified without the
manufacturer’s approval or without certification that it is in
conformity with ANSI/ASME B30 volumes.
4. NOT lift more than rated load for the hoist.
5. NOT use hoist with twisted, kinked, damaged, or worn load
chain.
6. NOT use the hoist to lift, support, or transport people.
7. NOT lift loads over people.
8. NOT operate a hoist unless all persons are and remain clear
of the supported load.
9. NOT operate unless load is centered under hoist.
10. NOT attempt to lengthen the load chain or repair damaged
load chain.
11. Protect the hoist’s load chain from weld splatter or other
damaging contaminants.
12. NOT operate hoist when it is restricted from forming a
straight line from hook to hook in the direction of loading.
13. NOT use load chain as a sling, or wrap chain around load.
14. NOT apply the load to the tip of the hook or to the hook latch.
15. NOT apply load unless load chain is properly seated in the
chain sprocket(s).
16. NOT apply load if bearing prevents equal loading on all load
supporting chains.
17. NOT operate beyond the limits of the load chain travel.
18. NOT leave load supported by the hoist unattended unless
specific precautions have been taken.
19. NOT allow the load chain or hook to be used as an electrical
or welding ground.
20. NOT allow the load chain or hook to be touched by a live
welding electrode.
21. NOT remove or obscure the warnings on the hoist.
22. NOT operate a hoist on which the safety placards or decals
are missing or illegible.
23. NOT operate a hoist unless it has been securely attached to
a suitable support.
24. NOT operate a hoist unless load slings or other approved
single attachments are properly sized and seated in the hook
saddle.
25. Take up slack carefully - make sure load is balanced and load
holding action is secure before continuing.
26. Shut down a hoist that malfunctions or performs unusually
and report such malfunction.
27. Make sure hoist limit switches function properly.
28. Warn personnel of an approaching load.
1. Maintain firm footing or be otherwise secured when operating
the hoist.
2. Check brake function by tensioning the hoist prior to each
lift operation.
3. Use hook latches. Latches are to retain slings, chains, etc.
under slack conditions only.
4. Make sure the hook latches are closed and not supporting
any parts of the load.
5. Make sure the load is free to move and will clear all
obstructions.
6. Avoid swinging the load or hook.
7. Make sure hook travel is in the same direction as shown on
the controls.
8. Inspect the hoist regularly, replace damaged or worn parts,
and keep appropriate records of maintenance.
9. UseYale Hoists recommended parts when repairing the unit.
10. Lubricate load chain per hoist manufacturer’s
recommendations.
11. NOT use the hoist’s overload limiting clutch to measure load.
12. NOT use limit switches as routine operating stops.They are
emergency devices only.
13. NOT allow your attention to be diverted from operating
the hoist.
14. NOT allow the hoist to be subjected to sharp contact with
other hoists, structures, or objects through misuse.
15. NOT adjust or repair the hoist unless qualified to perform
such adjustments or repairs.
Improper operation of a hoist can create a potentially
hazardous situation which, if not avoided, could result
in death or serious injury. To avoid such a potentially
hazardous situation, THE OPERATOR SHALL:
Improper operation of a hoist can create a potentially
hazardous situation which, if not avoided, could result
in minor or moderate injury. To avoid such a potentially
hazardous situation, THE OPERATOR SHALL:

3
Country Club Road
P.O. Box 779
Wadesboro, NC 28170 USA
TEL: [phone]
FAX: [phone]
YaleYEL series electric chain hoists are rugged, portable
hoists that provide quick, precise lifting.The hoists are
constructed of tough, but lightweight, die cast aluminum alloy
housings.An oil bath transmission, equipped with heat-treated,
alloy steel gears and an overload limiting clutch, provides
smooth and reliable operation.The electrical controls use an
ergonomically designed pushbutton station and a low voltage
circuit (24V standard, 115V optional).Terminal blocks allow for
easy voltage conversions on dual-voltage models.
Other features that ensure the safe operation ofYale electric
chain hoists include a magnetic disc brake that delivers sure
stopping and secure holding of the load.Adjustable upper and
lower limit switches regulate the load travel. As a standard,
hooks are supplied with safety latches.For additional safety,
a chain stop is attached to the slack end of the load chain.
Hoists are designed and tested in accordance with the
American Society of Mechanical Engineers Code B30.16,
“Safety Standard for Overhead Hoists.” Hoists are built in
compliance with CSA, file number LR 44484.Made in U.S.A.
*The 1HP, 115/230V models must have a dedicated power
circuit rated for at least 20A, 125V when they are wired for
115V.It is not unusual for these models to draw up to 20
amps at 115V when lifting at rated capacity depending on
the quality of the voltage source.
NOTE: The above data is the nominal motor current at full
load.At full load, it is not unusual for the hoist to draw
in excess of the values listed when lifting.It is critical to ensure
that the voltage at the reversing contactor does not drop below
10% of the nominal voltage while lifting a load.Low voltage will
result in higher amp draw, damage to the hoist, and potential
fire hazards.Yale Hoists is not responsible for any damages
caused by an inadequate power source.
Lifting
Model* Capacity Speed HP Reeving
Number (lbs) (fpm)
YEL1/8-**TH32S1 250 32 1/4 Single-chained
YEL2-**TH8S1 4000 8 1 Double-chained
YEL1-**TH16S1 2000 16 1 Single-chained
YEL1/4-**TH32S1 500 32 1/2 Single-chained
YEL1/2-**TH16S1 1000 16 1/2 Single-chained
YEL1/2-**TH32S1 1000 32 1 Single-chained
YEL1/4-**TH16S1 500 16 1/4 Single-chained
Failure to comply with Safety Precautions outlined
throughout this manual can result in serious injuries
or death. Before using this hoist, each operator
should become thoroughly familiar with all warnings,
instructions and recommendations in this manual.
TABLE OF CONTENTS
Safety Precautions......................................................................................................................................................................2
Hoist Specifications.....................................................................................................................................................................3
Application Information ...............................................................................................................................................................4
Safety Information.......................................................................................................................................................................4
Installation...................................................................................................................................................................................4
Operation ....................................................................................................................................................................................6
Maintenance ...............................................................................................................................................................................6
Trouble Shooting.......................................................................................................................................................................12
Wiring Diagrams .......................................................................................................................................................................13
Inspection and Maintenance Check List...................................................................................................................................16
Recommended Lubrication Schedule.......................................................................................................................................17
Replacement Parts List.............................................................................................................................................................18
Warranty ....................................................................................................................................................................................................Back Cover
Full Load Amps
Hoist 1-Phase 3-Phase
Horsepower 115/230V 208V 230/460V 380V 575V
1/4 HP 4.3/2.2 1.3 1.2/.6 .73 .35
1/2 HP 7.6/3.8 2.3 2/1 1.2 .76
1 HP 14/7* 3.6 3.2/1.6 1.9 1.2
Hoist Full Load Amps (fast/slow)
Horsepower 3-Phase Only
(fast/slow) 208V 230V 380V 460V 575V
.25/.083 1.2/1.3 1/1.1 .61/.67 .5/.55 .4/.44
.5/.17 1.9/2.4 1.7/2.1 1.1/1.3 .88/1.1 .7/.85
1/.33 3.6/4.3 3.2/3.8 1.9/2.3 1.6/1.9 1.3/1.5
Table 2 - Motor Amperage of 1-Speed Hoist Models
Table 3 - Motor Amperage of 2-Speed Hoist Models
Table 1 - Hoist Specifications
*Note: YEL*PT models are equivalent to the correspondingYEL*TH,
but are supplied with a plain trolley and lug suspension. Model
numbers for these units are the same as above except “TH”is
replaced by “PT”.
**Note: To complete Model Number, insert lift in place of asterisks.
HOIST SPECIFICATIONS

APPLICATION INFORMATION
This hoist is intended for general industrial use for lifting and
transporting freely suspended material loads within its rated
capacity.Yale Hoists cannot be responsible for applications
other than those for whichYale equipment is recommended.
Prior to installation and operation, we caution the user to
review his application for abnormal environmental or handling
conditions and to observe the applicable recommendations
as follows:
ADVERSE ENVIRONMENTAL CONDITIONS
Do not use the hoist in areas containing flammable vapors,
liquids, gases or any combustible dusts or fibers. Refer to
Article 500 of the National Electrical Code. Do not use this
hoist in highly corrosive, abrasive or wet environments.Do not
use this hoist in applications involving extended exposure to
ambient temperatures below -10°F or above 130°F.
LIFTING OF HAZARDOUS LOADS
This hoist is not recommended for use in lifting or transporting
hazardous loads or materials which could cause widespread
damage if dropped.The lifting of loads which could explode or
create chemical or radioactive contamination if dropped
requires fail-safe redundant supporting devices which are not
incorporated into this hoist.
LIFTING OF GUIDED LOADS
This hoist is not recommended for use in the lifting of guided
loads, including dumbwaiters and elevators.Such applications
require additional protective devices which are not
incorporated into this hoist.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).
SAFETY INFORMATION
1. Follow all local electrical and safety codes, as well as the
National Electrical Code (NEC) and the Occupational
Safety and Health Act (OSHA) in the United States.
2. Hoist must be securely and adequately grounded.Hoist
power cable is provided with an additional lead (green) for
grounding purposes.
3. Be careful when touching the exterior of an operating
motor; it may be hot enough to be painful or cause injury.
With modern motors this condition is normal if operated at
rated load and voltage (modern motors are built to operate
at higher temperatures).
4. Protect the power cable and control cable from coming in
contact with sharp objects.
5. Do not kink power cable and control cable and never allow
the cable to come in contact with oil, grease, hot surfaces,
or chemicals.
6. Make certain that the power source conforms to the
requirements of your equipment.
7. Inspect the unit daily before operating hoist.
8. Cluttered areas and benches invite accidents.
9. The operator should not engage in any practice which will
divert his attention while operating the hoist.
10. Before using the hoist, the operator should be certain that
all personnel are clear.
11. Do not operate hoist with loads exceeding its rated capacity.
12. Supporting frames or beams used as a hoist hanger must
have a greater load capacity than the hoist.
13. Do not attempt to operate hoist beyond normal maximum
lift range.
14. Align hoist for a straight line pull.Avoid side pull or end pull.
15. Do not operate hoist with twisted or damaged chain.
16. Do not operate a damaged or malfunctioning hoist until
necessary adjustments or repairs have been made.
17. Do not use hoist to lift people or to carry loads over people.
18. Do not leave a load suspended in the air unattended.
19. Always remove load before making repairs.
20. Do not remove or obscure capacity or warning decals.
INSTALLATION
1. Before installing the hoist, check the following:
a. Make sure all supporting structures and attaching devices
are strong enough to hold your intended loads. If in doubt,
consult a qualified structural engineer.
b. Provide proper branch circuit protection for the hoist as
recommended in the National Electrical Code.
c. The power supply should be plus or minus 10% of the
voltage specified on the motor nameplate. It is critical to
use adequate sized power cables, especially with 1-phase
hoists (SeeTable 5, page 11). Be sure dual voltage hoists
are connected or wired to correspond with your power
supply (See WIRING, page 9).
d. Installation area must provide operating conditions for the
operator including sufficient room for the operator and
other personnel to stand clear of the load at all times.
e. For installations where the slack chain hanging from the
unit may be objectionable or hazardous, the use of a
chain container is recommended (See CHAIN
CONTAINER, page 5).
2. ELCET models come with aYale ET push-type trolley and
an adaptable suspension lug.ET trolleys are made to run on
American Standard I-Beams and Wide Flange Beams with
flange widths up to 8".For assembly refer to the instructions
provided with the trolley.The hoist lug must be centered with
the sideplates (±1 washer).Due to the lug thickness, the
washer placement between each sideplate and the lug may
differ by 1 less washer than the generic instructions specify.
4
Country Club Road
P.O. Box 779
Wadesboro, NC 28170 USA
TEL: [phone]
FAX: [phone]
Always disconnect power source before working on
or near a hoist or its connected load. If the power
disconnect point is out of sight, lock it in the open
position and tag to prevent unexpected application
of power.

5
Country Club Road
P.O. Box 779
Wadesboro, NC 28170 USA
TEL: [phone]
FAX: [phone]
For installations where the trolley can not be slid onto the
end of a beam, leave the load pin nuts loose enough to get
the wheels around the beam flange.Check the flange width
setting before tightening the nuts to 125 ft-lbs.Be sure to
have end stops on your beam.
3. Before operating the hoist, be sure to observe the following:
a. ALWAYS DISCONNECT HOIST FROM POWER SUPPLY
before removing electrical cover or when making any
electrical connection in the hoist or pushbutton station.
b. The ground wire (green colored) of the power cable
should always be connected to a suitable ground by
means of a screw or clamp. An alligator clip does not
make a safe ground connection.
c. When installing a three-phase hoist, make only temporary
connections at the power source. Push the “UP”button
and observe the direction of the load block.If it raises, the
phasing is correct and permanent connections may be
made at the power source. If the load block lowers when
the “UP” button is pushed, release the button immediately
since the limit switches will not operate to protect the hoist
from over-travel. Reverse any two wires (except the green
ground wire) at the power source to correct the load hook
direction (phasing).Do not change connections in the
hoist or pushbutton assembly.
d. Make sure load chain is not twisted as it travels into the
hoist.
e. Operate hoist in a hanging position only.Hoist should be
permitted to align itself for a straight line pull.Do not
attempt to pull around corners.
f. Read ASME-B30.16 Safety Code for Hoists.
4. Lubricate the chain if necessary, see LUBRICATION,
page 10.
5. Check the function of the limit switches. Before placing hoist
in operation, check limit switch settings.Operate pushbutton
until near stop point and inch into stop limit, both top and
bottom.If either switch is not correct, adjust according to
LIMIT SWITCH ADJUSTMENT, page 8.
CHAIN CONTAINER (Optional Accessary)
Refer to Table 4.
For installations where the slack chain hanging from the hoist
may be objectionable or hazardous, the use of a chain
container is recommended.
Available chain containers include the standard metal
containers designed for lifts of up to 50 ft on single-chained
hoists and 25 ft on double-chained hoists. For longer lifts, the
JL927-5 metal container is available. For applications where a
fabric bag is preferred, the JL927-20F, JL927-40F and the
JL927-70F are all options.
Instructions are provided with each of these chain containers
and must be adhered to closely to ensure a proper installation.
To install the long lift chain container or a fabric chain
container, you must follow instruction sheets 679J89 and
679J96 respectively.The following instructions are for the
standard metal chain containers only.
Installation of Standard Metal Chain
Containers (JL927-1, JL927-3 and JL927-4)
Refer to Figure 1.
1. Remove dead end screw and washers and let chain hang free.
2. Place chain container bracket flush against housing.
Replace washers and screw.Tighten securely.
Do not attempt to store more chain in chain
container than that specified in the table below or
serious damage to hoist may result and hazardous
conditions may be created.
Chain Recommended for Use With:
Container Hoist Maximum Container Dimensions in Inches
Model Capacity Lift (ft) Material Width Length Depth
Table 4 - Optional Chain Containers
JL927-1 1 Ton & Under 20 Steel (.036" thick) 3 6½ 11½
2 Ton 10
JL927-3 1 Ton & Under 35 Steel (.036" thick) 3 6½ 18½
2 Ton 17
JL927-4 1 Ton & Under 50 Steel (.036" thick) 3 6½ 27
2 Ton 25
JL927-5 1 Ton & Under 143 Steel (.06" thick) 6 8 34
2 Ton 71
JL927-20F 1 Ton & Under 20 Open Weave Vinyl 7½ 7½ 10
2 Ton 10 Coated Polyester
JL927-40F 1 Ton & Under 40 Open Weave Vinyl 7½ 7½ 16
2 Ton 20 Coated Polyester
JL927-70F 1 Ton & Under 70 Open Weave Vinyl 7½ 7½ 20
2 Ton 35 Coated Polyester
Figure 1 — Installing Chain Container Assembly
Dead-end Screw

3. Attach chain container to bracket with two open links and
then close the links.
4. Run load hook down to its lowest position.Place the slack
end of chain in chain container.Feed the remainder of chain
into container by operating hoist in the “UP” direction to the
top limit.This will allow the chain to pile freely without
kinking, which occurs when you place the chain in the
container by hand.
OPERATION
This hoist is designed for safe operation within the limits of its
rated capacity. It is controlled by the “UP” and “DOWN”buttons
of the pushbutton station.Two-speed models utilize 2-step
buttons, the first step for operating the slow speed and the
second for the fast speed.Although theYaleYEL is built with
many features to ensure safety, it is a requirement that a hoist
operator understands safe lifting practices.The following points
must be observed.
1. Do not overload the hoist.
2. Do not make extreme side pulls with the hoist.
3. Operate the hoist only in a hanging position with
adequate support.
4. Do not “sling” the load hook and chain around the load.
Use an approved sling.
5. Be sure there are no twists in the load chain as it travels
into the hoist housing.This condition should be constantly
checked on double chain hoists because it is possible for
the load block to be “capsized” or turned over one or
more times.
6. Before raising a load, always check to see that it is held
securely in the hook or sling chains, etc.Raise the load
only until the load chain is taut and then double check the
rigging before continuing to raise the load.
7. Do not stand beneath a load! Do not move a load in such a
manner as to endanger personnel.
8. Don’t lower into areas where visibility is obscured unless
someone else is guiding the operation.
9. Use common sense at all times when operating a hoist.
10. Do not operate if direction of hook travel is not the same as
indicated on button being pushed.
11. Do not operate unless hook travel limit devices function.
Test without load each shift.
12. Do not operate when hoist is not centered over load.
13. Do not operate if chain is not seated properly in sprockets
or sheave grooves.
14. Do not operate damaged or malfunctioning hoist.
OVERLOAD LIMITING PROTECTION
This hoist is equipped with a factory-calibrated overload
limiting clutch that will permit the lifting of loads within its rated
capacity, but will prevent the lifting of damaging overloads while
the hoist is being operated.If the load being lifted exceeds the
lifting capability of the overload clutch, the hoist motor will
continue to run, causing overheating of both the clutch and
hoist motor.This condition should be avoided by immediately
releasing the “UP” button and reducing the load to within the
rated capacity of the hoist.See GEARING, page 11, for
additional instructions on this device.
MAINTENANCE
INSPECTIONS
A planned inspection routine should be established for this
hoist based upon frequency of use, severity of use, and
environmental conditions (Reference ASME Standard B30.16).
Some inspections should be made frequently (daily to monthly)
and others periodically (monthly to yearly). It is strongly
recommended that an Inspection and Maintenance Check List
and an Inspector’s Report, similar to those shown in Figures
10A and 10B, be used and filed for reference. All inspections
should be performed or overseen by a designated inspector.
Special inspections should be made following any significant
repairs or any operating occurrence leading one to suspect
that the hoist’s capability may have been impaired.
LOWERING WITHOUT POWER
If the power fails with a load suspended, the hoist will
automatically stop. In an emergency the load can be lowered
without power as follows:
1. DISCONNECT HOIST FROM POWER SUPPLY AND
REMOVE ELECTRICAL COVER.
2. Refer to Figure 6. Open disc brake manually by using two
screwdriver blades, one on each side of the brake at a point
close to the brake spring posts.Apply pressure to the
underside of the armature plate (points “X”) to close the
solenoid and release the brake.
3. Use several quick releases instead of holding brake open
continuously. Do not exceed normal lowering speed.
6
Country Club Road
P.O. Box 779
Wadesboro, NC 28170 USA
TEL: [phone]
FAX: [phone]
Do not allow screw driver blades to touch rotating
friction disc “C”.
Do not use hoist to lift, support or otherwise
transport people.
Do not allow the load to descend rapidly. This causes
the motor to race and serious damage may result.
The overload limiting clutch is an emergency
protective device and should not be used to measure
the maximum load to be lifted, or to sense the
overload imposed by a constrained load. While the
overload limiting clutch will protect the hoist from
damaging overloads, it will not ensure that a load is
within the rated capacity of the hoist.
Do not allow load to come in contact with the chain
container. If this situation exists reset the “UP” limit
switch so that the hook block stops below the chain
container (See LIMIT SWITCH ADJUSTMENT, page 8).

7
Country Club Road
P.O. Box 779
Wadesboro, NC 28170 USA
TEL: [phone]
FAX: [phone]
HOOKS
Refer to Figure 2.
1. Inspect hooks once daily for cracking, extreme wear or
spreading.Replace hooks showing any of these signs.If the
throat openings are spread wider than the maximum
permissible 15% increase listed here, the hooks have been
overstressed and must be replaced.Any hook that is bent or
twisted more than 10 degrees from the plane of an unbent
hook must also be replaced.
2. The hook latches should be inspected to ensure that they
close the hook throat opening in a secure manner when a
load is applied.Inspect the hook shank and nut for any
stripping of the threads or other damage.The hook nut
should be fully restrained by the retaining pin.
3. In addition to above, load hooks should be inspected for
cracks by the magnetic particle, dye penetrant or other
suitable crack testing inspection method.This should be
done at least once a year.
1 Ton & Under 111/32"1
7/32"
2 ton 111/32"1
11/32"
(*) Maximum permissible throat opening of hook.
CHAIN
Chain is to be kept clean and lubricated (See LUBRICATION,
page 10).Visually check chain every time hoist is used.Hoist
must not be operated when chain is twisted or kinked. An
important phase of hoist maintenance is chain inspection.
Check individual links and check for chain elongation.
1. Check the chain for overall wear or stretch by selecting an
unworn, unstretched length of chain (at the slack end for
example). Let the chain hang vertically with a light load
(about 20 pounds) on the chain to pull it taut.Use a large
caliper to measure the outside length of a convenient
number of links (about 12 inches).Measure the same
number of links in a used section of chain and calculate the
percentage increase in length of the worn chain.
2. If the length of the worn chain is more than 1½% longer than
the unused chain (0.015" per inch of chain measured), then
the chain should be replaced.If the chain is worn less than
1½%, check it at several more places along its length.If any
section is worn more than 1½%, the chain should be replaced.
Chain Replacement with Chain in Hoist
Refer to Figures 3 & 4.
1. Run hook up to its top limit.
2. DISCONNECT HOIST FROM POWER SUPPLY and
remove the electrical cover.
3. Using a screwdriver, pry the spring guide plate out of the
slots in the limit switch nuts (See Figure 3).Turn the gold
nut back to about the center of the threaded screw. Do not
disconnect the wires from the limit switches.
4. Remove the load block assembly from the old chain. On
double-chained hoists detach the chain from the chain
support and pull it through the load block assembly (See
Figure 4).
5. Make a “C” shaped chain link by grinding through the end
link on the load end of the old chain.
6. Using the “C” link, attach the new chain to the load end of
the old chain.Be sure that the welds of the upstanding links
of the new chain will face outward from the load sheave.
The end links must be oriented for attachment to the dead-
end screw and the chain support (double-chained only)
without any twist in the chain.
7. With the electrical cover off, connect the hoist to the power
supply. Be sure that the green ground wire is properly
grounded (See INSTALLATION, page 4).
8. Carefully jog the “UP” button and run the joined pieces of
chain into the hoist until about 15" of the new chain comes
out the other side.
9. DISCONNECT HOIST FROM POWER SUPPLY.
10. Remove the“C” link and the old chain. Remove the chain
stop from the old chain by prying off its retaining ring with a
flathead screwdriver. If attached, remove the old chain from
the side of the hoist by removing the dead-end screw and
washers (note placement of washers).
11. Attach the chain stop to the slack end of the new chain by
capturing the 12th link with the two stop halves positioned
with their tapered ends pointing towards the hoist. Slide the
sleeve over the halves and attach the retaining ring.If you
are not using a chain container, attach the slack end of the
new chain to the side of the hoist using the dead-end screw
and washers.With factory supplied hardware there should
be six washers between the hoist and chain link and two
washers between the chain link and screw head.DO NOT
allow twists in the chain.
12. Adjust the lower limit switch (See ADJUSTING LOWER
LIMIT, page 9).
Figure 3 — Limit Switch Assembly
Silver Nut
(Down)
Gold Nut
(Up)
Spring Guide
Plate
““XX””DDiimmeennssiioonn**
HHooiissttTTooppBBoottttoomm
CCaappaacciittyyHHooookkHHooookk
The chain used on this hoist has very carefully
controlled dimensions and has been heat treated. Do
not attempt to substitute other manufacturer’s chain.
Figure 2 — Hook
Inspection

13. Attach the bottom block on single-chained hoists using a
new load block screw (See Figure 23). On double-chained
hoists, feed the chain through the load block (welds
of the upstanding links will be in towards the sheave) and
fasten the end of the chain to the chain support using a
new chain support pin (See Figure 23).Be sure there are
no twists in the chain.
14. Adjust the upper limit switch (See ADJUSTING UPPER
LIMIT, page 8).
Chain Replacement with No Chain in Hoist
Refer to Figures 4 and 5.
1. DISCONNECT HOIST FROM POWER SUPPLY and move
hoist to a work table. Do not remove the electrical cover.
2. Lay the hoist on its side and remove the four screws that
attach the sheave housing to the gear housing
(See Figure 12, Ref. No.2).
3. Carefully pull the sheave housing and motor assembly loose
from the gear housing.
4. Turn the two hoist sections at right angles and remove the
chain guide screws and the nearest chain guide (Ref.No. 1,
Figure 5).
5. Remove the two chain guide plate screws (Ref.No.2) and
the nearest chain guide plate.Be careful not to lose the two
spacers that are between the chain guide plates.
NOTE: Inspect chain guides and load sheave for wear,
replace as needed.
6. Lay the new chain over the load sheave.Allow about 15" of
chain below the hoist on the slack end (See Figure 4). Be sure
the welds of the upstanding links are out away from the load
sheave and that proper orientation is observed for attachment
of the dead end.Also be sure the load hook assembly (if
already attached to the chain) is toward the center of the hoist
or to your right as you face the load sheave.
7. Replace the chain guide plate and the chain guide. Grease
the splined shafts that project from both the housing and
the motor.
8. Place the motor coupling on the splined shaft and carefully
fit the two hoist sections together. Be sure the dead-end nut,
the top hook and the chain support (double-chained hoists
only) are all in place.On single-chained hoists, the hook
shank goes in the center hole; on double-chained hoists, it
goes in the off-center hole (See Figure 4).Be careful not to
pinch any of the wiring.Turn the hoist on its side and replace
the four screws and tighten securely.
9. Follow steps 11 through 14 in the previous section, CHAIN
REPLACEMENT WITH CHAIN IN HOIST, to complete the
chain replacement procedure.
LIMIT SWITCH ADJUSTMENT
IMPORTANT: Before placing hoist in operation, check the limit
switch adjustment. Limit switches are provided to protect the
hoist against damage resulting from overtravel or to allow setting
the hook travel within the factory-set limits of travel.The standard
limit switch is designed for lifts of 50 ft or less on single-chained
hoists and 25 ft or less on the 2 ton, double-chained models.The
long lift limit switch allows for the maximum amount of lift, which
is 134 ft on 1/2 ton and under models, 143 ft on the 1 ton
models, and 71 ft on the 2 ton models.
The upper and lower limit switch adjusting nuts are color-coded
gold and silver respectively. Each limit nut has 10 slots for fine
adjustment, and the increment of adjustment is such that one
slot is equivalent to approximately one link of chain travel with
the standard limit switch. Movement of the limit switch nuts
toward or away from each other increases or decreases the
hook travel respectively.
Adjusting Upper Limit (Gold Nut)
Refer to Figure 3.
1. Suspend the hoist.For single chain models raise the load
block until there is a minimum clearance of 2" from the hoist
housing and the top of the block. Double chain models
require a minimum clearance of 1" from the chain support to
the top of the load block.
2. DISCONNECT HOIST FROM POWER SUPPLY and
remove the electrical cover.
3. With a screwdriver, pry the spring guide plate out of the slots
in the limit switch nuts.
4. Turn the slotted gold nut toward its limit switch until the
switch “clicks” then turn two slots farther.Release the spring
guide plate and be sure it slips back into the slots in both
limit switch nuts.Do not disturb the silver slotted nut if it has
been set previously.
8
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P.O. Box 779
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Figure 5 — Chain Replacement with No Chain in Hoist
1
2
There are wires running through the hoist. Carefully
ease the hoist sections apart. Do not jerk them apart.
Single-chained
Hoist
Double-chained
Hoist
Chain Support
Figure 4 — Chain Replacement Diagram
TON TON
Dead-End
Screw
Slack End
Load End

9
Country Club Road
P.O. Box 779
Wadesboro, NC 28170 USA
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Adjusting Lower Limit (Silver Nut)
Refer to Figure 3.
1. Suspend the hoist.Carefully lower the load block to a point
where the slack-end loop of the chain hangs down 6" or
more from the hoist housing (or the limit desired in any
particular application allowing the minimum 6").There
should be a minimum clearance of 1½" between the chain
stop and bottom of hoist.
2. DISCONNECT HOIST FROM POWER SUPPLY and
remove the electrical cover.
3. With a screwdriver, pry the spring guide plate out of the slots
in the limit switch nuts.
4. Turn the slotted silver nut toward its limit switch until the
switch “clicks,” then turn two slots farther. Release the spring
guide plate and be sure it slips back in the slots in both limit
switch nuts.Do not disturb the gold slotted nut if it has been
set previously.
Check Both Upper and Lower Limits
1. Connect the hoist to the power supply. Be sure the green
ground wire is properly grounded (See Installation 3-b,
page 5).
2. Check load hook direction (See Installation 3-c, page 5).
3. Carefully raise load block to upper limit and observe if it
stops automatically at desired level.Do not allow load block
to run into hoist housing — this will damage the hoist.
Maintain a minimum clearance of 2" from the hoist housing
and the top of the load block on single-chained models and
1" from the chain support to the top of the load block on
double-chained models.
4. Carefully lower load block to lower limit and observe if it
stops automatically at the desired level.Do not allow slack-
end loop of chain to become taut against hoist housing.This
will damage the hoist.There should be a minimum clearance
of 1½" between the chain stop and the bottom of the hoist.
5. If upper and lower limits operate satisfactorily, hoist is ready
for use.If they are not as desired, repeat adjustment.
BRAKE
Properly adjusted, this brake will release promptly when
energized.It is capable of both smoothly stopping and securely
holding the rated capacity of the hoist.If the hoist develops
either undesirable over-travel after the pushbutton is released
(this condition is most noticeable in the lowering direction) or
hesitates to lift the load promptly when the pushbutton is
depressed (this condition is most noticeable in the hoisting
direction), the brake should be adjusted.
Brake Adjustment
Refer to Figure 6.
1. DISCONNECT HOIST FROM POWER SUPPLY and
remove the electrical cover.
2. With reference to Figure 6, the gap between the brake
armature “A” and the field “B”should be checked.The
correct gap is 0.015".Adjustment should not be necessary
until gap reaches 0.040".
3.Adjust the gap using a 9/16" socket on the 3 locknuts “F”.
Check with a feeler gauge to be sure the gap is the same on
both ends of the solenoid.
4. Adjustment is now complete and the brake properly set.
Replace the electrical cover, reconnect the power supply,
and check hoist brake action.
HOIST CONTROLS
Both the pushbutton and the reversing contactor are
mechanically interlocked to prevent shorting the circuit and
causing serious damage.As part of maintenance, always
check for proper closure of contact points as well as for burned
contacts.If replacement is necessary, see Figures 16, 17, 18,
and 19 for replacement parts.
WIRING
Refer to Figures 9A, 9B, 9C & 9D.
Single-phase units (115/230V) are shipped wired for 115V
and the 1-speed, 230/460V-3 phase units are wired for 460V
unless otherwise specified when ordered.Hoists wired for
other voltages and 2-speed units are single voltage only.
Conversion of dual-voltage hoists to either the higher or lower
voltage can be done simply and quickly as follows:
1. DISCONNECT HOIST FROM POWER SUPPLY and
remove the electrical cover.
2. Each dual-voltage hoist has a terminal block assembly for
the interconnection of the electrical components of the hoist.
To convert the voltage, reconnect the leads to the terminal
blocks according to the wiring diagram located inside the
electrical cover or Figures 9A, 9B, 9C and 9D.
DO NOT move any wires or make any changes to the
electrical circuit except at the terminal block assembly.
Tug on wires to ensure they are securely connected.
3. After converting the voltage, recheck phasing and limit
switch operation (See INSTALLATION 3-c & 5, page 5).
IMPORTANT: Always refer to the wiring diagram located on
the inside of the electrical cover or Figures 9A, 9B, 9C and 9D
when performing electrical repairs.Make sure all connections
are secure and check for damaged insulation.It is also
imperative that the power circuit has conductors of adequate
size (SeeTable 5).
Figure 6 — Brake Assembly
Gap
Be sure the bottom of the armature does not bear
against the splined adapter “H”. As adjustments are
made, the built-in clearance will be reduced. When
this clearance is gone REPLACE BRAKE DISCS.
Minimum allowable disc thickness is .162".
If the wires running to the limit switches are ever
disconnected for any purpose, be sure to replace
wires in accordance with the correct wiring diagram
(See Figures 9A, 9B, 9C & 9D).
F
G
X
B
E
AX
D
H
C

LUBRICATION
Refer to Figure 11.
Proper lubrication is necessary for a long and relatively trouble-
free hoist operation.Refer to the following and the
RECOMMENDED LUBRICATION SCHEDULE for lubrication
points, type of lubricant, and frequency of lubrication.
Load Chain
Clean the load chain with acid-free solvent and coat with SAE
90 gear oil.Wipe excess oil to prevent dripping. Never apply
grease to the chain.
Gearing
The gear case of this hoist is filled at assembly with
approximately 1½ pints of SAE 90 EP gear oil. Check oil level
by removing the oil level check plug from the side of the hoist.
With the hoist hanging level, gear oil should be even with the
hole.Change oil periodically depending on the severity of the
application and the environmental conditions (at least every
200 hours of run time).
Bearings
All bearings except hook and idler sheave bearings are
lubricated at the factory and should not require additional
lubrication. Noisy or worn bearings should be replaced.
Limit Switch Shaft
Remove any dirt accumulation and spray with a general
purpose lubricant.
Hook Bearing
Apply a few drops of SAE 30 gear or motor oil around the edge
of the bearing.
Idler Sheave Bearing (Bushing)
Disassemble load block and apply a light coat of NLGI #2
grease, or equivalent, inside of bearing.
HOIST REPAIRS
1. For major repairs or when the hoist is to be sectioned in the
suspension area, it will be necessary to move the hoist to a
workbench or table.
2. For repairs which can be done by removing the electrical
cover only, the hoist need not be moved.Lowering the hoist
to a convenient working level is desirable.
NOTE: If you do not have an experienced mechanic to do your
repair work, we recommend that you send your hoist to an
approved service station for repairs. Use authorized repair
parts only.
The following repair instructions will help you in understanding
repair procedures, when related to the Replacement Parts
List starting on page 18. For clarity these are broken down
into areas.
Electrical Parts and Brake
1. Refer to Figures 16 and 17. Remove the cover to access the
controls.Single-phase models also have a starting switch and
capacitor mounted on the motor as shown in Figure 13.The
terminal blocks and end clamps snap off of the rails on the
plate using a small screwdriver. DO NOT SLIDE THE END
CLAMPS.
The reversing contactor can be slid off the rail, but it must be
snapped on.Where the contactor fits the rail, one side has
springs or pads that apply pressure against the edge of the
rail.By pressing against that side at the base of the contactor,
you can snap the part on or off using a rotating action. Note
the numbers that label the terminals on the contactor and
orient the part as shown in Figures 9A-9D. Single-phase
contactors have a small jumper that is not present on the
3-phase (note the 3 and 5 terminals on the reversing
contactor in Figure 9A).
2. Remove the electrical panel by removing the stand-off
screws (See Figures 16 & 17).The limit switch and brake are
now accessible as shown in Figure 7.
3. Remove the transformer bolted to the back of the panel plate
if it requires replacement.
4. Refer to Figure 15 to disassemble the brake. See BRAKE
ADJUSTMENT on page 9 to properly set the brake.
5. Refer to Figures 20 and 21 to disassemble the limit switch.
See LIMIT SWITCH ADJUSTMENT on page 8 to properly
set the upper and lower limits of travel.
6. Refer to Figures 18 and 19 for repairs on the pushbutton
station.Also refer to the wiring diagram inside the electrical
cover or Figures 9A, 9B, 9C and 9D for wiring instructions.
Motor
Refer to Figures 12, 13 and 14.
The hoist motor is located on the opposite end to that of the
electrical parts, but the two are tied together with electrical
leads running through the housing.
1.If it is necessary to replace or repair the motor,
DISCONNECT THE HOIST FROMTHE POWER SUPPLY
and remove the electrical cover.
2. Loosen the screw clamps on the terminal blocks and
reversing contactor to disconnect the motor leads
(See Figures 16 and 17).
3. Remove the four motor mounting bolts attaching the motor
to the housing.It will come loose at the motor coupling.
4. Inspect the motor coupling, motor shaft and all the bearings.
Replace as necessary.
5. Install new or repaired motor according to the wiring diagram
located inside the electrical cover or Figures 9A, 9B, 9C
and 9D.
10
Country Club Road
P.O. Box 779
Wadesboro, NC 28170 USA
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Figure 7 - Electrical Panel Removed
Remove load and disconnect hoist from power supply
before starting to do any repairs or to take any
sections apart.

11
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P.O. Box 779
Wadesboro, NC 28170 USA
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Gearing
Refer to Figures 8, 12 and 22.
As disassembly is extensive for gearing, disconnect the hoist
and move it to a workbench.
1. Remove the electrical cover.
2. Remove the electrical panel.
3. Remove the brake assembly and the limit switch assembly.
4. Drain the oil from the gearbox.
5. Remove the four screws that attach the gearbox cover to the
gear housing and remove the gearbox cover.The limit switch
drive shaft will come along with the cover.
6. Inspect gears for broken or severely worn teeth and inspect
all bearings.Replace as necessary.The overload slip clutch
is factory calibrated and must not be disassembled or
readjusted.
7. Reassemble in reverse order of disassembly, making sure
that the gasket is in place and in good condition.Coat gasket
with Permatex®or other gasket cement.Extreme care should
be taken to avoid damage to oil seals.
8. Check all wire terminals to be sure that they are properly
seated and in accordance with the correct wiring diagram.
Before placing the hoist back into service, check the brake
adjustment and limit switch settings.
Suspension
Refer to Figures 12 and 22.
The hoist sections must be separated at the top hook line in
order to inspect the load sheave and chain guides.See
CHAIN REPLACEMENT WITH NO CHAIN IN HOIST, page 8.
While this section is apart, check the following:
• Load Sheave
• Chain
• Chain guides and plates
• Bearings
• Chain support (on 2 ton models)
Replace parts as necessary including screws, lockwashers,
etc.When reassembled, recheck the limit switch settings. See
LIMIT SWITCH ADJUSTMENT, page 8.
Figure 8 - Assembled Gearing
Maximum Length of Power Cord in Feet
HP Voltage 14 AWG 12 AWG 10 AWG 8 AWG
(1-Phase)
Table 5 - Recommended Conductor Sizes for 1-Phase Hoists
1/4 115V 75 120 190 300
230V 350 560 900
POWER CORD PRECAUTIONS WITH 1-PHASE HOISTS
Electric hoists require a sufficient power supply. It is especially important with single-phase voltage to ensure that the
conductors running to the hoist from the power source are adequate in size to handle the power requirements of the hoist.
Inadequate power cables and branch circuits will cause low voltage, high amperage, damage to the hoist, and potential fire
hazards.Such problems can be minimized by using 230V power on 115/230V hoists.The following are recommendations for the
conductor gage size depending on the length, horsepower, and voltage.
1 115V 0 30 50 75
230V 120 190 310 490
1/2 115V 40 60 100 150
230V 200 330 520 810
Do not disassemble or readjust the clutch, or replace
it with a clutch assembly from another hoist. Doing so
will void the warranty and may create an unsafe
condition. If replacement is needed due to wear or
loss of adjustment, always use a new clutch assembly.

12
Country Club Road
P.O. Box 779
Wadesboro, NC 28170 USA
TEL: [phone]
FAX: [phone]
TROUBLE SHOOTING
Always disconnect unit from the power supply system before
removing hoist covers or the back cover of control station.
Failure to follow proper lockout/tagout procedures may
present the danger of electrical shock.
TO AVOID INJURY:
Disconnect power and lockout/tagout disconnecting
means before removing cover or servicing this
equipment.
1. Limit switch not operating 1. Check adjustment (See LIMIT SWITCH ADJUSTMENT, page 8). Check connections against wiring diagram.
Tighten loose connections or replace.
2. Brass limit switch nuts not moving on shaft 2. Check for stripped threads or bent nut guide.
3. Hoist reversing contactor malfunctioning 3. Remove electrical cover and check reversing contactor.
Hook fails to stop at end of travel
1. Power failure in supply lines 1. Check circuit breakers, switches and connections in power supply lines.
2. Wrong voltage or frequency 2. Check voltage and frequency of power supply against the rating on the nameplate of the motor.
3. Improper connections in hoist or pushbutton 3. Check all connections at line connectors and on terminal block. Check terminal block on dual voltage hoists for
station proper voltage connections.
4. Brake does not release 4. Check connections to the solenoid coil.Check for open or short circuit. Check for proper adjustment (See BRAKE
ADJUSTMENT, page 9).
5. Faulty hoist reversing contactor 5. Check coils for open or short circuit.Check all connections in control circuit.Check for burned contacts.
Replace as needed.
Hoist does not respond to pushbutton
1. Hoist overloaded 1. Reduce load to within rated capacity of hoist.
2. Brake not holding 2. Check brake adjustment (See BRAKE ADJUSTMENT, page 9).It may be necessary to replace discs.
Hook does not stop promptly
1. Three phase reversal 1. Reverse any two wires (except the green ground wire) at the power source (See INSTALLATION 3c, page 5).
2. Improper connections 2. Check all connections against wiring diagram.
Hook moves in wrong direction
1. “DOWN”circuit open 1. Check circuit for loose connections.Check “DOWN” limit switch for malfunction.
2. Broken conductor in pushbutton cable 2. Check each conductor in the cable.If one is broken, replace entire cable.
3. Faulty hoist reversing contactor 3. Check coils for open or short circuit.Check all connections in control circuit.Check for burned contacts.
Replace as needed.
4. Loose screw clamps 4. Ensure that screw clamps are tightened on the terminal blocks and reversing contactor.
Hook raises but will not lower
1. Hoist overloaded 1. Reduce load to within rated capacity of hoist.
2. Low voltage 2. Determine cause of low voltage and bring up to within plus or minus 10% of the voltage specified on the motor.
Measure voltage at the hoist reversing contactor while lifting a load.
3. “UP” circuit open 3. Check circuit for loose connections.Check “UP”limit switch for malfunction.
4. Broken conductor in pushbutton cable 4. Check each conductor in the cable.If one is broken, replace entire cable.
5. Faulty hoist reversing contactor 5. Check coils for open or short circuit, check all connections in control circuit.Check for burned contacts.
Replace as needed.
6. Faulty capacitor (single phase hoist only) 6. Check starting capacitor on motor.Replace if necessary.
7. Worn overload limiting clutch 7. Replace overload clutch assembly.
8. Loose screw clamps 8. Ensure that screw clamps are tightened on the terminal blocks and reversing contactor.
Hook lowers but will not raise
––– Probable Cause ––– ––– Remedy–––
1. Hoist overloaded 1. Reduce load within rated capacity of hoist.
2. Motor brake requires adjustment 2. Check motor brake adjustment (See BRAKE ADJUSTMENT, page 9).
3. Worn overload limiting clutch 3. Replace clutch.
4. Low voltage 4. Determine cause of low voltage and bring up to within plus or minus 10% of the voltage specified on the motor.
Measure voltage at the hoist reversing contactor while lifting a load.
5. Faulty SINPAC®starting switch or start capacitor 5. Replace faulty component.
(single phase hoists only)
Hoist hesitates to lift when energized
1. Excessive load 1. Reduce load to within rated capacity of hoist.
2. Low voltage 2. Determine cause of low voltage and bring up to within plus or minus 10% of the voltage specified on the motor.
Measure voltage at the hoist reversing contactor while lifting a load.
3. Extreme external heating 3. As the ambient temperature rises towards the 130°F limitation of the unit, frequency of the hoist operation must be
limited to avoid overheating of the motor. See ADVERSE ENVIRONMENTAL CONDITIONS, page 4.
4. Frequent starting or reversing 4. Excessive inching, jogging or reversing should be avoided since this type of operation will drastically shorten the life
of motor, contactor and brake.
5. Brake dragging 5. Check brake adjustment (See BRAKE ADJUSTMENT, page 9).
Motor overheats

13
Country Club Road
P.O. Box 779
Wadesboro, NC 28170 USA
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Figure 9A — Wiring Diagram for 115/230V - 1 Phase Models
TROUBLE SHOOTING CONTINUED
1. Brake needs adjustment 1. See BRAKE ADJUSTMENT, page 9.
2. Broken shading coil on brake frame 2. Replace shading coil or complete brake frame assembly.
Motor brake“buzz” (anytime hoist is running)
1. Brake needs adjustment 1. See BRAKE ADJUSTMENT, page 9.
2. Low voltage 2. Ensure that the voltage at the reversing contactor is within ±10% of the nominal voltage while lifting a load.
Motor brake noise or chatter (while starting hoist)
1. Hoist overloaded 1. Reduce load to within rated capacity of hoist.
2. Brake dragging 2. Check for proper brake adjustment or other defects.
3 Low voltage 3. Ensure that the voltage at the reversing contactor is within ±10% of the nominal voltage while lifting a load.
4. Overload limiting clutch intermittently slipping 4. Replace overload clutch assembly.
Lack of proper lifting speed

14
Country Club Road
P.O. Box 779
Wadesboro, NC 28170 USA
TEL: [phone]
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Figure 9B — Wiring Diagram for 1-Speed, 230/460V - 3 Phase Models
Figure 9C — Wiring Diagram for 1-Speed, 208V, 380V, 575V - 3 Phase Models
* Factory supplied diagrams will be numbered beginning with 985 for 575V, 987 for 208V,
and 988 for 380V.

15
Country Club Road
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Wadesboro, NC 28170 USA
TEL: [phone]
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Figure 9D — Wiring Diagram for 2-Speed, 3 Phase Models
* Factory supplied diagrams will be numbered beginning with 983 for 230 or 460V, 985 for 575V, 987 for 208V,
and 988 for 380V.

INSPECTION AND MAINTENANCE CHECK LIST
ELECTRIC POWERED OVERHEAD CHAIN HOIST
Type of Hoist ___________________________________________________________ Capacity (Tons) _________________________________________________
Location _______________________________________________________________ Original Installation Date _______________________________________
Manufacturer___________________________________________________________ Manufacturer’s Serial No. _______________________________________
Item Frequency of Inspection Possible Deficiencies OK Action
Frequent Periodic Required
Daily Monthly 1-12 Mo.
Operating Controls * * * Any deficiency causing improper operation
Limit Switches * * * 1. Any deficiency causing improper operation
2. Pitting or deterioration
Brake Mechanism * * * 1. Slippage or excessive drift
2. Glazing, contamination or excessive wear
Hooks * * * Excessive throat opening 15% bent or twisted more than 10
degrees, damaged hook latch, wear, chemical damage,
worn hook bearing. Cracks (use dye penetrant, magnetic or
other suitable detection method)
Suspension Lug (if used) * * * Cracks, excessive wear or other damage which may impair the strength of the lug. Cracks (use dye penetrant,
magnetic particle or other suitable detection method)
Chain * * * Inadequate lubrication, excessive wear or stretch, cracked,
damaged or twisted links, corrosion or foreign substance
Hook and Suspension * Cracks, bending, stripped threads
Lug Connections
Pins, Bearings, Bushings * Excessive wear, corrosion, cracks, distortion
Shafts, Couplings
Nuts, Bolts, Rivets * Looseness, stripped and damaged threads, corrosion
Sheaves * Distortion, cracks, and excessive wear.
Build-up of foreign substances
Housings, Load Block * Cracks, distortion. Excessive wear, internal build-up of
foreign substances
Wiring and Terminals * Fraying, defective insulation
Hoist Reversing
Contactor, other Electrical * Loose connections, burned or pitted contacts
Apparatus
Supporting Structure and Trolley * Damage or wear which restricts ability to support
(if used) imposed loads
Nameplates, Decals, *Missing, damaged or illegible
Warning Labels
NOTE: Refer to Maintenance and Inspection Sections of the Hoist-Maintenance Manual for further details.
FREQUENCY OF INSPECTION
Frequent — Indicates items requiring inspection daily to monthly.Daily inspections may be performed by the operator if properly designated.
Periodic — Indicates items requiring inspection monthly to yearly. Inspections to be performed by or under the direction of a properly designated period.The exact
period of inspection will depend on frequency and type of usage. Determination of this period will be based on the user’s experience.It is recommended
that the user begin with a monthly inspection and extend the periods to quarterly, semi-annually or annually based on user’s monthly experience.
Figure 10A — Recommended Inspection and Maintenance Check List
NOTE: This inspection and maintenance check list is in accordance with our interpretation of the requirements of the Safety
Standard for Overhead Hoists ASME B30.16.It is, however, the ultimate responsibility of the employer/user to interpret and
adhere to the applicable requirements of this safety standard.
16
Country Club Road
P.O. Box 779
Wadesboro, NC 28170 USA
TEL: [phone]
FAX: [phone]

17
Country Club Road
P.O. Box 779
Wadesboro, NC 28170 USA
TEL: [phone]
FAX: [phone]
INSPECTOR’S REPORT
ITEM REMARKS (LIST DEFICIENCIES AND RECOMMENDED ACTION)
Inspector’s Date
Signature Inspected Approved by Date
Figure 10B — Recommended Inspector’s Report
NOTE: All bearings except hook and idler sheave bearings are prelubricated and sealed.
(*) This lubrication schedule is based on a hoist operating in normal environment conditions. Hoists operating in adverse
atmospheres containing excessive heat, corrosive fumes or vapors, abrasive dust, etc., should be lubricated more frequently.
Figure 11 — Recommended Lubrication Schedule
RECOMMENDED LUBRICATION SCHEDULE*
YALE ELECTRIC POWERED CHAIN HOIST
PAGE AND COMPONENT TYPE OF LUBRICANT TYPE OF SERVICE AND
REFERENCE NO. FREQUENCY OF LUBRICATION
HEAVY NORMAL INFREQUENT
Pages 32 & 33 Load Chain SAE 90 gear oil Daily Weekly Monthly
Ref. No. 18
Pages 30 & 31 Gearing SAE 90 extreme pressure (EP) gear oil At periodic inspection (see Figure 12A)
Pages 28 & 29 Limit Switch Shaft Yale Dem-Kote No.5X628 multi- Monthly Yearly Yearly
Ref.Nos.9 & 7 purpose oil or general purpose spray
Pages 32 & 33
Ref. No. 38, 50 Load Hook Bearing SAE 30 gear oil or motor oil Weekly Monthly Yearly
Stock No. 4ZF46
Pages 32 & 33 Idler Sheave Bearing NLGI #2 — multipurpose lithium At periodic inspection (see Figure 12A)
Ref. No. 44 (Bushing) Assembly base bearing grease

18
Figure 12 - Basic Hoist
3
13
15
16
7
2
14
1
4
6
817
9
11
5
10
Ref Description Part Qty Ref Description Part Qty
No. No. No. No.
1 Motor — 1
(See Figures 13 & 14)
2 Sheave Housing Screw H2978P 4
3 Sheave Housing
1/2 Ton & Under JL33 1
1 & 2 Ton JL39 1
4 Gear Housing
1/2 Ton & Under JL35 1
1 & 2 Ton JL44 1
5 Gear Case Gasket JL560 1
6 Gearbox Cover JL34 1
7 Electrical Cover Gasket JL563 1
8 Electrical Cover JF36-6 1
9 1/4" Spring Lockwasher H4062P 1
10 1/4-20UNC X 3/4" Screw H1106P 1
11 10-24UNC X 1/2" Screw H2970 2
12 Top Hook Assembly w/ Latch
Rigid Hook (std.) 3M205A02S 1
†Swivel Hook 3M205A01S 1
13 Latch Kit Assembly 4X1305 1
14 Hook Hole Cover JF277-1 1
15 Suspension Lug* 50KG84 1
16 Yale Decal YJL677 2
17 Capacity Decal
250 lbs. YJL675-1 1
1/4 Ton YJL675-2 1
1/2 Ton YJL675-3 1
1 Ton YJL675-4 1
2 Ton YJL675-5 1
▲▲Plain Trolley (Lug Mounted)
1 Ton & Under 09292 1
2 Ton 09293 1
(Also requires item 15)*
▲▲Nylon cover
† 1/8 Ton 08770W 1
† 1/4 Ton 08771W 1
† 1/2 Ton 08772W 1
† 1 Ton 08773W 1
† 2 Ton 08774W 1
Parts List for Basic Hoist
(▲▲) Not Shown
(†) Optional
* Suspension lug is an option forYEL*TH Models and standard forYEL*PT Models.
12

19
Figure 13 - Hoist Motor, 115/230V - 1 Phase
Parts List for Hoist Motor, 115/230V - 1 Phase
10
1
6
13
12 2
3
8
14
9
75
11
4
14
†
† Refer to the motor nameplate for part number, voltage,
full load amperage, horsepower, and other motor
information.
1 Hoist Motor
1/4 hp, 115/230V-1Ph 861JL11 1
1/2 hp, 115/230V-1Ph 861JL12 1
1 hp, 115/230V-1Ph 861JL14 1
2 Stator Assembly * 1
3 Rotor Assembly * 1
4 End Shield JL021209-20 1
5 Rear Bearing 500K3 1
6 Front Bearing 732012C 1
7 Shim Washer JL4301-01 1
8 Capacitor
1/4 & 1/2 hp JL810-7 1
1 hp JL810-4 1
9 SINPAC®Starting Switch 839J2 1
10 Capacitor/Start Switch Cover JL3108-03 2
11 Gasket JL564 1
12 Thru Bolt
1/4 & 1/2 hp JL003801-41 4
1 hp JL003801-19 4
13 #10 Spring Lockwasher H4082P 4
14 8-32UNC X 5/16" Screw H2751 3
Ref Description Part Qty Ref Description Part Qty
No. No. No. No.
* Not available as an individual part.