Instruction Manual and Safety Instructions
for Owners (Operators)（No.2）
Chain lever hoist

Elephant lever model YA/YAⅢ(Automatic free chaining type)

Rated load : 0.8t to 9t(1,763 to 19,841lbs)
Model No. :Serial Number :Date of initial use :※The above information needs to be ﬁlled in by the purchaser.

WARNING
Owners (operators) are required to completely understand theinstallation, operation, maintenance and inspection of theequipment described within this instruction manual prior touse. Failure to understand or comply with the contents of thisManual may result in property damage, serious injury or
death.
●Thank you very much for your purchase of Elephant products.
●Before using Elephant lever hoists, please read this instruction manual carefully toensure that you fully understand the product and its proper use.
●Please store this instruction manual securely as it is required for maintenance,
inspection, disassembly and assembly of the product.

ELEPHANT CHAIN BLOCK CO.,LTD.

Index
1. Safety Information and Warnings
1.1 Terminology
1.2 Restrictions on the use of this Equipment are as follows :1.3 Warning Tags, Labels
2.Regarding the personnel operating and using lever hoists
2.1 Names of Parts
2.2 Unpacking the Product2.3 Speciﬁcations Table
2.3.1 YA Dimensions
2.3.2 YA Hook Dimensions
2.4 YAⅢ (with Overload Protection)
2.5 YAS Shipyard Hook
2.5.1 YAS Hook Dimensions
2.6 YAR Latch Lock Hook
2.6.1 YAR Hook Dimensions
3.Pre-Operational Procedures
3.1 Chain
3.2 Lever Hoist Installation
3.3 Pre-Operational Inspection and Test Run
4.Precautions for Use
4.1 General Handling
4.2 Precautions before Operation
5.Lever Hoist Operation
5.1 Regarding automatic free chaining operation
5.2 Adjustment of Load Chain Length (Free chaining Operation)
5.3 Lifting/Lowering Operation
5.4 Overload Protection (Model YAⅢ)
6. Inspection of lever hoists
6.1 Deﬁnition
6.2 General
6.3 Inspection Category
6.4 Pre-use inspections
6.5 Normal inspection
6.6 Routine Inspection
6.7 Load Chain Inspection
6.8 Operational Tests
6.9 Load Tests
6.10 Inspection, Testing Methods and Reference Values
7. Disassembly and Assembly Adjustment
7.1 Tools and Equipment/Consumables used forDisassembly/Assembly
7.2 Disassembly of Model YA
7.3 Assembly and Adjustment
7.4 Is this a malfunction!? First check for (commonly foundassembly errors)
Inspection records
Breakdown Schematics
Warranty
−1−

2
2
3
4
5
5
5
5
6
7
7
8
8
9
9
10
10
11
11
12
12
13
17
17
17
18
19
20
20
20
20
21
21
21
22
22
22
23
39
39
41
44
56
60
62
65

1. Safety Information and Warnings
1.1 Terminology

This Instruction Manual contains safety information necessary for owners responsible for the
installation, operation, maintenance and inspection of this Product, and for operators actuallyengaged in the operation of the Product. In order to fully comprehend the structure andoperation of this Product, please make sure that you understand the contents of thisInstruction Manual.
The safety information provided within this Instruction Manual includes circumstances possibly
leading to hazardous situations. The four terms Danger, Warning, Caution, and Notice areused to clearly indicate the seriousness of hazardous conditions.

DANGER

Danger indicates an imminently hazardous situation which, if
not avoided, may result in fatalities or serious injuries.

WARNING

Warning indicates a potentially hazardous situation which, if
not avoided, may result in fatalities or serious injuries.

CAUTION

Caution indicates a potentially hazardous situation which, if
not avoided, may result in minor or moderate injuries.

NOTICE

Notices cover implementation procedures which do not
require caution against personal injury.

DANGER●Never perform any operation that could result in a [DANGER] condition as
described in the Instruction Manual.

WARNING●Failure to comprehend and comply with the restrictions described within thisInstruction Manual may result in fatalities, severe injuries, or property damage.
●Owners and operators of this Equipment are prohibited from using the Equipment
for any purpose other than that for which it was originally intended, or make any
modiﬁcations that may impair the safety of this Equipment.
●This Equipment must not be used in a corrosive atmosphere such as acidic,
alkaline, steam, high temperature, toxic gas, salt water, etc.
●This Equipment must not be used in a condition where it is repeatedly subjected to
dynamic loads due to connecting it to other powered cranes or such load
application devices.
●This Equipment shall not be used for transporting, supporting, lifting, or lowering
people, or for transporting, supporting, lifting, or lowering loads above people. This
Equipment is not intended for transporting people in any way.

−2−

CAUTION●Owners and operators of this Equipment are required to record the model, serial
number, and initial date of use on the front cover of this Manual prior to using theEquipment.
●This Manual is intended to provide safety information on installation, operation,
maintenance, and inspection of the Equipment under normal operating conditions.
●If this Equipment is used in combination with other equipment, the supplier of theequipment combination concerned is responsible for ensuring compliance withapplicable industrial standards, federal, state, and local laws and regulations.
●Repair and maintenance of this Equipment shall be conducted only with parts
certiﬁed by ELEPHANT CHAIN BLOCK CO., LTD.

NOTICE●Owners and operators of this Equipment are responsible for ensuring that all
personnel engaged in the installation, operation, inspection, test, and servicing of
this Equipment suﬃciently comprehend the contents of this Manual, the applicableportions of ANSI/ASME B30.21 Lever Hoists standards, and OSHA regulations.
●Owners and operators are responsible for the installation, operation, inspection,
testing, and maintenance of this Equipment in accordance with the provisions of
the ANSI/ASME B 30.21 Lever Hoists standards and applicable OSHA
regulations.
●Owners and operators should contact the dealer of this Equipment if any item inthis Manual is unclear, or in case any additional information is necessary. Do notinstall, operate, inspect, test, or maintain this Equipment unless all uncertain
articles are clariﬁed accordingly.
●Designate a periodic inspection schedule for this Equipment in accordance with therequirements of ANSI/ASME B30.21 Lever Hoists, maintaining records of theinspections conducted.

1.2 Restrictions on the use of this Equipment are as follows :⑴This Equipment is to be used to pull or lift loads in horizontal or diagonal directions, or totighten loads.
⑵Do not use this Equipment to transport humans.
⑶Do not incorporate the Product as part of facility equipment or machinery.
⑷The Equipment is to be used within a temperature range of −40°
C to +60°
C (with humidity of
100%RH or less).
⑸Never use this Equipment in locations constantly subjected to wind, rain, or waves, or inlocations susceptible to salt damage, acid, alkali, etc., as this may cause damage to theEquipment and load chains.

−3−

1.3 Warning Tags, Labels

The warning tag indicated in Figure 1 below is attached to this Equipment upon shipment fromthe factory. Owners and operators of this Equipment are required to comprehend and comply
with all articles provided on warning tags and labels.
If tags are not attached on the no-load side of the load chain of the Equipment, procure tags
from your dealer and attach them accordingly. Read and follow all warnings attached to thisEquipment. (Tag is not shown actual size.)

WARNING

ADVERTENCIA●Indicates hazardous situations that, if not avoided, may
result in fatalities, serious injuries, or property damage.
●To avoid hazardous situations, perform thefollowing actions:●Indica situaciones peligrosas que, si no se evitan,
pueden provocar muertes, lesiones graves odaños materiales.
●Para evitar situaciones peligrosas, tome lassiguientes medidas :⑴ Read this Instruction Manual thoroughly andunderstand its contents.
⑵ Do not operate the Equipment controls except
by hand (do not use any tools or objects).
⑶ Never hang objects exceeding the rated load.
⑷ Never operate the Equipment by means ofpipes, etc. inserted into the Equipment or bystepping on the Equipment with your feet.
⑸ When hanging objects on the hook, be sure tohang in the correct position at the center of thehook. Do not use the Equipment if the loadcannot be hung in the correct position.
⑹ Do not remove caution labels or nameplates
from the unit or use the unit with caution labels
or nameplates that are illegible.
⑺ Never use load chains that are twisted, tangled,
cracked, that have abnormal meshing, or that areelongated or worn beyond the specified limits.
⑻ Do not use this Equipment if it is damaged oremits abnormal noises.
⑼ Do not use this Equipment as a slinging tool.
⑽ Do not apply lateral-wise loads to the neckportion of the hook.
⑾ Do not use this Equipment to support, lift, ortransport people.
⑿ Never suspend a load with the tip of the hook.
⒀ Never use Equipment with deformation ordamage on either the top or bottom hooks.
⒁ Never use Equipment with the latch for the
hook detached or damaged.
⒂ Do not modify this Equipment in any way.
⒃ Do not lift loads over people.
⒄ Do not operate the hoist when it is restrictedfrom forming a straight line from hook to hook in
the direction of loading.

⑴ Lea detenidamente este Manual de instrucciones
y asegúrese de que entiende su contenido.
⑵ No accione los mandos del equipo si no es con la
mano (no utilice ninguna herramienta u objeto).
⑶ No cuelgue nunca objetos por encima de lacarga nominal.
⑷ Para manejar el equipo, no introduzca nunca
tubos, etc., ni pise el equipo con los pies.
⑸ Cuando cuelgue objetos en el gancho,
asegúrese de hacerlo en la posición correcta en
el centro del gancho. No utilice el equipo si nopuede colgarse la carga en la posición correcta.
⑹ No retire las etiquetas de precaución ni las
placas de identificación de la unidad, ni utilice
la unidad si las etiquetas de precaución o las
placas de identificación son ilegibles.
⑺ No utilice nunca cadenas de carga que estén
torcidas, enredadas, agrietadas, que tengan unengranaje anormal o que se hayan alargado odesgastado más allá de los límites
especificados.
⑻ No utilice este equipo si está dañado o emite
ruidos anormales.
⑼ No utilice este equipo como una herramienta delanzamiento.
⑽ No aplique cargas laterales en la parte delcuello del gancho.
⑾ No utilice este equipo para sostener, levantar nitransportar personas.
⑿ No suspenda nunca una carga con la punta del gancho.
⒀ No utilice nunca el equipo si hay deformaciones
o daños en los ganchos superior o inferior.
⒁ No utilice nunca el equipo si el cierre delgancho está suelto o dañado.
⒂ No modifique este equipo de ningún modo.
⒃ No levamte cargas sobre personas.
⒄ No opere el polipasto cuando no pueda formar
una línea recta de gancho a gancho en la
dirección de la carga.

ELEPHANT CHAIN BLOCK CO., LTD.

ELEPHANT CHAIN BLOCK CO., LTD.
Figure 1−4−

2. Regarding the personnel operating and using lever hoists
2.1 Names of Parts
Top hook
Latch
Feed handle
Changeover knob
Chain on load side

Chain on no load side

Chain stop bolt

Chain stopper
Latch

Bottom hook

Figure 2

Minimum head room and liftLift⑴Check that the box labeling and product matches your order.
⑵Please conﬁrm the contents of the container.
⑶Make sure the product has not been damaged during transportation.
⑷Check that no accessories are missing or disengaged.
⑸Check the integrity and condition of screws, ﬁttings, etc. for allcomponents.

Minimum
head room

2.2 Unpacking the Product2.3 Speciﬁcations Table
Table 1 Speciﬁcations
Model
ＹＡ−80
ＹＡ−100ＹＡ−160
ＹＡ−320
ＹＡ−630
ＹＡ−900

Rated load
0.8t
1,763lbs
1t
2,204lbs
1.6t
3,527ｌｂｓ
3.2t
7,054ｌｂｓ
6.3t
13,889ｌｂｓ
9t
19,841ｌ
ｂｓ

Lift
5ft
5ft
5ft
5ft
5ft
5ft

Load chain
Diameter

Number ofchain falls

5.6mm
0.22in5.6mm
0.22in7.1mm
0.27in9mm
0.35in9mm
0.35in9mm
0.35in
−5−

1
1
1
1
2
3

Minimum
head room

Hand force

Self-weight

290mm

294N

6.0kg

11.41in

30kgf

13.22lbs

312mm

363N

6.2kg

12.28in

37kgf

13.66lbs

352mm

353N

9.2kg

13.85in

36kgf

20.28lbs

420mm

432N

15.5kg16.53in

44kgf

34.17lbs

564mm

441N

26.5kg22.20in

45kgf

58.42lbs

689mm

451N

42.0kg27.12in

46kgf

92.59lbs

2.3.1 YA Dimensions

a

b

d

Figure 3

YA−80
YA−100
YA−160e

YA−320︵c︶
Minimum headroomfg

YA−630

YA−900

Table 2Model
YA−80
YA−100
YA−160
YA−320
YA−630
YA−900

Rated load

a

b

c

d

e

f

g

0.8t

53mm

91mm

290mm

122mm

268mm

23mm

36mm

1,763lbs

2.08in3.58in11.41in

4.80in10.55in

0.90in1.41in

1t

53mm

91mm

312mm

122mm

268mm

28mm

43mm

2,204lbs

2.08in3.58in12.28in

4.80in10.55in

1.10in1.69in

1.6t

63mm

99mm

352mm

136mm

310mm

29mm

43mm

3,527ｌｂｓ

2.48in3.89in13.85in

5.35in12.20in

1.14in1.69in3.2t

82.5mm

104mm

420mm

180mm

360mm

36mm

53mm

7,054ｌｂｓ

3.24in4.09in16.53in

7.08in14.17in

1.41in2.08in6.3t

82.5mm

104mm

564mm

235mm

360mm

47mm

70mm

13,889ｌｂｓ

3.24in4.09in22.20in

9.25in14.17in

1.85in2.75in9t

82.5mm

104mm

689mm

300mm

360mm

73mm

85mm

19,841ｌｂｓ

3.24in4.09in27.12in11.81in14.17in

2.87in3.34in−6−

2.3.2 YA Hook Dimensions⑴Measure dimensions A, B, and C in Figure 4 below, and record the actual measurements at thetime of purchase. Although limit dimensions may also be determined based on the reference
standard values, it should be noted that there will be some dimensional errors due to theforging process.
⑵ If any of dimensions A, B, and C have reached the indicated limits, replace the hook with a
new one.
⑶The opening of the hook will expand in the event loads exceeding the rated load are applied tothe mouth, or if a concentrated load is applied to the tip section.
⑷Hooks with expanded openings lose their original strength and shock-absorbing capabilities,
and should be replaced upon exceeding the limit.
⑸Never reuse hooks with expanded openings straightened by heating or repairing. Suchattempts could cause extremely hazardous results. Hooks with ﬂaws 1 mm or more deep or
bent/twisted hooks should also be replaced.
Table 3Model
YA−80
YA−100
YA−160
YA−320
YA−630
YA−900

Rated load

A

B

C

0.8t

46.6mm19mm

15mm

1,763lbs

1.83in0.74in0.59in

1t

51mm

22mm

16mm

2,204lbs

2.00in0.86in0.62in

1.6t

55mm

26mm

21mm

3,527ｌｂｓ

2.16in1.02in0.82in

3.2t

67mm

35mm

28mm

7,054ｌｂｓ

2.63in1.37in1.10in6.3t

91.5mm46mm

34mm

13,889ｌｂｓ

3.60in1.81in1.33in9t

125mm

61.1mm

47.5mm

19,841ｌｂｓ

4.92in2.40in1.87in※Dimensions of the top and bottom hooks
are the same.
A

Exterior
dimensionsof the convex
sectionPurchased Product
Model

A

B

C

B

Figure 4

2.4※Record actual measurement value
at the time of purchase.

C

YAⅢ (with Overload Protection)※The Ⅲ in model YAⅢ indicates overload protection.
※Except for the presence of dedicated parts, model YAⅢ does not diﬀer from model YA. (Seebreakdown schematics)※Overload protection means that when attempting to hoist a load in excess of the rated load,
the lever will idle away (slip) preventing the load from being lifted. (The overload setting cannot
be altered.)
−7−

2.5

YAS Shipyard Hook

The S in model YAS indicates the attachment of a shipyard hook.
The Shipyard hook is a special hook to facilitate canning and butting
operations within the shipbuilding industry.
The shipyard hook has a reinforced tip, as compared to a normal hook.

WARNING⑴Read this Instruction Manual thoroughly and understand its
contents.
⑵Do not apply lateral-wise load to the neck portion of the hook.
⑶Make sure canning hooks are securely ﬁxed to the load and will notdislodge from the load.

2.5.1

YAS Hook Dimensions
Table 4Model
YAS−80
YAS−100
YAS−160
YAS−320

Rated load

A

B

C

0.8t

54.0mm

23.5mm19.0mm

1,763lbs

2.12in0.92in0.74in1t

54.0mm

23.5mm19.0mm

2,204lbs

2.12in0.92in0.74in1.6t

55.0mm

28.5mm23.0mm3,527lｂｓ

2.16in1.12in0.90in3.2t

70.2mm37.0mm28.0mm2.76in1.45in1.10in7,054lｂｓ※Dimensions of the top and bottom hooks are the same.

Purchased Product
Model

A

B

C

B
A

Figure 5※Record actual measurement value
at the time of purchase.

C

−8−

2.6

YAR・Latch Lock Hook

※The R in model YAR indicates a latch lock hooks.
Latch lock hooks are outward-opening, allowing easy removal ofslinging tools.
The hook will not open when under load.
The hook will not open unless the operator unlocks it even when noload is applied.

WARNING⑴Read this Instruction Manual thoroughly and understand its
contents.
⑵Do not apply lateral-wise load to the neck portion of the hook.
⑶Make sure the latch lock hooks are securely ﬁxed to the load andwill not dislodge from the load.

2.6.1

YAR Hook Dimensions

Model
YAR−80
YAR−100
YAR−160
YAR−320

Table 5

Rated load

A

B

C

0.8t

29.5mm

19.5mm14.0mm

1,763lｂｓ

1.16in0.76in0.55in1t

29.5mm

19.5mm14.0mm

2,204lｂｓ

1.16in0.76in0.55in1.6t

47mm

28.5mm24.0mm3,527lｂｓ

1.85in1.12in0.94in3.2t

52mm

39.0mm28.0mm7,054lｂｓ

2.04in1.53in1.10in※Dimensions of the top and bottom hooks are the same.

A

Purchased Product
Model

B

Figure 6A

B

C※Record actual measurement value
at the time of purchase.
C−9−3. Pre-Operational Procedures
3.1 Chain

WARNING⑴Make sure the chain stopper is attached to the second-to-last chain link on the no-load sideof the load chain.
⑵Before operating the equipment, make sure the load chain is not twisted or tangled. Hookfor 6.3t (2 falls) and 9t (3 falls) are multiple falls hook. Make sure the hooks are notreversed. Be sure to correct any problems before using this equipment. (Figure 7, Figure 8)

Figure 7

Twisted chains

Correctly oriented chain

Figure 8−10−

Twisted chain due toreversed hook

Do notoperateequipmentin thisstate!

3.2 Lever Hoist Installation

WARNING⑴Never install lever hoists without suﬃcient expertise in the equipment.
⑵Make sure the location of equipment installation has suﬃcient strength to support theequipment under load.
⑶When suspending a load from the hook, be sure to hang it in the correct position at thecenter of the hook.
⑷Never suspend loads from the tip of a hook.
⑸Never use the hoist with the hook working as a fulcrum (the suspended hook is shifted fromits vertical position).

CAUTION※Do not attach hooks in the manner illustrated in the ﬁgure
below (both up and down) as it is dangerous.

Suspended objects orslings are not hung in theproper position.

Correct usage
Suspend from theaxis of the hook.

The latch is not
functioning
properly.

Figure 9

The tip of the hook is notcapable of fully supporting
the load.

NOTICE⑴When installing the hoist outdoors, lubricate the load chain. After use, clean the lever, apply
lubricant, and store in a dry place.

3.3 Pre-Operational Inspection and Test Run

WARNING⑴Before use, check the chain sling, wire rope, sling and all other hoisting equipment for
appropriate rated load. Inspect all equipment for damage, replace it as needed with new
equipment, or have it repaired before use.
⑵Before operating this equipment, check the entire length of the chain and straighten any
twists.
⑶Measure the dimensions of the top and bottom hooks at the time of purchase, and record
the actual measurements.
⑷Make sure the model, serial number, and initial date of use for this equipment is recorded
accordingly at the time of purchase.
⑸Make sure the location of equipment installation has suﬃcient strength to support theequipment under load
−11−

3.3 Pre-Operational Inspection and Test Run (continued)

WARNING⑹Make sure the equipment has been installed correctly.
⑺Make sure all nuts, bolts, and cotter pin are suﬃciently secured in position.
⑻Understand the work to be done with the equipment and operate accordingly.
⑼Users are required to ensure this equipment has been safely installed and operated inaccordance with the applicable provisions of ANSI/ASME B30.21 Lever Hoists standard
and OSHA regulations, and that the maintenance and inspection requirements have been
met.
⑽Before operating this equipment, make sure no interfering objects are present within its
entire range of operation.

4. Precautions for Use
4.1 General Handling

DANGER⑴Individuals unfamiliar with the contents of the
instruction manual and caution nameplate must not
operate this product.
⑵Do not use this product to support, lift, or transport
people.
⑶Do not allow anyone to enter the area underneath orwithin the movement range of suspended loads.
Additionally, do not move the load above anyone.
(Figure 10)⑷Use this product within a temperature range of−40℃ to +60℃（with humidity of less than
100%RH）.
⑸Do not use this product in water.
⑹Never use this equipment in locations constantly
subjected to wind, rain, or waves, or in locations
susceptible to salt damage, acid, alkali, etc., as this
could cause damage to the equipment and load
chains.

Figure 10

WARNING⑴Only operators who have thoroughly read and fully understand the contents of this
instruction manual should carry out work related to inspection and repair of the equipment.
It is also necessary to understand the ANSI / ASME B30.21 and ANSI / ASME B30.10 and
related standards of ANSI / ASME. Use of this product without thorough understanding of
all relevant information is strictly prohibited.
⑵Those without an accurate understanding of its controls are not to operate this equipment.
⑶Those without an understanding of the proper operating procedures for attaching loads tothe top and bottom hooks are not to use this equipment.

−12−

WARNING⑷Operator are required to understand the adjustment, failure, and repair of this equipment.
Operators unable to stop operation and take corrective action in the event of a malfunction
are not to use this equipment.
⑸Operators should be attentive of potential malfunctions of the equipment which may require
adjustment or repair, and must stop operation and contact a supervisor immediately in theevent such a malfunction occurs.
⑹Individuals with restrictions in eyesight, ﬁeld of vision, reaction time, or manual dexterity are
not to operate this equipment.
⑺Individuals without suﬃcient bodily control, those with physical deﬁciencies, are emotionallyunstable, have a history of seizures, are prone to seizures, or are otherwise likely tooperate the equipment in a manner potentially hazardous to the operator or others are not
to operate this equipment.
⑻Operator under the inﬂuence of drugs, medical drugs, or alcohol are not to operate thisequipment.

NOTICE
Understanding of the hazard tags/labels and nameplate (tonnage) attached to the unit isrequired.
※From the provisions of the ANSI/ASME B30 standard:●Engineering functions of this equipment alone cannot mitigate all hazards, which include
hazards that can be mitigated by the operator's knowledge, experience, caution, and common
sense. In order to enhance awareness of the above, fully understand the contents of this
instruction manual and use the equipment safely.

4.2 Precautions before Operation

WARNING⑴Never suspend loads exceeding the rated
load.(Figure 11)⑵Do not use this equipment if it is damaged oremits abnormal noises.
⑶Never use load chains that are twisted,tangled, cracked, have abnormal meshing, orare elongated or worn beyond speciﬁedlimits.
⑷If attached with two or more load chains, do
not use this equipment if the bottom hook isin an abnormal state of passing through theload chains. (Figure 12)⑸Do not intrude into the area beneath the loador within the moving range of the load.
Additionally, do not move the load above
anyone.
⑹Never operate the hoist in such a manner as
to let the load drop even a slight distance.
⑺Never cut, splice, or weld the load chain.
⑻Do not operate the lever hoist if the loadcannot be suspended from the center
portion of the hook.
−13−

ive
essht
c
x
E eig
w

Figure 11

Figure 124.2 Precautions before Operation (continued)

WARNING⑼Do not use this equipment as a sling suspension
device. Also, do not use with the load chain
wrapped around the load.
⑽Never operate equipment by means of pipes,
etc. inserted into the Equipment or by steppingon the Equipment with your feet. (Figure 13)⑾Never apply loads exceeding the rated load ona single unit of this equipment when performing
two-hoist lifting. (Figure 14)⑿Never over-wind or over-lower loads.
⒀Never suspend a load with the tip portion of thehook. (Figure 15)⒁When suspending loads from the hook, neveroperate the hook in such a way that a lateralload is applied to either the top or bottom
hooks.
⒂Do not leave the load suspended for a longtime.
⒃Do not connect the grounding from welding
machines to the load chain. (Figure 16)⒄Never allow welding electrodes to come incontact with the load chain.
⒅Do not remove caution labels or nameplates
from the unit or use the unit with caution labels
or nameplates in an illegible condition.
⒆Do not use the product if the nameplate aﬃxed
to the main unit is illegible.
⒇Make sure that all personnel are clear of the
support load.
Do not allow sparks from welding, etc. into
come in contact with this equipment.
When lifting or moving a load, notify
surrounding workers.
Never install this equipment without suﬃcientexpertise in the equipment.
Make sure the location of equipment installation
maintains suﬃcient strength to support theequipment under load.

Figure 13

Both hoists arefor 1 ton loads

Figure 14

Building

Heat
generation

Grounding to building structure

Figure 15−14−

Figure 16

4.2 Precautions before Operation (continued)

WARNING
Do not allow anyone to ride on suspended loads.
Never use the lever hoist for human transport
purposes. (Figure 17)
Never reverse a suspended load without suﬃcientexpertise in doing so.
Do not suspend excessive loads.
When maintaining the load in a suspended condition
for a short period of time, be sure to leave the switch
pawls in the lifting position.
Never use the hoist or the hook to work as a fulcrum.
Do not use damaged or deformed top/bottom hooks.
Never use this equipment if the load chain is deformed
or damaged.
Do not operate the equipment with the load chain
lodged against a steel plate or other corners. (Figure18)
Do not operate the load chain by any means otherthan human power (do not use any tools or objects on
the controls).
Do not apply abrupt force to the load chain during idle
operation.
Suspend slings properly onto the hook.
During lifting, temporarily pause winding once either
the load chain or sling comes under tension.
Keep the lever hoist unit and load chain clean and freeof sand and other debris.
Make sure the lifting height is suﬃcient for theintended work.
Make sure the load chain is suﬃciently lubricated.
Do not modify this equipment in any way.
Do not use with the load chain wrapped around theload. (Figure 19)
Do not suspend the load chain directly from rope hookﬁxtures on trucks. Do not use the load chain as asuspension device. (Figure 20)

Figure 17

Figure 18

Truckplatform

Figure 19

Figure 20−15−

4.2 Precautions before Operation (continued)

WARNING
Do not hang hooks onto the rope hookﬁxtures of trucks in a manner subjecting theneck portion of hooks to strain when tying
down the cargo (could result in neckbreakage).
(Do not use hooks in a manner that it issubjected to lateral bending forces.) (Figure
21)
Instead, hook wire slings onto the rope hookﬁxtures ﬁrst, and then tie down the cargo.

Truckplatform

Figure 21

CAUTION⑴When operating this equipment, be sure to maintain a ﬁrm foothold, and otherwise ensure
safe working conditions (for performance of operations).
⑵Always check the brake function before using this equipment.
⑶Make sure the latch for the hook is properly attached. The latch helps prevent slings, chain
slings, and other slinging tools and loads from being released.
⑷Make sure all obstacles are removed from the vicinity of the load.
⑸Avoid shaking either the load or the hook.
⑹Make sure the hook is moving in the predetermined direction.
⑺Inspect this equipment periodically and replace any damaged or worn parts. Maintainrecords of the inspections.
⑻Never use other than genuine parts from the manufacturer of this equipment.
⑼When measuring applied loads, do not use the overload protection device as the measuring
instrument.
⑽Do not become distracted from the load during operation.
⑾Repairs of the equipment must only be done by qualiﬁed service technicians.
⑿After ﬁnishing operation of the hoist, wipe oﬀ any mud, water, and foreign matter, and apply
lubrication to the chain and hook.
⒀Never apply lubricants to the brake parts.
⒁Store the equipment in a dry location, protected from rain and dew.
⒂Always loosen the brake for storage, and never store the equipment with the brake in atightened condition.
※If the hoist is stored with the brake tightened, it will not be able to perform lowering
operations the next time it is used.
In this case, perform a lowering operation once to disengage the brake.
⒃When disposing of this equipment, disassemble it to prevent its reuse by others.

−16−

5. Lever Hoist Operation
5.1 Regarding automatic free chaining operation
Model YA lever hoists are equipped with an automatic free chaining operation system enabling
free chaining operation by simply switching the changeover knob in the absence of loads.
※Automatic free chaining operation enables the load chain to move freely by releasing thebrake when there is no load.

5.2 Adjustment of Load Chain Length (Free chaining Operation)

DANGER⑴Never select the free chaining operation when a load is applied to the equipment. Always
select it when there is no load.
⑵Do not touch the feed handle when lifting or lowering loads.

WARNING⑴Be sure to check that the changeover knob is set to the correct position.

To adjust the length of the load chain in
the absence of loads, perform the freechaining operation in the order shown in
Figures 22 to 24 below:⑴Set the changeover knob to N . Thechangeover knob is located beneaththe feed handle.

Top hook
Latch⑵Turn the feed handle leftward(counterclockwise) about 1/2 rotation.
⑶Slowly pull the load chain on the noload side (chain stopper side), thenslowly pull the load chain on the loadside (bottom hook side) to adjust theposition according to the work to be
performed.

Feed handle
Changeover knob
Chain onload side

Chain stop

Chain on no load side
Chain stopper

Bottom hook

−17−

Latch

Free chaining method⑴Setchangeoverknob toposition N .

UP

DOWN

N

Figure 22⑵Turn feed
handleleftward(counterclockwise)
about 1/2
rotation.

Pu

Pull

ll

Figure 23⑶Slowly pull load
chain on the noload side ( chain
stopper side) , thenslowly pull load
chain on the loadside ( bottom hookside) , adj usting theposition according
to the work to be
performed.

Figure 24

CAUTION⑴Do not abruptly pull on the load chain during free chaining operation.
⑵Pulling with excessive force causes the brake to engage, rendering the load chain
immobile. In such situations, readjustment is required.

5.3

Lifting/Lowering Operation⑴Set the hoist and adjust the load chain using free chaining operation to a height allowing foreasy suspension of the load on the bottom hook.
⑵Suspend the load on the bottom hook.
⑶Set the changeover knob to (UP), and apply load to the load chain.
(Rotate the feed handle clockwise to remove any slack or twist in the load chain.)⑷Clockwise rotation of the lever raises the load chain and the bottom hook.
⑸Set the changeover knob to (DOWN) and move the lever counterclockwise to lower the load
chain and the bottom hook.
⑹If the lever is heavy when lowering, apply force to the lever only at the beginning of operation.
⑺After tightening, be sure to set the changeover knob into the (UP) position.
⑻If the load chain does not move either upward or downward even when lifting/lowering withthe lever when no load or a light load is applied, operate while pulling on the load chain lightly
without a load. (This is not a malfunction)⑼When lifting or lowering, the brake will engage the moment the load is applied.
⑽When lifting, the mechanical brake rotates while in a tightened condition, immediately
supporting the load by means of pawls upon ceasing the lifting operation.
⑾When lowering, the mechanical brake is loosened corresponding to the amount of lever
operation, and the load chain is wound down, with the mechanical brake immediately
tightening to support the load when the lowering operation stops.
−18−

Free
chaining

UP

DOWN

Lifting

UP

DOWN

Lowering

UP

DOWN

UP

DOWN

N

N

N

Figure 25

Figure 26

Figure 27

WARNING⑴Make sure the location of equipment installation has suﬃcient strength to support theequipment under load.
⑵When performing two-hoist lifting, each unit involved in the suspension shall be individuallycapable of bearing the entire suspended load.
⑶Never over-wind or over-lower loads.
⑷Inspect the slings prior to hoisting. Some slinging methods may be extremely dangerous.
⑸Do not operate the feed handle when lifting or lowering.

CAUTION⑴Before lifting/lowering, make sure the hoist is not in free chaining operation, and thechangeover knob is set to the correct position.
⑵If the load chain does not descend upon performing the lowering operation under light loadconditions, lightly pull the chain on the load side.

5.4

Overload Protection (Model YAⅢ)

The overload protection device prevents loads in excess of the rated load from being lifted or
drawn by letting the lever idle away (slip). (The overload setting cannot be altered.)

DANGER⑴Do not lift loads exceeding the rated load.
⑵If overload protection is activated, stop the lifting operation immediately and unload theload. In such situations, lighten the suspended load or change the capacity of thisequipment.
⑶Do not adjust, modify, or disassemble the overload protection device.
⑷In case of problems with the overload protection device, replace the device.
⑸Do not use the overload protection device for unintended purposes including load
measurement.
−19−

6. Inspection of lever hoists
6.1 Deﬁnition
This inspection procedure is compliant with the provisions of the ANSI / ASMEB30.21 standard.
The following word deﬁnitions, considered important, are from ANSI / ASME B30.21 and are
relevant to the following inspection procedures:
Inspection criteria reﬂecting dimensional and geometrical characteristics are provided
separately.
●Normal Service
Form of maintenance to be performed on equipment operated with randomly distributed loads
within the rated load range and uniform loads of less than 65% of the rated load for 15% orless of the overall usage time.
●Heavy Service
Form of maintenance to be normally performed on equipment used under static loads
exceeding the level of normal service.
●Severe Service
Form of maintenance to be performed on equipment subjected to operations exceeding thelevel of normal or heavy services and exhibiting abnormal behavior.
●Personnel Competence
Personnel performing duties identiﬁed within this document shall meet the applicablequaliﬁcation criteria described in this document.
Additionally, those personnel are required to acquire abilities to perform the duties of theposition as determined by the employer or the employer's representative and, whereappropriate, to ensure competency based on education, training, experience, skills, andphysical ﬁtness.
●Qualiﬁed Person
To be in possession of a recognized degree or have certiﬁcate of professional standing in theapplicable ﬁeld, or extensive knowledge, training, and experience making one competent tosolve job-related problems.

6.2 General⒜All inspections are to be performed by designated personnel in accordance with therecommendations of the manufacturer and the requirements of this document. Defects
identiﬁed shall be investigated and determined by qualiﬁed personnel as to whether they
constitute a hazard and whether or not more detailed inspection or disassembly is required.
⒝Inspection frequency
Inspection intervals shall be determined by a qualiﬁed person based on the intended operating
conditions and the impact of such conditions on critical hoist components.

6.3 Inspection Category⒜Initial inspection: Hoists to be used for the ﬁrst time and hoists experiencing repairs andcomponents exchange shall be inspected in accordance with the routine inspection
requirements of Section 6.5.
⒝Pre-use inspection: A visual pre-use inspection, for which no records are required, shall be
performed at the beginning of each operation.
⒞Normal inspection: A visual inspection for which no records are required.
⑴Normal service: Monthly basis⑵Heavy service: Weekly to monthly basis⑶Severe service: Daily to weekly basis⒟Routine Inspection: A documented visual inspection to provide the basis for ongoingevaluation. Coded markings inscribed on the exterior of hoists are acceptable identiﬁcation inlieu of a record.
⑴Normal service: Annual basis⑵Heavy Service: Semi-annual basis⑶Severe service: Quarterly basis−20−

⒠Hoists not in use on a regular basis⑴Hoists unused for a duration of one month or more but less than one year shall be inspectedin accordance with the provisions of Section 6.5 prior to use.
⑵Hoists unused for a duration of one year or more shall be inspected in accordance with theprovisions of Section 6.6 prior to use.

6.4 Pre-use inspections
Minimum inspection requirements include the following items:⒜Proper operability and appropriate adjustment of the operating mechanism, and any abnormal
noise emission.
⒝Routine inspection of hooks in accordance with ASME B30.10. (item numbers 10-1.10.3 and10-2.10.3)⒞Application of load to the load chain without overall damage. Inspection items (refer to Section
6.7.)⒟Load sheaves, idle wheels⒠Proper installation of load chain terminal anchorage.
⒡Deformation, cracks, and/or other damage to the hoist unit and levers.
⒢Evidence of damage to the support structure

6.5 Normal inspection
Minimum inspection requirements include the following items:⒜Proper operability and appropriate adjustment of the operating mechanism, and any abnormal
noise emission.
⒝Routine inspection of hooks in accordance with ASME B30.10. (item numbers 10-1.10.3 and10-2.10.3)⒞Application of load to the load chain without overall damage. Inspection items (refer to Section
6.7.)⒟Load sheaves, idle wheels⒠Proper installation of load chain terminal anchorage.
⒡Deformation, cracks, and/or other damage to the hoist unit and levers.
⒢Evidence of damage to the support structure

6.6 Routine Inspection⒜Routine inspections can be performed at the location of usage, and disassembly of the hoist is
not necessary.
⒝Covers and other parts of the structure may be released or removed for inspection, but thecovers must be closed or replaced before the hoist is restored to its normal state.
⒞Minimum inspection requirements include the following items:⑴Items listed in section 6.5⑵Routine inspection of hooks, including latches, in accordance with ASME B30.10 Hooks(items 10-1.10.4 and 10-2.10.4)⑶Inspection for loose fasteners including rivets and bolts.
⑷Inspection for wear, corrosion, cracks, and distortion of structural parts.
⑸Damage and wear of load sheaves, idle wheels, etc.
⑹Inspection for traces of worn or oil-contaminated friction discs, worn pawls and ratchet
wheels, corroded, stretched or broken pawl springs due to the structure of the friction
brake.
⑺Inspection for damage to the support structure.
⑻One or more labels as required under provision ASME B30.21 21-1.1.4 to be intact andclearly visible.
⑼Inspection for deterioration, corrosion, cracks, damage, and deformation of load chain
terminal anchorage.
⑽Inspection for missing hoist mounts and hoist ﬁtting mounts.

−21−

6.7 Load Chain Inspection⒜Load chains should initially be inspected with the hoist suspended in a vertical position andsubjected to a load of approximately 50 pounds (23 kg), with the chain integrated into the
hoist.
⑴With the designated load applied, operate the hoist in both lifting and lowering directions,conﬁrming that the load chains and load sheaves operate to feed the chain smoothly out of
the load sheave.
⑵If the load chain is tangled, jumpy, or noisy, conﬁrm that the load chain is clean and properly
lubricated. If the problem persists, inspect the load chain and mating parts for wear, warping,or other damage.
⒝Load chains are to be inspected over their entire length for overall damage that may bedirectly hazardous, such as:⑴Visual inspection for melt damage, weld spatter, corrosion, and deformed links.
⑵Verify the smooth feed of load chains back and forth against the sprocket wheels during thelifting and lowering operation under load.
⑶Loosen the load chain and move adjacent links to one side, inspecting the contact points forwear.
When wear is evident or if elongation deformation is suspected, dimensional measurement of
the chain should be performed.
Refer to the section on inspection and inspection contents and standard dimensions of load
chains concerning the dimensional measurement of load chains.

6.8 Operational Tests
Newly manufactured hoists are tested by the manufacturer.
All hoists experiencing modiﬁcations or repairs, as well as previously used hoists that have notbeen operated within 12 months, are to be tested by, or under the direction of designatedpersonnel, to ensure compliance with the requirements of this instruction manual.
⒜All functions of the hoist are to be conﬁrmed with the hoist suspended under no load. (Somehoists require the application of their rated load or manual pulling on the hook to test thelowering action.)⒝After the no-load test, 100 pounds (46kg) per load chain should be loaded to conﬁrm thebraking control capability.

6.9 Load Tests⒜New hoists are tested by the manufacturer with a test load of at least 125% of the rated load.
⒝Hoists experiencing modiﬁcations, replacements or repairs to load-bearing components are to
be statically or dynamically load tested.
⑴The need for load testing of the hoist is to be determined by qualiﬁed persons.
⑵A written report of the test must be prepared and kept on ﬁle.
⑶The test load must not exceed 100% of the rated load of the hoist, or 125% of the rated loadof the hoist.
⑷Load chain replacement is speciﬁcally excluded from this load test. However, hoist operation
testing is to be conducted in accordance with the provisions of Section 6.8.
⒞The test location and hoisting method needs to be approved by a qualiﬁed person.

−22−6.10 Inspection, Testing Methods and Reference Values
Inspection/testing method and standard values are as follows:
Inspection and testing methods for YA parts (*Refer to the breakdown schematics for part numbers.)※Although details of inspection and limit dimensions are speciﬁed for respective parts, users should
determine the frequency of use and duration of service individually, replacing the necessary parts withnew parts or new products in order to prevent accidents and enhance the operational safety factor.
※Please note, some of the parts are forged and may have slight dimensional errors.
The following dimensions are limit values based on reference standard values.
Inspection item
(part name)part number
Top hook set（No.1）

MethodInspection/test details/standard values

Measures

Visualinspection,measurement

Inspect opening of the hook, hook thickness
and wear in vertical/horizontal dimensions
Inspect diameter of the top hook pin-hole for
elongation
Inspect the hook for bends, twists, damage,etc. and smooth hook rotation
Dimensions are not to exceed the reference
standard values.

Replace with a new part.

Table 6
Limit Value

Rated load

Position
Ａ：Between punches

0.8t

Ｂ：Hook thickness, vertical

1763lbs

Ｃ：Hook thickness, horizontal
Ｄ：Hole diameter, top hook pin
Ａ：Between punches

1t

Ｂ：Hook thickness, vertical

2204lbs

Ｃ：Hook thickness, horizontal
Ｄ：Hole diameter, top hook pin
Ａ：Between punches

1.6t

Ｂ：Hook thickness, vertical

3527lbs

Ｃ：Hook thickness, horizontal
Ｄ：Hole diameter, top hook pin
Ａ：Between punches

3.2t

Ｂ：Hook thickness, vertical

7054lbs

Ｃ：Hook thickness, horizontal
Ｄ：Hole diameter, top hook pin
Ａ：Between punches

6.3t

Ｂ：Hook thickness, vertical

13889lbs

Ｃ：Hook thickness, horizontal
Ｄ：Hole diameter, top hook pin
Ａ：Between punches

9t

Ｂ：Hook thickness, vertical

19841lbs

Ｃ：Hook thickness, horizontal
Ｄ：Hole diameter, top hook pin

Reference （ A dimension should notstandard
exceed actual measured value
valuesat the time of purchase）
46.6mm1.83in19.0mm0.74in15.0mm0.59in12.5mm0.49in51.0mm2.00in22.0mm0.86in16.0mm0.62in12.5mm0.49in55.0mm2.16in26.0mm1.02in21.0mm0.82in14.5mm0.57in67.0mm2.63in35.0mm1.37in28.0mm1.10in16.5mm0.64in91.5mm
3.60in46.0mm1.81in34.0mm1.33in16.5mm0.64in125.0mm
4.92in61.1mm2.40in47.5mm1.87in16.5mm0.64inB

Not to exceed dimension A
18.0mm0.70in14.2mm0.55in13.1mm0.51inNot to exceed dimension A
20.9mm0.82in15.2mm0.59in13.1mm0.51inA

Not to exceed dimension A
24.7mm0.97in19.9mm0.78in15.2mm0.59inNot to exceed dimension A

DC

33.2mm1.30in26.6mm1.04in17.3mm0.68inNot to exceed dimension A
43.7mm1.72in32.3mm1.27in17.3mm0.68inNot to exceed dimension A
58.0mm2.28in45.1mm1.77in17.3mm0.68inDimension A is not to exceed dimension A value.
Actual measured values of dimensions B, C, and D are not to indicate
wear of 5% or more.

−23−

Figure 28Inspection item
(part name)part number
Safety latch set（No.2）

MethodInspection/test details/standard values

Visualinspection,measurement

Conﬁrm engagement with the hook, therepulsive force of the spring, and if there isany damage or deformation.

Measures
Replace with a new part.

Table 7
Rated load

0.8t
1763lbs

1t
2204lbs

1.6t
3527lbs

3.2t
7054lbs

6.3t
13889lbs

9t
19841lbs

Engraving

Dimension A

Dimension B

45.0mm22.0mm1.77in0.86in48.0mm22.0mm1.88in0.86in54.0mm

31.0mm2.12in1.22in66.5mm

37.2mm2.61in1.46in82.0mm

45.0mm3.22in1.77in109.5mm60.0mm4.31in2.36inB

Ｃ−３Engraving

A

Ｆ−４

Ｆ−５

Ｃ−８

５.０

Ｃ１０

−24−

Figure 29Inspection item
(part name)part number

MethodInspection/test details/standard values

Measures

Bottom hook set

Visualinspection

Inspect the opening of the hook, hookthickness and wear in vertical/horizontal
dimensions, elongation of the chain retaining
bolt hole
Inspect the hook for bends, twists, damage,etc. and smooth hook rotation
Dimensions are not to exceed the reference
standard values.

Replace with a new part.

（No.7）

Table 8Rated load

Position

Ａ：Between punches
0.8t

Ｂ：Hook thickness, vertical

1763lbs

Ｃ：Hook thickness, horizontal
Ｄ：Chain stop bolt hole diameter
Ａ：Between punches

1t

Ｂ：Hook thickness, vertical

2204lbs

Ｃ：Hook thickness, horizontal
Ｄ：Chain stop bolt hole diameter
Ａ：Between punches

1.6t

Ｂ：Hook thickness, vertical

3527lbs

Ｃ：Hook thickness, horizontal
Ｄ：Chain stop bolt hole diameter
Ａ：Between punches

3.2t

Ｂ：Hook thickness, vertical

7054lbs

Ｃ：Hook thickness, horizontal
Ｄ：Chain stop bolt hole diameter
Ａ：Between punches

6.3t

Ｂ：Hook thickness, vertical

13889lbs

Ｃ：Hook thickness, horizontal
Ｄ：Chain stop bolt hole diameter
Ａ：Between punches

9t

Ｂ：Hook thickness, vertical

19841lbs

Ｃ：Hook thickness, horizontal
Ｄ：Chain stop bolt hole diameter

Limit Value
Reference（ A dimension should notstandard
exceed actual measured value
valuesat the time of purchase）
46.6mm1.83in19.0mm0.74in15.0mm0.59in8.8mm
0.34in51.0mm2.00in22.0mm0.86in16.0mm0.62in8.8mm
0.34in55.0mm2.16in26.0mm1.02in21.0mm0.82in10.8mm0.42in67.0mm2.63in35.0mm1.37in28.0mm1.10in12.7mm
0.5in
91.5mm
3.60in46.0mm1.81in34.0mm1.33in12.7mm
0.5in
125.0mm
4.92in61.1mm2.40in47.5mm1.87in13.4mm0.52inNot to exceed dimension A

D

18.0mm0.70in14.2mm0.55in9.3mm
0.35inA

Exterior
dimensionsof theconvexsectionNot to exceed dimension A
20.9mm0.82in15.2mm0.59in9.3mm
0.35inB

Not to exceed dimension A
24.7mm0.97in19.9mm0.78in11.3mm0.43inNot to exceed dimension A
33.2mm1.30in26.6mm1.04in13.2mm0.51inNot to exceed dimension A
43.7mm1.72in32.3mm1.27in13.2mm0.51inNot to exceed dimension A
58.0mm2.28in45.1mm1.77in13.9mm0.53inDimension A is not to exceed dimension A value.
Dimensions B and C are not to indicate wear of 5% or more in relation to
the actual measured value.
Dimension D is not to indicate wear of 0.5 mm (0.01 in) or more in
relation to the above reference standard value.

−25−

C

Figure 30

Inspection item
(part name)part number
Top hook pin（No.6）

MethodVisualinspection,measurement

Inspection/test details/standard values
Inspect for pin diameter wear.

Measures
Replace with a new part.

Table 9Rated load

0.8t
1763lbs

1t
2204lbs

1.6t
3527lbs

3.2t
7054lbs

6.3t
13889lbs

9t
19841lbs

Dimension A
referencestandard value

Limit value

12mm

11.4mm0.47in0.44in

12mm

11.4m

0.47in0.44in14ｍｍ

13.3mm0.55in0.52in16mm

15.2mm0.62in0.59in16mm

15.2mm0.62in0.59in16mm

15.2mm0.62in0.59inDimension A

Figure 31

Not to indicate wear of 5% or more in relation to above dimensional value.

−26−

Inspection item
(part name)part number

MethodInspection/test details/standard values

Chain stop bolt set

Visualinspection

Inspect for wear of the chain stop bolt
diameter; damage or deformation of theretaining bolt; cracks in the hex. castle nut
Deterioration of the cotter pin（No.8）

Table 10Rated load

Dimension A

Dimension A
Dimension B
limit value

0.8t

8.5mm

8.0mm

23.0mm1763lbs

0.33in0.32in0.90in

1t

8.5mm

8.0mm

23.0mm2204lbs

0.33in0.32in0.90in1.6t

10.5mm

10.0mm

29.5mm3527lbs

0.41in0.40in1.16in3.2t

12.5mm12.0mm39.0mm7054lbs

0.49in0.47in1.53in6.3t

12.5mm12.0mm39.0mm13889lbs

0.49in0.48in1.53in9t

13.0mm

12.5mm

48.0mm19841lbs

0.51in0.50in1.88inDimension C

Engraving

M6XP1

EF

M6XP1

EF

M8XP1.25

EH

M10XP1.5

EK

M10XP1.5

EK

M12XP1.75

None

Measures
Replace with a new part.
※Periodic replacemen
is recommended

Engraving

Wear shall not 0.5 mm (0.01 in) or more of the above dimensional value

C

A
B

A

Figure 32

Hex. nut（Ｎo．
１３）

Visualinspection

Inspect for damage, wear, deformation,
etc.

Replace with a new part.

Spring washer
（Ｎo．
１４）

Visualinspection

Inspect for damage, wear, deformation,
etc.

Replace with a new part.

Gear cover set
（Ｎo．
１８）

Visualinspection

Inspect for signiﬁcant deformation andwear with bumps identiﬁable by hand.
Inspect for cracks, wear, or rattling of
the metal clasped to thegear cover.

Replace with a new part.

Metal

Figure33
Visualinspection

Inspect for chipped gear teeth, bumpy
wear or damage, and smooth rotation of
the gear when passing through the dischub and feed gear.

Replace with a new part.

Washer for pinion shaft
Visual（Ｎo．
２０）
inspection

Inspect for signiﬁcant deformation, wearwith bumps identiﬁable by hand.

Replace with a new part.

Pinion shaft
（Ｎo．
１９）

Hex. castle nut
（Ｎo．
２１）

Visualinspection

Inspect for damage, wear, deformation,
etc.

Replace with a new part.

Cotter pin
（Ｎo．
２２）

Visualinspection

Inspect for damage, wear, deformation,
etc.

Replace with a new part.

2nd and 3rd gear set
Visual（Ｎo．
２3）
inspection

Inspect for chipped gear teeth, bumpy
wear or damage

Replace with a new part.

−27−

Inspection item
(part name)part number

MethodInspection/test details/standard values

Load gear（Ｎo．
２４）

Visualinspection

Inspect for chipped gear teeth, bumpy
wear or damage

Replace with a new part.

Load sheave（No.25）Visualinspection

Inspect for bumpy wear, damage,deformation, etc., on parts engaging thechain (pocket). Inspect for signs of
obduction by the chain

Replace with a new part.

Measures

Locations withpossibility of
being obductedby the chain

Figure 34
Chain guide set
（Ｎo．
２６）

Visualinspection

Inspect for bumpy wear, damage andsigns of obduction by the chain

Replace with a new part.

Chain stripper
（Ｎo．
２７）

Visualinspection

Inspect for bumpy wear, damage andsigns of obduction by the chain

Replace with a new part.

Disk hub（Ｎo．
２８）

Visualinspection

Inspect for chipped gear teeth, bumpy
wear and damage; smooth rotation when
the pinion shaft is passed through.

Replace with a new part.

E-ring for disc hub
（Ｎo．
２９）

Visualinspection

Inspect for opening of ring and damage

Replace with a new part.

Ratchet wheel
（Ｎo．
３０）

Visualinspection

Inspect for chipped teeth, wear inpositions engaging the pawls, damage
Braking section to be free of any bumpy
wear

Replace with a new part.

Table 11
Rated load

Dimension A

Dimension A
limit value

0.8t

66.0mm

62.7mm1763lbs

2.59in2.46in1t

66.0mm

62.7mm2204lbs

2.59in2.46in1.6t

72.0mm

68.4mm3527lbs

2.83in2.69in3.2t

72.0mm

68.4mm7054lbs

2.83in2.69in6.3t

72.0mm

68.4mm13889lbs

2.83in2.69in9t

72.0mm

68.4mm19841lbs

2.83in2.69inA

Dimension A :Ratchet wheel diameter

Figure 35

Not to indicate wear of 5% or more in relation to above dimensional value.

−28−

Inspection item
(part name)part number

MethodInspection/test details/standard values

Brake lining

Visual（Ｎo．
３１）

inspection

Inspect for chipped teeth, wear in positions
engaging the pawls, damage
Braking section to be free of any bumpy wear

Measures
Replace with a new part.

Table 12Dimension A
Dimension B Dimension C
limit value

Rated load

Dimension A

0.8t

3.0mm

2.8mm

1763lbs

0.118in

0.110in

2.16in1.35in

1t

3.0mm

2.8mm

55.0mm

34.5mm2204lbs

0.118in

0.110in

2.16in1.35in

1.6t

3.5mm

3.3mm

64.0mm

40.5mm3527lbs

0.13in0.12in2.51in1.59in

3.2t

3.5mm

3.3mm

64.0mm

40.5mm

55.0mmC

34.5mm7054lbs

0.13in0.12in2.51in1.59in

6.3t

3.5mm

3.3mm

64.0mm

40.5mm13889lbs

0.13in0.12in2.51in1.59in

9t

3.5mm

3.3mm

64.0mm

40.5mm19841lbs

0.13in0.12in2.51in1.59inA

B

Figure 36

To be free of wear deviating 0.2mm or more from the dimensional value above

Lever set（Ｎo．
３３）

Visualinspection

Inspect for signiﬁcant deformation andnormal movement of the changeoverknob.

Replace with a new part.

Lever grip
（Ｎo．
３４）

Visualinspection

Inspect for cracks in the rubber handle,
deformation, etc.

Replace with a new part.

Bracket screw
（Ｎo．
３５）

Visualinspection

Inspect for attachment of bracket
screwsReplace with a new part.

Name plate
（Ｎo．
９２）

Visualinspection

Inspect for damage, legibility

Replace with a new part.

Hex. nut（Ｎo．
36）

Visualinspection

Inspect for damage, wear, deformation,
etc.

Replace with a new part.

Spring washer
（Ｎo．
37）

Visualinspection

Inspect for damage, wear, deformation,
etc.

Replace with a new part.

Feed gear（Ｎo．
３８）

Visualinspection

Inspect for chipped gear teeth, bumpy
wear and damage
Inspect for smooth rotation when thepinion shaft is passed throughReplace with a new part.

Ratchet for feed gear
（Ｎo．
３９）

Visualinspection

Inspect for signiﬁcant deformation andwear with bumps identiﬁable by hand.

Replace with a new part.

Ratchet spring pin
（Ｎo．
４０）

Visualinspection

Inspect for damage, deformation andwear

Replace with a new part.

−29−

Inspection item
(part name)part number

MethodInspection/test details/standard values

MeasuresLever cover set
（Ｎo．
４３）

Visualinspection

Inspect for any signiﬁcant deformationand catching in the rotating parts.

Replace with a new part.

Gear-side plate set
（Ｎo．
82）

Visualinspection

Inspect for damage or deformation of
the top hook pin hole, sheave hole, andstay bolt.

Replace with a new part.

Table 13
Rated load

Dimension A

Dimension A
limit value

0.8t

12.5mm13.0mm1763lbs

0.49in0.50in1t

12.5mm13.0mm2204lbs

0.49in0.50in1.6t

14.5mm

15.0mm3527lbs

0.57in0.58in3.2t

16.5mm17.0mm7054lbs

0.64in0.65in17.0mm

6.3t

16.5mm13889lbs

0.64in0.65in9t

16.5mm17.0mm19841lbs

0.64in0.65inTop hook pinhole positionA

A (Limit value)

Stay bolt

Figure 37

To be without wear of 0.5 mm (0.01 in) or more in relation to the above
dimensional value. Measurement to be taken at 90°angles horizontallyand vertically.
Lever-side plate set
（Ｎo．
８３）

Visualinspection

Inspect for damage or deformation of the top
hook pin hole and sheave hole.

Replace with a new part.

Table 14
Rated load

Dimension A

Dimension A
limit value

0.8t

12.5mm13.0mm1763lbs

0.49in0.50in1t

12.5mm13.0mm2204lbs

0.49in0.50in1.6t

14.5mm

15.0mm3527lbs

0.57in0.58in3.2t

16.5mm17.0mm7054lbs

0.64in0.65in6.3t

16.5mm17.0mm13889lbs

0.64in0.65in9t

16.5mm17.0mm19841lbs

0.64in0.65inA

Top hook pinhole position
A (Limit value)

Pawl pin

Figure 38

To be without wear of 0.5 mm (0.01 in) or more in relation to the above
dimensional value. Measurement to be taken at 90°angles horizontallyand vertically.

−30−

Inspection item
(part name)part number

Method

Pawl
（Ｎo．
１５）

Visualinspection

Inspect for chipped teeth on pawls,
bumpy wear and damage

Replace with a new part.

Pawl spring
（Ｎo．
１６）

Visualinspection

To be without wear on the surfaces
contacting the pawls.
Bending portion of the spring to be freeof indicate cracks or breaks.
Spring to be free of expansion/contraction
or deformation due to compression.

Replace with a new part.

Inspection/test details/standard values

Measures

Figure 39

E-ring for pawl
（Ｎo．
１７）

Visualinspection

Inspect for opening of ring and damage

Replace with a new part.

Ratchet spring
（Ｎo．
８5）

Visualinspection

Inspect for expansion/contraction beyond thespeciﬁed value.

Replace with a new part.

Table 15
Rated load

Dimension A reference
standard value

0.8t

35mm

1763lbs

1.37in1t

35mm

2204lbs

1.37in1.6t

48mm

3527lbs

1.88in3.2t

48mm

7054lbs

1.88in6.3t

48mm

13889lbs

1.88in9t

48mm

19841lbs

1.88inTo be without
expansion/contra
ction beyond thedimensionindicated on theleft (to be without
deformation due
to compression)

−31−

A

Figure 40

Inspection item
(part name)part number
Spring for ﬂoating
mechanism（Ｎo．
８７）

MethodInspection/test details/standard values

VisualInspect for expansion/contraction beyond thespeciﬁed value.

inspection

Measures
Replace with a new part.

Table 16
Rated load

Dimension A reference
standard value

0.8t

32.5mm1763lbs

1.27in1t

32.5mm2204lbs

1.27in1.6t

38.5mm3527lbs

1.51in3.2t

42.0mm7054lbs

1.65in6.3t

42.0mm13889lbs

1.65in9t

42.0mm19841lbs

1.65inTo be without
expansion/contra
ction beyond thedimensionindicated on theleft (to be without
deformation due
to compression)

A

Figure 41

Feed handle
（Ｎo．
８８）

Visualinspection

To be without damage or deformation

Replace with a new part.

Chain stopper

Visualinspection,measurement

Inspect for expansion/contraction beyond thespeciﬁed value.

Replace with a new part.

（Ｎo．
９１）

Table 17
Rated load

A

B

C

0.8t

50mm

20mm

1mm

1763lbs

1.96in0.78in0.03in

1t

50mm

20mm

1mm

2204lbs

1.96in0.78in0.03in

1.6t

63mm

26mm

1mm

3527lbs

2.48in1.02in0.03in

3.2t

79mm

34mm

1mm

7054lbs

3.11in1.33in0.03in

6.3t

79mm

34mm

1mm

13889lbs

3.11in1.33in0.03in

9t

79mm

34mm

1mm

19841lbs

3.11in1.33in0.03inCheck washer

Visual（Ｎo．
１０２）

inspection

Hex. socket
head cap screw set
（Ｎo．
１０３）

Visualinspection

Tag
（Ｎo．
１10）

Visualinspection

A
To be without
expansion/contra
ction beyond thedimensionindicated on theleft (to be without
deformation due
to compression)

C

B

Figure 42

Inspect for signiﬁcant deformation, wear withbumps identiﬁable by hand.

Replace with a new part.

Inspect for damage, deformation and wear

Replace with a new part.

Inspect for damage, deformation and wear

Replace with a new part.

−32−

Inspect and test Model YAⅢ parts indicated below:
Inspection item
(part name)part number
TORCON device
set forModel YAⅢ
（Ｎo．
138）

MethodVisualinspection

Spring for ﬂoating
Visualmechanism forinspection,
Model YAⅢ
measurement
（Ｎo．
1８７）

Inspection/test details/standard values

Measures

Inspect for chipped gear teeth, bumpy
wear and damage
Inspect for smooth rotation when thepinion shaft is passed throughReplace with a new part.

Inspect for expansion/contraction
beyond the speciﬁed value.

Replace with a new part.

Table 18
Rated load

Dimension A reference
standard value

0.8t

22mm

1763lbs

0.86in1t

22mm

2204lbs

0.86in1.6t

24mm

3527lbs

0.94in3.2t

24mm7054lbs

0.94in6.3t

24mm

13889lbs

0.94in9t

24mm

19841lbs

0.94inFeed handle forModel YAⅢ
（Ｎo．
1８８）

Visualinspection

Hex. socket head cap
screw set for
Model YAⅢ
（Ｎo．
17３）

inspection

Name plate forModel YAⅢ
（Ｎo．
９２）

VisualVisualTo be without
expansion/contra
ction beyond thedimensionindicated on theleft (to be without
deformation due
to compression)

A

Figure 43

To be without damage or deformation

Replace with a new part.

Inspect for damage, deformation and wear

Replace with a new part.

Inspect for damage, legibility

Replace with a new part.

inspection※Parts other than the above are in common with Model YA.

−33−

Inspect and test Model YAS parts indicated below:
Inspection Items/Points
Top hook set
（Ｎo．
401）

Table 19

Rated load

Inspection contents/methods

Countermeasure

Inspect opening of the hook, hook thickness and wear invertical/horizontal dimensions; diameter of the top hookpin-hole for elongation
Inspect the hook for bends, twists, damage, etc. andsmooth hook rotation.
Dimensions are not to exceed the reference standard
values.

Replace with a new part.

Position
Ａ：Between punches

0.8t

Ｂ：Hook thickness, vertical

1763lbs

Ｃ：Hook thickness, horizontal
Ｄ：Hole diameter, top hook pin
Ａ：Between punches

1t

Ｂ：Hook thickness, vertical

2204lbs

Ｃ：Hook thickness, horizontal
Ｄ：Hole diameter, top hook pin
Ａ：Between punches

1.6t

Ｂ：Hook thickness, vertical

3527lbs

Ｃ：Hook thickness, horizontal
Ｄ：Hole diameter, top hook pin
Ａ：Between punches

3.2t

Ｂ：Hook thickness, vertical

7054lbs

Ｃ：Hook thickness, horizontal
Ｄ：Hole diameter, top hook pin

Limit Value
Reference（ A dimension should notstandard
exceed actual measured value
valuesat the time of purchase）
54.0mm21.2in23.5mm0.92in19.0mm0.74in12.5mm0.49in54.0mm21.2in23.5mm0.92in19.0mm0.74in12.5mm0.49in55.0mm2.16in28.5mm1.12in23.0mm0.90in14.5mm0.57in70.2mm2.76in37.0mm1.45in28.0mm1.10in16.5mm0.64inB

Not to exceed dimension A
22.3mm0.87in18mm
0.70in13.1mm0.51inA

Not to exceed dimension A
22.3mm0.87in18mm
0.70in13.1mm0.51inD

Not to exceed dimension A
27.0mm
1.06in21.8mm0.85in15.2mm0.59inC

Not to exceed dimension A
35.1mm1.38in26.6mm1.04in17.3mm0.68inDimension A is not to exceed dimension A value.
Actual measured values of dimensions B, C, and D are not to indicate wear
of 5% or more.
※Parts other than the hook section are in common with Model YA.

Figure 44−34−

Inspection Items/Points

Inspection contents/methods

Countermeasure

Safety latch set
（Ｎo．
40２）

Conﬁrm engagement with hook, the repulsive force of thespring, and if there is any damage or deformation

Replace with a new part.

Table 20
Rated load

Dimension A

Dimension B

Dimension C

0.8t

55.5mm

23.5mm

30.5mm1763lbs

2.18in0.92in12.0in1t

55.5mm

23.5mm

30.5mm2204lbs

2.18in0.92in12.0in1.6t

55.5mm

23.5mm

30.5mm3527lbs

2.18in0.92in12.0in3.2t

72.0mm28.0mm35.0mm7054lbs

2.83in1.10in1.37inBottom hook set
（Ｎo．
407）

Table 21
Rated load

B

A

C

Figure 45

Inspect opening of the hook, hook thickness and wear invertical/horizontal dimensions; diameter of the chain
retainer bolt-hole for elongation
Inspect the hook for bends, twists, damage, etc. andsmooth hook rotation.
Dimensions are not to exceed the reference standard
values.
Position

Ａ：Between punches
0.8t

Ｂ：Hook thickness, vertical

1763lbs

Ｃ：Hook thickness, horizontal
Ｄ：Chain stop bolt hole diameter
Ａ：Between punches

1t

Ｂ：Hook thickness, vertical

2204lbs

Ｃ：Hook thickness, horizontal
Ｄ：Chain stop bolt hole diameter
Ａ：Between punches

1.6t

Ｂ：Hook thickness, vertical

3527lbs

Ｃ：Hook thickness, horizontal
Ｄ：Chain stop bolt hole diameter
Ａ：Between punches

3.2t

Ｂ：Hook thickness, vertical

7054lbs

Ｃ：Hook thickness, horizontal
Ｄ：Chain stop bolt hole diameter

Limit Value
Referencestandard （ A dimension should notexceed actual measured value
valuesat the time of purchase）
54.0mm21.2in23.5mm0.92in19.0mm0.74in8.8mm
0.34in54.0mm21.2in23.5mm0.92in19.0mm0.74in8.8mm
0.34in55.0mm2.16in28.5mm1.12in23.0mm0.90in10.8mm0.42in70.2mm2.76in37.0mm1.45in28.0mm1.10in12.7mm0.5in

Replace with a new part.

D

Not to exceed dimension A
22.3mm0.87in18mm
0.70in9.3mm
0.35inA

Not to exceed dimension A
22.3mm0.87in18mm
0.70in9.3mm
0.35inB

Not to exceed dimension A
27.0mm
1.06in21.8mm0.85in11.3mm0.43inNot to exceed dimension A
35.1mm1.37in26.6mm1.04in13.2mm0.51inDimension A is not to exceed dimension A value.
Dimensions B, and C are not to indicate wear of 5% or more in relation to theactual measured value.
Dimension D is not to indicate wear of 0.5 mm (0.01 in) or more in relation to
the above reference standard value.
※Parts other than the hook section are in common with Model YA.

−35−

C

Figure 46

Inspect and test Model YAR parts indicated below:
Inspection Items/Points
Top hook set
（Ｎo．
501）

Inspection contents/methods

Countermeasure

Inspect opening of the hook, hook thickness and wear invertical/horizontal dimensions; diameter of the top hookpin-hole for elongation Inspect the hook for bends, twists,
damage, etc. and smooth hook rotation. Dimensions are
not to exceed the reference standard values.

Replace with a new part.

Table 22
Rated load

Position

Ａ：Interior dimensions of the hook
0.8t

Ｂ：Hook thickness, vertical

1763lbs

Ｃ：Hook thickness, horizontal
Ｄ：Hole diameter, top hook pin
Ａ：Interior dimensions of the hook1t

Ｂ：Hook thickness, vertical

2204lbs

Ｃ：Hook thickness, horizontal
Ｄ：Hole diameter, top hook pin
Ａ：Interior dimensions of the hook

1.6t

Ｂ：Hook thickness, vertical

3527lbs

Ｃ：Hook thickness, horizontal
Ｄ：Hole diameter, top hook pin
Ａ：Interior dimensions of the hook

3.2t

Ｂ：Hook thickness, vertical

7054lbs

Ｃ：Hook thickness, horizontal
Ｄ：Hole diameter, top hook pin

Limit Value
Reference（ A dimension should notstandard
exceed actual measured value
valuesat the time of purchase）
29.5mmNot to exceed dimension A
1.16in18.5mm
19.5mm0.72in0.76in13.3mm14.0mm0.52in0.55in13.1mm
12.5mm0.51in0.49in29.5mmNot to exceed dimension A
1.16in18.5mm
19.5mm0.72in0.76in13.3mm14.0mm0.52in0.55in13.1mm
12.5mm0.51in0.49in47.0mmNot to exceed dimension A
1.85in27.0mm
28.5mm
1.06in1.12in22.8mm24.0mm0.89in0.94in15.2mm
14.5mm0.59in0.57in52.0mmNot to exceed dimension A
2.04inB

A

D

C

37.0mm1.45in26.6mm1.04in17.3mm0.68in39.0mm1.53in28.0mm1.10in16.5mm0.64inDimension A is not to exceed dimension A value. Actual measured values ofdimensions B, C, and D are not to indicate wear of 5% or more.
※Parts other than the hook section are in common with Model YA.

Figure 47−36−

Inspection Items/Points

Inspection contents/methods

Countermeasure

TriggerConﬁrm hook engagement, the repulsive force of thespring, and if there is any damage or deformation

Replace with a new part.

Bottom hook set
（Ｎo．
507）

Inspect the hook opening, hook thickness, and wear invertical/horizontal dimensions; Check for elongation of thechain stop bolt-hole Inspect the hook for bends, twists,
damage, etc. and smooth hook rotation. Dimensions are
not to exceed the reference standard values.

Replace with a new part.

D

Table 23
Rated load

Position

Ａ：Interior dimensions of the hook
0.8t

Ｂ：Hook thickness, vertical

1763lbs

Ｃ：Hook thickness, horizontal
Ｄ：Chain stop bolt hole diameter
Ａ：Interior dimensions of the hook1t

Ｂ：Hook thickness, vertical

2204lbs

Ｃ：Hook thickness, horizontal
Ｄ：Chain stop bolt hole diameter
Ａ：Interior dimensions of the hook

1.6t

Ｂ：Hook thickness, vertical

3527lbs

Ｃ：Hook thickness, horizontal
Ｄ：Chain stop bolt hole diameter
Ａ：Interior dimensions of the hook

3.2t

Ｂ：Hook thickness, vertical

7054lbs

Ｃ：Hook thickness, horizontal
Ｄ：Chain stop bolt hole diameter

Limit Value
Referencestandard （ A dimension should notexceed actual measured value
valuesat the time of purchase）
29.5mm1.16in19.5mm0.76in14.0mm0.55in8.8mm
0.34in29.5mm1.16in19.5mm0.76in14.0mm0.55in8.8mm
0.34in47.0mm1.85in28.5mm1.12in24.0mm0.94in10.8mm0.42in52.0mm2.04in39.0mm1.53in28.0mm1.10in12.7mm
0.5in

Not to exceed dimension A

A

22.3mm0.87in18mm
0.70in9.3mm
0.35inNot to exceed dimension A
22.3mm0.87in18mm
0.70in9.3mm
0.35inB

Not to exceed dimension A
27.0mm
1.06in21.8mm0.85in11.3mm0.43inNot to exceed dimension A
35.1mm1.37in26.6mm1.04in13.2mm0.51inDimension A is not to exceed dimension A value. Dimensions B and C
are not to indicate wear of 5% or more in relation to the actual measured
value. Dimension D is not to indicate wear of 0.5 mm (0.01 in) or morein relation to the above reference standard value.
※Parts other than the hook section are in common with Model YA.

C

Figure 48−37−

Inspection item
(part name)part number

MethodInspection/test details/standard values

Load chain（No.53）Visualinspection

Inspect for any damage, deformation, or
elongation beyond the speciﬁed value

Measures
Replace with a new part.

Table 24
Diameter (mm)Rated load

Pitch (P×5) (mm)Standard value

Limit valueStandard value

Limit value

0.8t

5.6mm

5.3mm

85.6mm

88.2mm1763lbs

0.22in0.20in3.37in3.47in

1t

5.6mm

5.3mm

85.6mm

88.2mm2204lbs

0.22in0.20in3.37in3.47in

1.6t

7.1mm

6.7mm

105.3mm

108.4mm3527lbs

0.27in0.26in4.14in4.26in

3.2t

9.0mm

8.5mm

135.3mm

139.3mm7054lbs

0.35in0.33in5.32in5.48in

6.3t

9.0mm

8.5mm

135.3mm

139.3mm

13889lbs

0.35in0.33in5.32in5.48in

9t

9.0mm

8.5mm

135.3mm

139.3mm19841lbs

0.35in0.33in5.32in5.48inWear of the diameter is not to exceed 5% of the dimension value
indicated above. 5-link pitch must not be elongated by 3% or more of
the dimension value indicated above.

diameterFigure 49

5-link pitch（P×5）

Pitch measurement method

5-link pitch

Figure 50

Figure 51※Model YAⅢ uses ﬁve diﬀerent parts: No.138 feed gear, No.187 spring for ﬂoating
mechanism, No.188 feed handle, No.92 name plate, and No.173 Hex. socket head cap
screw set.

Lubrication and greasing of various parts
Load chain●First, use cleaning solution to remove dust and dirt from the load chain.
●Apply NLGI No. 00 grease.
●Depending on the frequency of use and other conditions, increase the frequency ofgrease application to the load chain during daily inspections.

Gears and other parts●First, use cleaning solution to remove any dust and dirt from the old grease coating of
the gears.
●Apply NLGI No. 1 grease evenly to the gear sections.
●Apply grease to the pawls and rotating parts of the lever, as well as the rotating partsof the load sheave and side plate.
−38−

7. Disassembly and Assembly Adjustment
7.1 Tools and Equipment/Consumables used for Disassembly/Assembly
Prepare the following tools and supplies :1. Wrench
Part No. and parts used
2. Phillips screwdriver
Ｎo.2
Hexagon socket head cap screws：
3. Nippers
Ｍ４, ５, ６, ８, 10
4. Pliers
Ｎo.8
Chain stop bolt sets：Ｍ６, ８, 10, 12
5. Hexagonal wrench
Ｎo.13
Hex.nuts：Ｍ８, 10
6. Radio pliers
Ｎo.21
Hex. castle nuts：Ｍ10/12
7. Snap ring pliers
Ｎo.36
Hex.nuts：Ｍ８
8. Plastic hammer
Ｎo.103 Hex. socket head cap screw sets：Ｍ６
9. Brush
10. Grease（NLGI. No. 1）
11. Oil（NLGI. No. 00）
12. Waste cloth
13. Cylindrical or square pipe-shaped object (Height: approx. 100 mm; hole diametershould be enough to ﬁt the pinion shaft)※Apply gear grease（NLGI. No. 1）and load chain oil（NLGI. No. 00）.
※Use the following tools to disassemble and reassemble the hoist.
Be sure to work carefully.
1. Wrench

2. Phillips screwdriver

3. Nippers

4. Pliers−39−

5. Hexagonal wrench

6. Radio pliers

7. Snap ring pliers

8. Plastic hammer

9. Brush−40−

7.2 Disassembly of Model YA※Refer to the breakdown schematics for detailed part numbers.

⑲Pinion shaft

Disassembly of the main unit,
lever, and chain

Feed handle

Remove chain stop bolt set ⑧ on
the load side of the load chain, thenremove bottom hook set ❼.
Remove chain stopperon theno-load side.
Set changeover knob to position N(revolving), perform free chaining
operation and rotate the feed
handleto remove the chain.
Remove cotter pin ㉒, hex. castle
nut ㉑ and check washer
frompinion shaft ⑲.
Remove hex. socket head cap
screw sets
securing the feed
handle , and disengage thehandle.
Remove hex. nut ⑬ and spring
washer ⑭ holding lever set
inplace.
While turning feed gear ㊳,
disengage lever set from the mainunit.

⑬Hex. nut
⑭Spring washer㉒Cotter pin㉑Hex. castle nut
Check washer
Hex. socket head cap
screw set
Changeover knob
Lever set
Load chain
Chain stopper⑧Chain stop bolt set❼Bottom hook set❶Top hook set

Lever setsection⑥Top hook pin
Spring for ﬂoating
mechanism㉙E-ring for disc hub㉘Disk hub
㉛Brake lining㉚Ratchet wheel⑰E-ring for pawl
Pawl pin⑮Pawl⑯Pawl spring⑲Pinion shaft

Lever-side plate set−41−

Disassembling the
hoist body
Remove spring for
ﬂoating mechanism .
Pull out the top hook pin⑥ and remove the top
hook set ❶.
Remove E-ring for dischubs ⑳ attached topinion sfaft ⑲
Remove brake parts.
(Remove in this order:
brake linings ㉛; ratchet
wheel ㉚; brake linings㉛; disk hub ㉘)
Remove in this order:
E-ring for pawl ⑰
attached to the pawl pin;pawl ⑮; pawl spring ⑯.
Remove lever-side plate
set .

Remove chain guide set ㉖
and chain stripper ㉗.
※ Prepare an assembly
mounting (if possible)
If a mounting is unavailable,
substitute with anappropriate surface.
The assembly mounting
should be a pipe-shaped
cylinder, with suﬃcient
length to house pinion shaft⑲ and capable ofsupporting load sheave ㉕.
Turn the main unit over andplace it on the assembly
mounting.
Remove hex. nuts ⑬ andspring washer ⑭ securing
gear cover set ⑱, anddisengage the gear cover.

⑭Spring washer㉕Load sheave㉖Chain guide set⑲Pinion shaft㉗Chain stripper⑱Gear coverset⑬Hex. nut

Remove 2nd and 3rdgear set ㉓
Remove Pinion shaft⑲
Remove washer for
pinion shaft ⑳
Remove Load gear㉔
Remove gear-side
plate set
Remove Loadsheave ㉕ fromassembly mounting㉓2nd and 3rd gear set⑲Pnion shaft㉓2nd and 3rd gear set⑳Washer for pinion shaft㉔Load gearGear-side plate set㉕Load sheave

Assembly mounting−42−

Disassembling the lever section㊳Feed gear

㊴Ratchet for
feed gear㊵Ratchet springpin
Ratchet spring
Lever set

Lever set
and lever coverset ㊸ can be disassembled into
two parts by removing hex.
nuts ㊱ and spring washer ㊲
holding the two sets together.
Remove ratchet for feed gear㊴, ratchet spring pin ㊵ andratchet springfrom the leverset.
Disengage feed gear ㊳ fromthe lever cover set.

㊸Lever cover set

Remove theC-type concentricsnap ring from theshaft retaining thelever cover set,
and disassemble
cover set.

Cover snap ring
Brake coverC-type concentricsnap ring for shaft

Lever cover※This completes the disassembly of the lever. Then, remove (clean) any dirt, dust, or grease
from the disassembled parts for inspection and re-assembly.
Inspect respective parts in accordance with the inspection standards. Replace any damaged
or deteriorated parts with new parts.
In case many parts are damaged or deteriorated, the purchase of new levers is recommended
to enhance safety.

−43−

7.3 Assembly and Adjustment※Refer to the breakdown schematics for detailed part numbers.
Start re-assembly of the Model YA lever hoist. (Assuming all parts are intact and in normal condition)

１. Prepare lever set.

３. Assemble lever cover set ㊸.

※The grip and assembly screws to bepre-assembled.

※Be sure to apply grease to the rotatingparts.

C-type concentricsnap ring for shaft

Cover snap
ring

㉝Lever set

Brake
cover

Lever cover

Grease２. Assemble the lever set.
Install ratchet for feed gear ㊴, ratchetspring pin ㊵, and ratchet spring
to thelever set.
※When installing ratchet for feed gear,the changeover knob must be set to theN (free chaining) position.
※Apply grease to parts ㊴, ㊵ andwitha brush or similar tool.

４. Assemble lever set and lever coverset.
Apply grease to the gear portion of feed
gear ㊳. Then, place the feed gear on leverset , cover it with the lever cover set,and secure with spring washer ㊲ and hex.
nut ㊱.

Lever
Lever set

Grease㊳Feed gear

㊴Ratchet for
feed gear㊸Lever cover set

Grease㊲Spring washer㊵Ratchet spring pin㊱Hex. nut

Ratchet spring−44−

５. This completes the assembly of thelever set and lever cover set.

７. Install gear-side plate set
mounted load sheave.

on theGear-sideplates set

Assembly
mounting

６. Prepare assembly mounting（if possible）㉕Load sheave

８. Unit with the load sheave and thegear-side plate set installed※In case mounting is unavailable, substitutewith an appropriate surface.
※Assembly mounting should be a pipe-shaped
cylinder, with suﬃcient length to house thepinion shaft and capable of supporting load
sheave ㉕.
First, apply grease to the rotating portion ofload sheave ㉕ and place it on the assembly
mounting.
㉕Load sheave

Grease−45−

９. Install load gear ㉔ on the load
sheave with the recessed section
facing upward.

Recessedsection

11. Apply grease to the area indicatedby the arrow and assemble pinion
shaft ⑲.

⑲Pinion shaft㉔Load gear

Grease⑳Washer for
pinion shaft㉕Load sheave㉔Load gear

10. Install washer for pinion shaft ⑳(ﬂat part to face the load gearside) on top of the installed loadgear ㉔.

12. Prepare the 2nd and 3rd gear set㉓, apply grease to the sectionthat contacts the metal part of theside plate. The gear section isprovided with markings. Install
gears with the marks facing eachother.
※After installing the gears, conﬁrm smoothrotation by turning them.
Gear combination
0.8、1t⑳Washer for pinion shaft

1.6t
3.2t、6.3t、9t㉔Load gear

※Misalignment of marks may result in
preventing the gears from rotating or cause
other problems.
㉓2nd and 3rd gear set⑲Pinion shaft

PinionMetal

Grease−46−

13. This completes the installation of
second and third gears.
Apply grease to the load gear, pinion shaft,second and third gears, and all of the rotatingparts.
2nd and 3rdgear set

15. Secure the gear cover set andgear-side plate set with spring
washer ⑭ and hex. nut ⑬.

2nd and 3rdgear set⑬Hex. nut

⑱Gear cover set⑭Spring
washer⑲Pinion shaft

Gear-sideplate setGear-side plate set

Apply grease to the entire area.

14. Cover the gear section with gear coverset ⑱.
※Align the top hook pin hole side, convex
part, and screw hole positions.
⑱Gear coverset

16. Remove the parts installed so far
from the assembly mounting andplace them on the work table.
⑲Pinion shaft

Top hook
pin sideGear-sideplate set

㉕Load sheave
Gear-sideplate set

Convex partand hole forsetting⑱Gear cover set
Convexpart⑱Gear cover set

Convex partand hole forsettingGear-sideplate set−47−

17. Next, install chain guide set ㉖ andchain stripper ㉗.

19. Condition of the hoist with the gearside and lever side installed※Be sure to align the parts correctly forassembly. Install the chain stripper withthe higher end facing the stopper and thelower end facing toward the bottom hook.

⑲Pinion shaft
Lever-side plate set㉖Chain guide set

Gear-side plate set

Fig.1 Enlarged View

⑱Gear cover set

Gear-side plate
set㉗Chain stripper

20. Install pawl spring ⑯, pawl ⑮ andE-ring for pawl ⑰ to the lever-side
plate.
※Apply a small amount of grease to the pin
before attaching the pawl.

18. Install the lever-side plate set.

⑰E-ring for pawl

Lever side plate set⑲Pinion shaft⑮Pawl⑯Pawl spring⑲Pinion shaft

GreaseLever-side plate㉕Load sheave⑱Gear cover set
Gear-side plate set−48−

23. Install ratchet wheel ㉚ andbrake linings ㉛ to disc hub ㉘.

21. Install disc hub ㉘ onto pinion
shaft ⑲.
Since the shaft is threaded, turn the disk
hub by hand and tighten until it does not
move.
※Open the two pawls sideways and attachso that they do not touch each other.

※Be sure to attach the ratchet wheel inthe correct orientation.
※If the direction is reversed, the brakes
will not work and the pawls will not
engage with the ratchet wheel.

㉘Disc Hub

㉛Brake Lining㉚Rachet wheel⑲Pinion shaft㉛Brake Lining⑮Pawl㉘Disc Hub

22. Condition of the hoist with thedisk hub installed onto the pinion
shaft

24. This completes the installation of
the brakes⑲Pinion shaft⑲Pinion shaft⑮Pawl㉘Disc Hub

⑮Pawl

⑮Pawl

−49−

㉚Ratchet wheel

27. Install top hook set ❶.

25. Install the E-ring for disc hub
onto the pinion shaft.

Align top hook hole with the hook hole on
the side plate, and secure hook with ⑥ top
hook pin.

※Install E-ring for disc hub securely onto
the shaft as far as it will go (with thecurved part facing the disc hub).

❶Top hook set⑲Pinion shaft㉙E-ring fordisc hub⑥Top hook pin

28. With top hook set installed

26. With E-ring for disc hub installed⑲Pinion shaft❶Top hook set㉙E-ring for disc hub⑥Top hook pin−50−

29. Install spring for ﬂoating
mechanism
onto the pinion
shaft.
※The end with the smaller spring diametershould face the disk hub.
※The diameter of the spring is the same on
both ends in the case of Model YAⅢ.

31. Secure the body part attachedwith the top hook and leversection with spring washer ⑭ andhex. nut ⑬.

⑬Hex. nut
End with thesmaller spring
diameterSpring for ﬂoating
mechanism⑭Spring washer⑲Pinion shaft

30. Attach the lever part to the bodypart with the top hook.

32. Next, install feed handle

Align the top hook hole on the lever coverwith the screw hole. Both the feed gear andpinion shaft are threaded. Attach feed gearto the shaft by rotating the gear by hand.

Insert handle onto the pinion shaft and alignwith the screw hole on the feed gear.

⑥Top hook pin⑲Pinion shaft

Top hook pin side
㊸Lever cover set㊳Feed gear
Lever-side
plate set

Feed handle⑲Pinion shaft㊳Feed gear

−51−

.

33. Secure feed handle using hex.
socket head cap screw sets .

35. Next, screw hex. castle nut ㉑ onto
the pinion shaft.
※Screw the nut onto the pinion shaft by
hand.

Feed handle㉑Hex. castle nut⑲Pinion shaft

Hex. socket head cap screw set

34. Pass check washer
through thepinion shaft and attach to the feed
handle.

36. Pinion shaft with hand-tightenedhex. castle nut

Feed handle㉑Hex. castle nut⑲Pinion shaft⑲Pinion shaft
Check washer−52−39. Attach chain stopper
to thesecond link of the load chain on
the no-load side.

37. Viewing the assembled leverfrom above, orient the feed
handle to the right and the gearside to the left. In this state,
install the load chain.

※When top hook and lever section are
correctly aligned, the left side becomes isthe load side (lifting side) and the rightside is the no-load side (lowering side) as
viewed from the feed handle side.

Set changeover knob to the free chaining(N) position. Place the load chain in the load
sheave ㉕ with the vertical link (weldingside) facing upward, and feed the load chain
to the no-load side while turning the feed
handleby hand.
㉕Load sheave
Feed handle

Second link

Verticallink

Load chain

Load chain
no-load side
Changeoverknob（N position）

Chain stopper

Horizontal link

38. When load chain is installed onto
the main unit

40. Install bottom hook set ❼ onto theload side of the load chain.

Load chainload side

Chain stopper side

Bottom hook side

−53−

❼Bottom hook set

43. Conﬁrm hole position of the hex.
castle nut and the cotter pin holeof the pinion shaft. Even if the holepositions are aligned, loosen by
one groove. If the holes are halfaligned or not aligned at all, loosen
the nut by two grooves.
Next, insert the cotter pin into theadjusted hole and secure the nut
with the cotter pin to prevent itfrom loosening.

41. Install chain stop bolt set ⑧,
orienting the welded side of thesecond link of the load chain
toward the nut.

Welded side of
the second link

㉑Hex. castle nut㉒Cotter pin⑧Chain stopbolt set㉑Hex. castle nut

42. Hook the top and bottom hooks ofthe lever onto the ﬁxing bracket,
set the changeover knob to thelifting position, then tighten hex.
castle nut ㉑ until it does not turnby hand. Next, turn the feed
handle lift-ward by hand until it
stops turning.

㉒Cotter pin

When the hole position is aligned※Apply load to the lever.

Fixing bracket

1 groove

Feed handle

Hole position

Changeover knob

When the hole position is not aligned㉑Hex. castle nut

2 grooves

1 groove

Hole position
Fixing bracket−54−46. This completes the assembly
process.
After completing the assembly,
be sure to perform an operation
check before use.

44. Condition with cotter pin ㉒
secured.

※Points for operation check①Check overall appearance foranomalies.
Are there any leftover parts?
②Does the hoist make any
abnormal noises whenlifted/lowered under no-loadcondition?
Can the engaging of the pawl be
audibly conﬁrmed when lifting?
Is the manual power required toturn the lever not too heavy?

㉒Cotter pin③After conﬁrming normal operation
under no-load conditions, test
operation upon applying a load.
Is there any slippage of thebrake?
Insert and bend cotter pin ㉒.

45. Set changeover knob to lowering
position and move handle toloosen load chain .
Apply oil to the load chain.

Changeover knob

−55−

7.4 Is this a malfunction!? First check for (commonly found assembly errors)
・Check again according to the instructions below before calling for repairs:
When in this situation:①Lever does not move
either up or down. Thereis no audible pawl
engaging sound.

The cause and target of
inspection is:
Ratchet wheel in the brakesection is not assembled
correctly. Ratchet wheel isassembled backwards and is notengaged with the pawl.
Pawl
Ratchet wheel

How to ﬁx:
Reassemble ratchet wheel
correctly.
Make sure the pawl and theratchet wheel are engaged, andalso check for the clicking soundwhen the ratchet wheel is turned.
Pawl
Ratchet wheel②Lever does not move
either up or down. Thereis no audible pawl
engaging sound.

The brake part is assembled
correctly, but there is no sound of
the pawl and ratchet wheel
engaging.
Check the brake section, pawl
and pawl spring for dirt,
corrosion, or spring failure.

Disassemble, clean and lubricate
the brake, pawl, and pawl springparts. Replace pawl spring andcheck the spring force.

③Lever does not move
either up or down. Thereis no clicking sound of thepawl engaging.

Ratchet wheel is not assembled
correctly. Pawl does not makeproper contact with the wheel.
Pawl spring is damaged.

Assemble correctly so that thepawl engages the ratchet wheel.
Conﬁrm the clicking sound ofratchet wheel meshing with thepawl before use.

④Lever does not move
either up or down.

E-ring for disc hub is not
attached. When E-ring for dischub is not attached, a gap will becreated in the brake section,interfering with the lift-lowering
operation.

Install E-ring for disc hubcorrectly.

⑲Pinion shaft㉙E-ring for disc hub−56−⑲Pinion shaft㉙E-ring for disc hub

The cause and target of
inspection is:

When in this situation:⑤Lever does not move
either up or down.
There is no audible pawl
engaging sound.

When attaching feed gear pawl to
the lever, the pawl may havebeen attached without checking
the setting of the changeoverknob to position N.

How to ﬁx:
Check that the changeover knob
is set to N, and then install theratchet for feed gear.
After installing the lever, alignratchet for feed gear to UP and
DN positions, and check if thefeed gear pawl and feed gear
engage each other with audible
clicking sounds.

Lever set
㊴Ratchet for feed gear
㊵Ratchet spring pin
Ratchet spring⑥Lever does not move.
Lever rotation is heavy.

Incorrectly assembled second andthird gears.

Marks are engraved on the 2nd
and 3rd gears. Install them so ○and I are facing each other.
After installing, rotate gears tomake sure they are not stuck.

Gear combination
0.8、1t
1.6t
3.2t、6.3t、9t⑦Chain does not movesmoothly.

Chain stripper is not oriented
correctly.

㉖Chain guide set

Gear-side plate set㉖Chain guide set㉗Chain stripper−57−

Make sure the chain stripper isoriented correctly.

When in this situation:

The cause and target
of inspection is:

How to ﬁx:⑧Chain does not movesmoothly.

Chain is not threaded in thecorrect position, and the meshing
between the chain and the load
sheave is not suﬃcient.

Reassemble the chain in thecorrect position and check the
chain engagement rise.

⑨Chain does not movesmoothly.

Incorrect assembly of theauto-rotating spring.
The end of the spring with thelarger diameter is facing the disk
hub side.

Reassemble correctly. Assemble
so that the end of the spring withthe smaller diameter is positionedon the disk hub side and the end
with the larger diameter is on thefeed handle side.

Larger spring diameter

Smaller spring diameter

Spring for ﬂoating
mechanism⑩Bottom hooks on two-hoist
lifting type equipment
does not lift fully to theend (touching the body).

⑲Pinion shaft

Bottom hook is reversed and thechain is twisted.

Restore reversed bottom hookand check if the chain is twisted.
Then conﬁrm whether the bottom
hook rises fully until it touches
the main unit.
Twisted chains

Chain in correctorientation−58−

Twisted chain due
to reversed hook

Do notoperateunit inthiscondition!

When in this situation:⑪Unable to perform
lowering operation

The cause and target
of inspection is:

How to ﬁx:

Hex. castle nut is left tightened tothe end.
Impact load has been applied.
(Unable to perform lowering
operation due to biting)Loosen Hex. castle nut by one or
two holes and readjust.
In case of biting, lift load once andrelease brake by setting lever tolowering.

Hex. socket head cap screw set⑲Pinion shaft

If hole position is just right,
loosen by one groove.

If nut is positioned over the holeposition, loosen nut by 2 grooves.

When the hole position is aligned

When the hole position is not aligned
2 grooves

1 groove1 groove
Hole position

Hole position⑫Load slips and skids whiledescending.

Foreign matter is lodged in thebrake section. Brake section is
not assembled correctly. Brake isdamaged or worn.

Remove foreign matter and clean
the brake section.
Reassemble correctly.
Replace with a new part.

⑬The lever cannot belowered after it has beenused once.

Brake has become engaged.
※The brake section is conﬁgured
similarly to a bolt and nut
mechanism. Biting is similar toexcessively tightened nuts.
When disassembling the lever, it
was removed without lowering(release the brake).

Apply load to the lever andprovide some extra force to thelowering motion to release thebrake.
Clean the brake section.

⑭Load chain does not movefreely during free chaining
operation.

Load chain was pulled too hardduring free chaining operation,and the brakes engaged.

Pull slowly on the load chain.

−59−

Inspection records
Model

Date of inspection

Tonnage

Name ofqualiﬁed person(Name ofinspector)

Production No.
Lift

Inspection Part
（Part No., Part Name）
1

Top hook set

Inspection contents
Check for openings in hook, twists, damage, etc.
Between punches
Hook thickness, vertical
Hook thickness, horizontal
Hole diameter of top hook pin

Safety latch set

Whether the hook is engaged, damaged, deformed, etc.

6

Top hook pin

Inspect for pin diameter wear.

7

Bottom hook set

Check for openings in hook, twists, damage, etc.

2

Between punches
Hook thickness, vertical
Hook thickness, horizontal
Hole diameter of chain stop bolt set
2

Safety latch set

Whether the hook is engaged, damaged, deformed, etc.

8Chain stop bolt set

Check the bolt diameter for wear, damage, deformation, etc.

13

Hex. nut

Inspect for damage, wear, deformation, etc.

14

Spring washer

Inspect for damage, wear, deformation, etc.

18

Gear cover set

Inspect for wear with bumps identiﬁable by hand and other damage.

19

Pinion shaft

Inspect for chipped gear teeth and other damage

20

Washer for pinion shaft

Inspect for damage, wear, deformation, etc.

21

Hex. castle nut

Inspect for damage, wear, deformation, etc.

22

Cotter Pin

Inspect for damage, wear, deformation, etc.

23

2nd and 3rd gear set

Inspect for chipped gear teeth and other damage

24

Load gear

Inspect for chipped gear teeth and other damage

25

Load sheave

Inspect for engagement with the chain, damage, deformation, etc.

26

Chain guide set

Inspect for proper operation of the changeover knob

−60−

Judgment Remarks

Inspection Part
（Part No., Part Name）

Inspection contents

27

Chain stripper

Inspect for cracks in the rubber handle, deformation, etc.

28

Disk hubInspect for damage, wear, deformation, etc.

29

E-ring for disc hub

Inspect for damage, wear, deformation, etc.

30

Ratchet wheel

Inspect for chipped gear teeth and other damage

31

Brake lining

Inspect for chipped pawls, wear, etc.

33

Lever setInspect for damage, wear, deformation, etc.

34 Lever grip

Inspect for damage, wear, deformation, etc.

35 Bracket screw

Inspect for wear and deformation of thepin hole diameter in the respective parts

92 Name plate

Inspect for wear and deformation of thepin hole diameter in the respective parts

36

Hex. nut

Inspect for damage, wear, deformation, etc.

37

Spring washer

Inspect for damage, wear, deformation, etc.

38

Feed gear

Inspect for wear with bumps identiﬁable
by hand and other damage.

39

Ratchet for feed gear

Inspect for damage, wear, deformation, etc.

40

Ratchet spring pin

Inspect for openings in the snap ring and damage, etc.

43

Lever cover set

Inspect for damage, wear, deformation, etc.

82

Gear-side plate set

Inspect for damage, wear, deformation, etc.

83

Lever-side plate set

Inspect for damage, wear, deformation, etc.

15 Pawl

Inspect for damage, wear, deformation, etc.

16 Pawl spring

Inspect for damage, wear, deformation, etc.

17 E-ring for pawl

Inspect for damage, wear, deformation, etc.

85

Ratchet spring

Inspect for damage, wear, deformation, etc.

87

Spring for ﬂoating mechanism

Inspect for damage, wear, deformation, etc.

88

Feed handle

Inspect for damage, wear, deformation, etc.

91

Chain stopper

Inspect for chipped gear teeth and other damage

102

Check washer

Inspect for openings in the snap ring and damage, etc.

103

Hex. socket head cap screw set

Inspect for chipped gear teeth and other damage

110

Tag

Inspect for chipped gear teeth and other damage

53

Load chain

Inspect for wear, damage, deformation, etc.

Judgment Remarks

Judgment : ○（Good）, ×（Replacement）※Perform the inspections and tests indicated above. Be sure to maintain records of the inspections.
※Be sure to replace any parts that are found to be even slightly unsafe with new parts.
※Please inspect based on ASME B30.21.

−61−

Breakdown Schematics and Parts Names : Models YA-80, 100, 160, 320, 630, 900

2
87

13

38

1

14
82
14

88
21

102

39

103

43

37

36

13

18

6

40
24

85

20

19

23

83
92
33

31

22

25

34

26

28
27

35

30

2

53

29

91

17

1

15

16

1

110

T ag

8

8

2

7
7

7

8

2

2
2

Model YA-900 Top/
Bottom hooks

Model YA-630 Top/Bottom hooks
Symbols in
Breakdown
Schematics

Parts Names

Symbols in
Breakdown
Schematics

Parts Names

Symbols in
Breakdown
Schematics

Parts Names

Symbols in
Breakdown
Schematics

Parts Names

Set Individual
Set Individual
Set Individual
Set Individual
unit
unit
unit
unit
17 E-ring for pawl
22 Cotter Pin
35 Bracket screw
1
Top hook set
85 Ratchet spring
23 2nd and 3rd gear set
92 Name plate
２ Safety latch set
24 Load gear
36 Hex. nut
６ Top hook pin
87 Spring for ﬂoating
mechanism
Bottom hook set
25 Load sheave
37 Spring washer
7
88 Feed handle
26 Chain guide set
38 Feed gear
２ Safety latch set
91 Chain stopper
27 Chain stripper
39 Ratchet for feed gear
８ Chain stop bolt set
1 2 Check washer
28 Disk hub
40 Ratchet spring pin
１３ Hex. nut
29 E-ring for disc hub
43 Lever cover set
１４ Spring washer
1 3 Hex. socket head cap
screw set
30 Ratchet wheel
82 Gear-side plate set
１８ Gear cover set
Lever-side plate set
Tag
83
11
31 Brake lining
１９ Pinion shaft
53 Load chain set
Lever set
15 Pawl
２０ Washer for pinion shaft 33
34 Lever grip
16 Pawl spring
21 Hex. castle nut※Parts indicated with black lines are included in the※The black line parts are also provided for sale individually.
parts with gray lines.
※Only for Model YA-630, the chain stop bolt set is included in
Example : Part No. 7, Bottom hook set includes Part the top hook.
No. 2, Safety latch set and Part No. 8, Chain stopbolt set.
−62−

ＹＡⅢ
187

138
188

Symbols in
Breakdown
Schematics

Set Individual
unit

173

Parts Names

138

TORCON device set

173

Hex. socket head cap screw set

187

Spring for ﬂoating mechanism

188

Feed handle

ＹＡS

401
402
Symbols in
Breakdown
Schematics

Set Individual
unit
401

Top hook set
402

407

402

−63−

Safety latch set
Bottom hook set

402

407

Parts Names

Safety latch set

ＹＡR

501

Symbols in
Breakdown
Schematics

Set Individual
unit
501

505

Top hook set
505

507

−64−

Trigger set
Bottom hook set

505

507

Parts Names

Trigger set

Warranty
In this section, ELEPHANT CHAIN BLOCK CO., LTD is hereinafter referred to as ELEPHANT .
In this section, Owners or Operators are hereinafter referred to as Customer .
ELEPHANT warrants that the product (Manually Lever Operated Chain Hoist) manufactured andmarketed by ELEPHANT will be free from defects in material and workmanship for the following
period from the initial date of use by Customer.
Manually Lever Operated Chain Hoist 1 year
Customers are requested to write down the start date of use of the product on the cover of thisInstruction Manual.
However, the product must be used in accordance with ELEPHANT's recommendations. In
addition, the product must not be subjected to rough use, inadequate maintenance, misuse,careless use, incorrect repairs or modiﬁcation. If ELEPHANT's inspection of the product reveals
that the product has become defective in material and workmanship within the period indicatedabove, ELEPHANT agrees, at its sole discretion, to send and deliver the aﬀected parts to theCustomer for replacement free of charge (not including installation work).
The Customer must follow the instructions provided by ELEPHANT to obtain a return
authorization prior to returning the product for warranty evaluation.
If you have a complaint about a product, please submit the product and the following documents.
1) Detailed description at the time of use
2) Photos or videos that show the usage status
3) Record of start date of use (cover of this manual)
4) Inspection record (based on ASME)
5) Product (stored as it was at the time of the accident and not disassembled)
In addition, the return shipment must be made with freight prepaid, to the address and in the
shipping way directed by ELEPHANT.
After returning from repair, the product shall be warranted for the remainder of the original
warranty period.
Replacement parts installed after the expiration of the original warranty period shall bewarranted (not including installation labor) only for a period of one year from the date of
installation.
If the product is found to be without defect or it is determined by ELEPHANT that themalfunction was caused by Customer s operating condition, the customer shall be responsible
for the cost of returning the product. If ELEPHANT repairs the product according to the requestof the customer, the customer shall be responsible for the cost of repair and returning the
product.
ELEPHANT shall make no other express or implied (unwritten) warranties as to the suitability ofthe product or its applicability to particular purposes.
ELEPHANT shall not be liable for any loss or expense incurred in connection with the use of the
product, resulting in death, injury to persons or property, or for incidental, special orconsequential damage.
In addition, ELEPHANT shall not be liable for any loss or expense incurred as a result of any act
or omission or for any other reason, whether due to negligence or intentional.

−65−

The goods has passed rigid inspection by us ahead of delivery inaccordance with our standard in terms of test load and all otherrespects in good and satisfactory condition.
Inspector

ELEPHANT CHAIN BLOCK CO.,LTD.
180 Iwamuro 2-chome, Osaka-Sayama-City,
Osaka, Postal code 589-8502, JAPAN
Phone : 072-365-7778 Fax : 072-365-7869（#951-261）2023. 7. 2,000 S