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Yale 11353395D User's Manual

1. Ref Part Qty No Number Description Req d GHB 800 B Frame Hoist Limit Switch Assembly Includes Ref Nos 1 16 1 GHB 801 Limit Switch 1 2 GHB 802 Pan Head Machine Screw Phillips 210 32 x 1 1 4 Long 2 3 GHB 803 Lockwasher 10 2 4 GHB 804 Limit Switch Bracket 1 5 GHB 805 Limit Switch Rod 1 6 GHB 806 Dowel Pin 3 16 Diameter x 1 2 Long 1 7 GHB 807 S Hook 1 2 Eye 1 8 GHB 808 Coil Chain 1 9 GHB 809 Hex Head Bolt 1 4 20 x 1 3 4 2 10 GHB 810 1 4 Diameter Flat Washer 2 11 GHB 811 Limit Switch Weight Half 2 12 GHB 812 Self Locking Nut 1 4 20 2 13 GHB 813 Hex Socket Head Cap Screw 7110 32 2 14 GHB 814 Limit Switch Hub 1 15 GHB 815 Hex Head Bolt 1 4 20 x 1 1 4 2 16 GHB 812 Self Locking Nut 1 4 20 2 C Frame Block Operated Limit Switch Components for Figure 9 8 Ref Part Qty No Number Description Req d GHC 800 B Frame Hoist Limit Switch Assembly Includes Ref Nos 1 16 1 GHC 801 Limit Switch 1 2 GHC 802 Pan Head Machine Screw Phillips 2210 32 x 1 1 4 Long 2 3 GHC 803 Lockwasher 10 2 4 GHC 804 Limit Switch Bracket 1 5 GHC 805 Limit Switch Rod 1 6 GHB 806 Dowel Pin 3 16 Diameter x 1 2 Long 1 7 GHB 807 S Hook 1 2 Eye 1 8 GHB 808 Coil Chain 1 9 GHB 809 Hex Head Bolt 1 4 20 x 1 3 4 2 10 GHB 810 1 4 Diameter Flat Washer 2 11 GHB 81
2. ra Figure 9 3 Motor Driven Trolley Frame and Drive B Frame Shown B Frame Trolley Frame and Drive Components for Figure 9 3 Ref Part Qty No Number Description Req d 1 Side Plate 1 GHB 301A Drum Side 25 Lift Frame GHB 301B Drum Side 40 Lift Frame 2 Side Plate 1 GHB 302A Drive Side 25 Lift Frame GHB 302B Drive Side 40 Lift Frame 3 Counterweight 1 GHB 303A Counterweight 25 Lift Frame GHB 303B Counterweight 40 Lift Frame 4 GHB 304 Lockwasher 5 8 2 5 GHB 305 Hex Head Bolt Grade 5 5 8 11 x 1 1 2 2 6 Alignment Bar 2 GHB 306A Alignment Bar 4 Thru 14 Trolley Beam Flange Width GHB 306B Alignment Bar 14 1 8 Thru 20 Trolley Beam Flange Width 7 Hex Cross Shaft 1 GHB 307A Hex Cross Shaft 4 Thru 14 Trolley Beam Flange Width GHB 307B Hex Cross Shaft 14 1 8 Thru 20 Trolley Beam Flange Width 8 GHB 308 Motor Specify HP Phase Voltage Frequency amp Number of Speeds 1 9 Traverse Gear Reducer See Figure 9 11 for Components 1 GHB 309A 50 FPM GHB 309B 75 FPM 10 GHB 310 Hex Head Bolt Grade 5 3 8 16 x 1 4 11 GHB 311 Lockwasher 3 8 4 12 GHB 312 Hex Head Bolt Grade 5 5 16 18 x 7 8 4 34 B Frame Trolley Frame and Drive Components for Figure 9 3
3. Ref Part Qty No Number Description Req d 13 GHB 313 Lockwasher 5 16 4 14 Threaded Rod 2 GHB 314A Threaded Rod 4 Thru 14 Trolley Beam Flange Width GHB 314B Threaded Rod 14 1 8 Thru 20 Trolley Beam Flange Width 15 GHB 315 Heavy Hex Nut 3 4 10 12 16 GHB 316 Flat Washer 3 4 8 17 GHB 317 Hex Clamp Collar 2 18 GHB 318 Cross Shaft Pinion 2 19 GHB 319 Flat Washer 4 20 GHB 320 Hex Bore Ball Bearing 2 21 GHB 321 Driver Wheel 6 1 2 Diameter Tread 2 22 GHB 322 Trailer Wheel 6 1 2 Diameter Tread 2 23 GHB 323 External Retaining Ring 4 24 GHB 324 Ball Bearing 8 25 GHB 325 Internal Retaining Ring 4 26 GHB 326 Axle 4 27 GHB 327 External Retaining Ring 4 C Frame Trolley Frame and Drive Components for Figure 9 3 Ref Part Qty No Number Description Req d 1 Side Plate 1 GHC 301A Drum Side 25 Lift Frame GHC 301B Drum Side 40 Lift Frame 2 Side Plate 1 GHC 302A Drive Side 25 Lift Frame GHC 302B Drive Side 40 Lift Frame 3 Counterweight 1 GHC 303A Counterweight 25 Lift Frame GHC 303B Counterweight 40 Lift Frame GHC 303C Counterweight Mounting Cap Not Shown 4 4 GHC 304 Lockwasher 3 4 4 5 GHC 305 Hex Head Bolt Grade 5 3 4 10 x 2 2 6 GHC 306 Alignment Bar 2 7 GHC 307 Hex Cross Shaft 1 8 GHC 308 Motor Specify HP Phase Voltage Frequency amp Number of Speeds 1 9 Traverse Gear Reducer See Figure 9 12 for Components 1 GHC 309A 50 FPM
4. 1 Lower the lower block to a scaffold 6 to 7 feet below hoist to relieve tension on wire rope Lower block may be lowered to the floor if desired however to handle less weight and for ease of reeving adequate scaffold below the hoist is recommended y J v J 4 Remove outer lower block sheave covers 5 Remove lower block sheaves and wire rope 6 Remove two 2 rope retention bolts and nuts from upper block yoke 7 Remove two 2 bolts and key plate to allow removal of upper block sheave pin 8 Securely grasp the upper block sheave before carefully sliding the sheave pin out Note that two spacers will also be released as the pin is removed 9 Remove wire rope from sheave 10 Remove retaining rings or cotter pins from dead end anchor pin Securely grasp the swaged wire rope and in some cases spacers before removing the pin 11 Remove Rope Guide 12 Make certain all personnel are clear of hoist and operate hoist DOWN to completely unwind all wire rope from drum Stop hoist so all 3 rope clamps are accessible Remove rope clamps and wire rope from drum AWARNING Winding rope on rope drums with power can be hazardous Keep hands safe distance from drum wear gloves and use extreme care when winding rope FIGURE 5 6 Reeving Diagram 4 Part Single Reeved Note Arrow on Drum Indicates Direction of Drum when Lowering ACAUTION
5. Be certain all personnel are clear of hoist as components hardware and wire rope are removed from hoist 2 Remove block operated limit switch weight from rope 3 Remove retaining rings from lower block sheave pin d Installing new rope 1 Thread rope to drum from trolley frame side then secure with rope clamps as follows a Make sure that the rope clamp groove size utilized as marked directly above the groove matches the rope size for your hoist 7 16 on the B Frame and 9 16 on the C Frame b With the rope lying in the bottom of the drum groove begin tightening the rope clamp at the tail end of the rope Torque to 50 ft lbs c With tension on the rope keeping it properly seated in the drum groove 17 torque the remaining two 2 rope clamps in sequence to 50 ft lbs 2 With all personnel clear of hoist TURN ON POWER 3 Operate hoist UP guiding six 6 wraps of new rope into drum grooves with gloved hand 3 Re install rope guide over rope in rope drum grooves as shown in Figure 5 3 and outlined in Section V Paragraph 5 6 Continue lubricating as rope is spooled onto the drum until about 28 0 remain unwound 7 With outer lower block covers removed thread the wire rope through the sheaves of the upper and lower block as shown in Figure 5 6 8 Attach swaged rope end to the dead end anchor pin fastening cotter pins or retaining rings as requi
6. GHC 908 Lockwasher 1 4 CO N 0 On AOIN gt GHC 909 Socket Head Cap Screw 1 4 20 x 3 4 SB BB 43 4 po Po a a a 42 7 r 7 A ZA Yj Yj 7 7 ANA A IIL SOC NUN NANG SAC y 7 A 77 v Wr X Figure 9 10 Hoist Motor Brake B Frame Hoist Brake Components for Figure 9 10 Ref Part Qty No Number Description Req d 1 GHB 10011 Brake Disc 1 GHB 1002 Brake Fan Kit Includes items 2 thru 7 1 2 Fan 1 3 External Retaining Rings Fan 2 4 External Retaining Ring Fan Hub 1 5 Fan Hub 1 6 Key Hub 1 7 Key Fan 1 GHB 1008 Brake Hub Kit Includes items 8 thru 11 1 8 External Retaining Ring Brake Hub 1 9 Spacer 1 10 Key Brake Hub 1 11 Brake Hub 1 GHB 1012 Brake Hardware Kit Includes items 12 thru 15 1 12 Hollow Core Bolts 3 13 O Ring 1 14 Bolts Brake Mounting 3 15 Springs 3 16 GHB 1016 Magnet Body Includes GHB 1012 Hardware Kit 1 GHB 1017 Fan Shroud Kit Includes items 17 and 18 1 17 y Fan Shroud 4 18 Bolt Brake and Fan Shroud 1 19 GHB 1019 Brake End Bell Assembly for 7 5 1 25 HP Motor 1 20 GHB 1020 Gearcase End Bell Assembly for 7 5 1 25 Motor Not Shown 1 21 Rotor Assembly for 7 5 1 25 HP Motor Not Shown 1 GHB 1021A
7. for Points Not Shell amp Oil Co Rotella amp 10W Rotella amp 10W 30 nee Normal Sun amp Oil Co Sunvis amp 932 Sunvis amp 968 sr Texaco Inc Rando Oil 46 Rando Oil 68 MPG NLGI Grease No 1 No 2 Multipurpose 6ASTM Worked 310 340 265 295 Grease Penetration Dropping Point 360 F 182 C 360 F 182 C Grease Lubricated Base Lithium Lithium Wear Points Amoco Oil Co Amolith Grease 1 EP Amolith Grease No 2 EP Provided with Mobil Oil Corp Mobilith amp AW 1 Mobilith amp AW 2 Fittings and Grid or FShell Oil Co a Retinax LC Gear Type Flexible l Sun Oil Co Prestige 741 EP Sunoco Multipurpose 2 EP Couplings Texaco Inc Multifak EP 1 Multifak EP 2 10 4 7 LUBRICANT SPECIFICATIONS AMBIENT TEMPERATURE CONT D 20 to 50 F 50 to 100 F 100 to 250 F 29 to 10 to 38 C 38 to 121 C 10 C GCOT AGMA Lubricant No 5S No 8 Compounded Refer to Yale Hoist Gear Case ISO Viscosity Grade 220 680 Field Service Oil American Lubricants SHC 90W AGMA 8 Gear Oil Department for Mobil Oil Corp Mobil SHC Extra Hecla Super Gearcase Operating Traverse 630 Temperatures above Gear Case Shell amp Oil Co Omala RL ValvataG J 680 200 F 220 Fiske Brothers amp SPO MG SPO 288 Texaco Inc Pinnacle Vanguard 680 220 SECTION V
8. Geared Upper amp Lower Limit Switches and Optional Fuses 1 i i 7 E oy N UK l y f c K A Wr Y 27 Figure 8 2 Component Diagram for a Two Speed Hoist and Two Speed Trolley with TAS Hoist Block Operated Limit Switch Geared Upper amp Lower Limit Switches and Optional Fuses WIRE JEVICE CONNECTED CONNECT PER NAMEPLATE FOR PROPER VOLTAGE 2 SUPPLY HLI HL2 i L1 12 13 VN NY FU U D PFU U D PFU U D FU HCPT PFU HCPI C U D F D RL EC HLI HL2 HL3 vas OA HLI HL2 H FC le d Ny HTI u p Nda HT2 D M I HT11 F ee ee ee ee eee HT12 EM uro 92 A H2 C 1A OA 92 92 HT11 HTI HT3 HT13 0 B1 n T J 40A CLI CL2 CL3 41 40B 41A 42 DF 0C B1 e deese OH TBI D BCM 1 B1 zs LE ie A J D R Conk PURIS eee 4 H B1 U BCh S 2 mr 40 B2 10A QR D E 40B 2 D C 41A 40A 92 92 CTI1 CH CT3 C 1 i don 288 8 z e gzs 92 BCM R L FC CBI CB2 HB1 HB2 R PE LIMIT S YPE LIMIT ETRE MIS A ORMES EN V 28 SECTION IX PARTS LIST 9 1 GENERAL The par
9. INSPECTION AND PREVENTATIVE MAINTENANCE 5 1 GENERAL All Yale Global King hoists are inspected and tested at the factory Regular in service inspection and preventative maintenance programs not only help reduce overall maintenance costs but may also prevent service shutdowns by forewarning of problems that could cause these shutdowns Regular inspections periodic minor adjustments regular cleaning and lubrication and replacement of worn parts can help preserve good performance and operation of your hoist Many factors influence the inspection and preventative maintenance program required for your hoist Frequency and severity of service and material handled local environmental conditions and various applicable codes are some of the factors that the user must consider to adjust inspection and maintenance program outlined in this section to meet his specific conditions The inspection and maintenance services outlined in this section are considered minimum Recommended in the schedule are minimum inspection and maintenance intervals based on average daily use in a normal environment Average daily use is based on 1000 total operational hours per year maximum and intermittent operation of the hoist eight hours per day five days per week with a maximum 50 percent on time and the average loading not exceeding 65 percent of rated load For more details regarding hoist duty cycles please reference ANSI ASTM HST 4 Environment
10. MainConauctors Jo p opo po opo op o p S Maincotlectors Jo jp p opo p o opo op o p 2 S SSS E rE X Record Hook Throat Opening CONTROL fof jejefelejejo o wovev EEENOINOOSOBESSSNRSECLULN ol TTT TT TT TT TTT ILL LLLI DL mm y Pe cece Pele as E ese s Fs ope ene Mlle Is 6990 ai STATION OR PUSHBUTTON RUNWAYS sero TROLLEY Load attachment Chains fe o p po jo RoeSigs amp Comecions Jof TO p po bdo Change Gearcase Lubricant oo o o dos GroundingFauts Pol oy ft oo do o Seetext for DAILY amp WEEKLY REQUIREMENTS SIGNED amp DATED REPORT OSHA O INSPECTION INTERVAL X MAGNETIC PARTICLE OR EQUIVALENT EXAMINATION REQUIRED Typical Inspection Schedule and Maintenance Report form 12375gwr 13 User must adjust Inspection Interval and components to suit his individual conditions and usage AWARNING Do not operate a hoist having unusual vibrations sounds or with anything wrong or apparently wrong Danger may be present that the hoist operator cannot see Determine and correct the cause of unusual conditions and make certain hoist can be operated safely 5 2 INSPECTION OF LOWER BLOCK 14 a Check lubrication of all parts Also lubricate the shank of the hook that passes through the crosshead If the thrust bearing is removed apply MPG grease Section IV Para 4 7 Check each sheave to insur
11. or sheaves b Make certain that all sheaves bearing and hanger pins are free of foreign material Bearings without grease fittings are lubricated for the life of the bearing and require no further lubrication c Make certain that the rope retention bolts are not bent loose or otherwise distorted bolts must have close clearance to sheave flange to keep rope in sheave grooves 5 4 INSPECTION OF ELECTRICAL CONTROLS Arrangement of electrical control equipment varies with the type of control physical space and the optional control features ordered with the hoist Note the location in the electrical enclosure of the control circuit fuse transformer limit stop switches and the hoist contactors Trolley contactors and optional hoist and trolley fuses are also located in this enclosure Use wiring diagrams furnished with hoist to determine electrical components on your hoist then determine component location and identity on your AWARNING Be certain that main power switch is locked in open position OFF before opening hinged control enclosure cover mounted to the counterweight a Open hinged control panel enclosure cover mounted to the counterweight and inspect wiring and terminals Terminals should be securely crimped to wires and insulation sound Terminal screws should be tight b Check condition of contactor assembly transformer and upper limit switches AWARNING Check to be certa
12. 4 10 6 6 GHB 106 High Strength Hex Head Bolt Grade 5 3 4 10 x 2 1 2 6 7 GHB 107 Heavy Hex Self Locking Nut 5 8 11 4 8 GHB 108 Gearcase 1 9 GHB 109 Gearcase Gasket 1 10 GHB 110 Gearcase Cover 1 11 GHB 111 Lockwasher Hi Collar 1 2 9 12 GHB 112 Socket Head Cap Screw 1 2 13 x 2 1 4 7 13 GHB 113 Hex Shoulder Bolt 3 8 16 x 2 Long 1 2 shoulder 2 14 GHB 114 Vent Plug with Sealant 1 2 14 NPT 1 15 GHB 115 Pipe Plug 1 2 14 NPT 2 16 GHB 116 Heavy Hex Lock Nut 1 2 13 2 17 GHB 117 Hardened Flat Washer 1 2 2 18 GHB 118 Gearcase End Drum Frame 1 19 GHB 119 Hex Head Grade 5 Bolt 1 2 13 x 1 1 4 4 20 GHB 120 Hardened Flat Washer 5 8 4 21 GHB 121 Thin Hex Self Locking Nut Grade 5 5 8 18 4 22 GHB 122 Socket Head Cap Screw Plated 7 16 14 x 1 1 4 3 23 GHB 123 Lockwasher Hi Collar 7 16 3 24 GHB 124 Rope Clamp 3 25 Drum 1 GHB 125A Drum 25 Lift GHB 125B Drum 40 Lift 26 GHB 900 Rope Guide See Figure 9 9 for Rope Guide and its components 1 27 GHB 127 Flange Mounted Ball Bearing 1 30 B Frame Hoist Components for Figure 9 1 Ref Part Qty No Number Description Req d 28 GHB 128 Lockwasher 7 16 4 29 GHB 129 High Strength Hex Head Bolt Grade 5 7 16 14 x 1 1 2 2 30 GHB 130 High Strength Hex Head Bolt Grade 5
13. 7 16 14 x 1 3 4 2 31 GHB 131 Outboard End Drum Frame 1 32 GHB 132 Limit Switch Bracket 1 33 GHB 133 Retaining Ring 1 34 GHB 134 Drum Shaft Insert for Geared Limit Switch 1 35 GHB 135 Geared Limit Switch 1 36 Drum Frame Rod GHB 136A Drum Frame Rod 25 Lift 2 GHB 136B Drum Frame Rod 40 Lift 2 C Frame Hoist Components for Figure 9 1 Ref Part Qty No Number Description Req d 1 15 HP Hoist Motor 2 Speed with Brake and Fan Note See Figure 9 10 for Parts 1 GHC 101A 230 volt 3 phase 60 Hertz GHC 101B 460 volt 3 phase 60 Hertz GHC 101C 575 volt 3 phase 60 Hertz 2 GHC 102 Heavy Hex Nut 3 4 10 2 3 GHC 103 Lockwasher 3 4 2 4 GHC 104 High Strength Hex Head Bolt Grade 5 3 4 10 x 3 1 4 2 5 GHC 105 Self Locking Nut ESNA 1 8 6 6 GHC 106A Socket Head Cap Screw 1 8 x 3 2 6 GHC 106B Socket Head Cap Screw 1 8 x 4 2 7 GHC 107 Heavy Hex Self Locking Nut 7 8 9 4 8 GHC 108 Gearcase 1 9 GHC 109 Gearcase Gasket 1 10 GHC 110 Gearcase Cover 1 11 GHC 111 Lockwasher Hi Collar 5 8 9 12 GHC 112 Socket Head Cap Screw 5 8 11 x 2 3 4 7 13 GHC 113 Hex Shoulder Bolt 1 2 13 x 2 1 4 Long 5 8 shoulder 2 14 GHC 114 Vent Plug with Sealant 1 2 14 NPT 1 15 GHC 115 Pipe Plug 1 2 14 NPT 2 16 GHC 116 Heavy Hex Self Locking Nut 3 4 10 2 17 GHC 117 Hardened Flat Washer 3 4 2 18 GHC 118 Gearcase End Drum Frame 1 20 GHC 117 Hardened Flat Washer 3 4 4 21 GHC 121 Thin Hex Self Locking Nut Grade 5 3 4 16 4 22 GHC 122 Socket
14. GHC 309B 75 FPM 10 GHC 310 Hex Head Bolt Grade 5 3 8 16 x 1 4 11 GHC 311 Lockwasher 3 8 4 12 GHC 312 Socket Head Cap Screw 5 16 18 x 1 4 13 GHC 313 Lockwasher 5 16 4 14 GHC 314 Threaded Rod 2 15 GHC 315 Heavy Hex Nut 3 4 10 12 16 GHC 316 Flat Washer 3 4 8 17 GHC 317 Hex Clamp Collar 2 18 GHC 318 Cross Shaft Pinion 2 19 GHC 319 Flat Washer 4 20 GHC 320 Hex Bore Ball Bearing 2 21 GHC 321 Driver Wheel 8 Diameter Tread 2 22 GHC 322 Trailer Wheel 8 Diameter Tread 2 23 GHC 323 External Retaining Ring 4 24 GHC 324 Ball Bearing 8 25 GHC 325 Internal Retaining Ring 4 26 GHC 326 Axle 4 27 GHC 327 External Retaining Ring 4 35 N Figure 9 4 Lower Block Assembly B Frame Lower Block Components for Figure 9 4 Ref Part Qty No Number Description Req d GHB 400Y Lower Block Assembly Includes Ref Nos 1 17 1 1 GHB 401 Lower Block Frame Hook Beam 1 2 GHB 402 Hook 1 3 GHB 403 Thrust Bearing 1 4 GHB 404 Castle Nut 1 5 GHB 405 Spring Pin 1 6 GHB 406Y Sheave Covers Yellow 4 7 GHB 407 Flat Head Socket Cap Screws 1 4 20 x 1 2 4 8 GHB 408 Sheave Pin 1 9 GHB 409 Sheaves 2 10 GHB 410 Ball Bearings 2 11 GHB 411 Internal Retaining Rings 2 12 GHB 412 External Retaining Rings 2 13 GHB 413 Socket Head Cap Screws 1 4 20 x 2 3 4 Long 8 14 GHB 414 Hi Collar Lockwashers 1 4 8 15 GHB 415 Self Loc
15. and locked out 3 Drain the oil from the gear case per Section IV Paragraph 4 2 19 4 Disconnect the wiring and conduit from the motor junction box 5 Provide a means to support the hoist motor The hoist motor weighs approx imately 250 Ibs And must be held level while removing and installing O Once the motor is properly supported remove the hardware fastening it to the gear case Carefully withdraw the motor horizontally straight out from the gear case Do not tip or move the motor from side to side N Replace the motor shaft seal using an appropriate seal driver It is recommended that a new seal be installed each time the motor is removed from the case IMPORTANT Before installing the motor pack the gear teeth with MPG grease Paragraph 4 7 and wrap the gear teeth with a number of layers of Teflon tape to protect the seal lip from being damaged by the gear teeth Coat the seal lip and the motor shaft with MPG grease ANOTICE Failure to use a factory replacement seal will cause premature seal failure due to specific lip material requirements that must be met 20 9 Install the motor to the gear case The motor shaft must be in line with the seal bore and perpendicular to the mounting surface before attempting to insert the shaft through the seal The motor shaft must remain horizontal and not rock up and down or side to side while instal
16. at slow speed depressing button completely operates hoist or trolley at full speed 3 3 OPERATING PRECAUTIONS Safe operation of an overhead hoist is the operator s responsibility Listed below are some basic rules that can make an operator aware of dangerous practices to avoid and precautions to take for his own safety and the safety of others Observance of these rules in addition to frequent examinations and periodic inspection of the equipment may save injury to personnel and damage to equipment AWARNING Equipment covered herein is not designed or suitable as a power source for lifting or lowering persons a DO read ASME B30 16 Safety Standard for Overhead Hoists and the Operation Service and Parts Manual b DO be familiar with hoist operating controls procedures and warnings c DO make sure hook travel is in the same direction as shown on the controls If opposite direction occurs see Pre Operation Checks Section Il Paragraph 2 4 b d DO make sure hoist limit switches function properly e DO maintain firm footing when operating hoist f DO make sure that the load slings or other approved single attachments are properly sized and seated in the hook saddle g DO make sure that the hook latch is closed and not supporting the load h DO make sure that load is free to move and will clear all obstructions aa bb CC DO take up slack carefully check load balance lift a fe
17. case with the cover it will disengage from the drum allowing the drum to drop Be certain all shaft assemblies stay in the case Only once the output shaft is free of the rope drum can the output shaft assembly be safely removed from the gear case Provide an adequate means to support this shaft and gear assembly before removing as it weighs approximately 80 lbs C Frame Hoist 6 The pinion shaft and gear assemblies may be removed as necessary Inspect all gears pinions bearings and the output shaft spline for wear pitting or mechanical damage Replace as necessary See Section IX Figure 9 2 for replacement parts It is recommended that gears and pinions only be replaced as sets Thoroughly clean the output shaft external spline teeth before reassembly N Assembly is opposite of removal Use a new gasket Do not attempt to assemble the cover to the gear case without a gasket as the spacing between bearings will be reduced Severe damage to the hoist will occur if no gasket or the wrong gasket is used Refill gear case with new lubricant per Section IV Paragraph 4 2 before use Using SG Paragraph 4 7 grease the spline teeth on the output shaft before reinstalling rope drum 9 Test hoist per Section V Paragraph 5 13 to ensure proper lubrication Hoist Motor 1 Lower hook block to the floor and relieve all load from ropes 2 Make sure power to hoist is off
18. disk against the motor end bell generating the torque necessary to stop the hoist machinery and hold the load It will be necessary to compensate for the friction disk wear when a greater amount of hook movement drift is noticed when stopping There is no torque adjustment of the brake Friction disk wear can only be compensated for by resetting air gap B NX uf j CIT b I NS Qs AY b Figure 5 9 Motor Brake Friction Disk Inspection and Air Gap Adjustment 1 Lower hook block to the floor and relieve all load from ropes 2 Make sure power to the hoist is off and 3 locked out Remove the four 4 bolts attaching the fan shroud to the motor and remove the fan shroud See Figure 5 9 Carefully roll the large O ring from the groove over the air gap back toward the magnet body Do not excessively stretch this O ring Measure the air gap using feeler gages If the air gap exceeds the maximum value shown in Table 5 1 the air gap must be reset To measure the thickness of the friction disk it is necessary to remove the brake body from the motor end bell Remove the three 3 brake mounting bolts and draw the brake body away from the friction disk Carefully set the brake body down on the motor shaft directly in front of the fan Draw the friction disk away from the end bell and measure the
19. hoist in service If misadjusted repeat steps above Allow 3 for hook drift in both directions Never allow less than two 2 complete wraps of rope on drum with hook in lowest position 26 a Loosen screws at cable connectors and clamps at top of cable b Adjust steel support cable to proper length and tighten screws c Loosen upper cable grip and pull excess cable into connection box at hoist d Tighten cable grip and cut off excess cable e Strip cable sheath and connect wires with the same type of terminals previously furnished care must be taken to match previous wire color coding with wire markers in accordance with wiring diagram furnished with hoist SECTION VIII WIRING DIAGRAMS 8 1 GENERAL Comprehensive wiring diagrams for Yale electric hoists have been omitted from this book because of the many possible variations This is due to different currents and types of electrical components used in their construction Figures 8 1 and 8 2 are examples of typical two speed hoist and trolley wiring diagrams respectively However please consult the exact wiring diagrams for your hoist A print of the correct wiring diagram for each hoist is furnished as a separate insert and shipped with the hoist We suggest you carefully file the wiring diagram with this book for future reference Figure 8 1 Elementary Wiring Diagram for a Two Speed Hoist and Two Speed Trolley with TAS Hoist Block Operated Limit Switch
20. misadjusted SEVERE DAMAGE AND OR A DROPPED LOAD COULD RESULT Allow 3 for hook drift in both directions Never allow less than two 2 complete wraps of rope on drum with hook in lowest position Damage to the hoist may occur if the block operated limit switch fails during testing Damage can be avoided by immediately releasing the pushbutton once the lower block has traveled through the limit switch weight The block operated limit switch may now be tested by slowly and carefully raising the hook until the limit switch weight contacts the lower block If the hook does not stop when the limit switch weight is lifted immediately release the pushbutton before damage to your hoist occurs If the block operated switch functions properly proceed by testing in the same manner with rated load on the hook Once it has been determined that the block operated limit switch is functioning properly the geared limit switch must be reconnected and tested Position the lower block three inches 3 below the point where the block operated limit switch is activated The geared limit switch shall be reconnected by sliding the locking plate back into position ensuring slots on adjustment discs are fully engaged and tightening locking plate screws to 4 in Ibs See Figure 7 2 The geared limit switch must then be tested Test the geared limit switch by raising the lower block until it stops Ensure that the geared limit
21. stops unless recommended They are emergency devices only DO NOT use hoist to lift transport people support or DO NOT lift loads over people DO NOT leave a suspended load un attended unless specific precautions have been taken DO NOT allow sharp contact between two hoists or between hoist and obstructions DO NOT allow the rope or hook to be used as a ground for welding DO NOT allow the rope or hook to be touched by a live welding electrode DO NOT remove or obscure the warnings on the hoist DO NOT adjust or repair a hoist unless qualified to perform hoist maintenance DO NOT attempt to lengthen the wire rope or repair damaged wire rope Personnel not physically fit or properly qualified shall not operate hoist DO NOT operate hoists unless hook moves in the same direction as indicated on the push button If opposite direction occurs see pre operation checks Section Il Paragraph 2 4 b DO NOT operate hoist unless limit switch is operating properly DO avoid operating hoist when hook is not centered under hoist Avoid side pulls and swinging of load or load hook when traveling hoist DO operate hoist within recommended duty cycle and do not jog unnecessarily DO conduct regular visual inspections for signs of damage and wear DO NOT operate hoist with hooks that have opened up See Section V Paragraph 5 2 f DO provide supporting structure that has an appropriate design factor based o
22. thickness over the friction surfaces If the friction disk thickness is less than the minimum shown in Table 1 it must be replaced See Section IX Figure 9 10 If the friction disk thickness is within the allowable reassemble the brake body to the motor end bell and torque the mounting bolts to the value shown in Table 5 1 Whenever the friction disk is replaced it is necessary to reset the air gap Hoist B Frame C Frame Mounting Bolt 18 ft lbs 18 ft lbs Torque Nominal Air Gap 0 016 in 0 016 in Maximum Air Gap 0 031 in 0 035 in Minimum Brake 9 453 in 0 472 in Disk Thickness Table 5 1 Motor Brake Data To reset the air gap begin by releasing the 3 mounting bolts 1 2 turn Turn the hollow spacer bolts into the magnet body approximately 1 4 turn Retighten all three mounting screws Measure the air gap at a minimum of three places around the circumference Threading the hollow spacer bolts into the magnet body will decrease the air gap while backing these spacer bolts out of the magnet body will increase the air gap Repeat this step as necessary until the required air gap is 9 achieved The air gap must be the same all the way around the brake Once the air gap is correct torque the mounting bolts to the value shown in Table 5 1 Replace the large O ring over the air gap and reassemble the fan shroud to the motor Test hoist per Section V Paragr
23. 1 Limit Switch Weight Half 2 12 GHB 812 Self Locking Nut 1 4 20 2 13 GHB 813 Hex Socket Head Cap Screw 7110 32 2 14 GHB 814 Limit Switch Hub 1 15 GHC 815 Hex Head Bolt 1 2 13 x 2 2 16 GHC 816 Self Locking Nut 1 2 13 2 17 GHC 817 Lockwasher 1 2 Not Shown 2 18 GHC 818 Flat Washer 1 2 Not Shown 2 41 Figure 9 9 Rope Guide Assembly B Frame Rope Guide Components for Figure 9 9 Ref Part Number Description Qty Req d GHB 900 B Frame Rope Guide Assembly Includes Ref Nos 1 9 GHB 901 Rope Guide Frame Machined GHB 902 Plastic Shroud GHB 903 Extension Spring GHB 904 Shoulder Bolt 1 4 20 x 1 1 2 Long 5 16 Shoulder GHB 905 Compression Spring GHB 906 Grease Fitting GHB 907 Anti Rotation Clip GHB 908 Lockwasher 1 4 X oo 1 Oj O1 BY Go Ro gt GHB 909 Socket Head Cap Screw 1 4 20 x 3 4 J iN aja a a C Frame Rope Guide Components for Figure 9 9 Ref z 2 Part Number Description 2 lt Req d GHC 900 C Frame Rope Guide Assembly Includes Ref Nos 1 9 GHC 901 Rope Guide Frame Machined GHC 902 Plastic Shroud GHC 903 Extension Spring GHC 904 Shoulder Bolt 5 16 18 x 1 1 2 Long 3 8 Shoulder GHC 905 Compression Spring GHC 906 Grease Fitting GHC 907 Anti Rotation Clip
24. 111 Slow Speed Key 1 12 GHB 1112 Pipe Plug Socket Head Coated and Plated 1 8 27 NPTF 6 13 GHB 1113 Vent Shield 1 14 GHB 1114 Drive Pin 4 x 3 16 Stainless Steel 2 15 GHB 1115 Slow Speed Cover Standard 1 16 GHB 1116 Slow Speed Cover Special 4 17 GHB 1117 Hex Head Cap Screw 5 16 18 x 7 8 Long Coated with Polylock 12 18 GHB 1118 High Speed Seal 1 19 GHB 1119 Slow Speed Seal 2 20 GHB 1120 Motor Adapter 1 21 GHB 1121 Hex Head Cap Screw 5 16 18 x 1 1 4 Long Coated with Polylock 4 22 GHB 1122 Hollow Slow Speed Shaft with Hex 1 23 Slow Speed Gear 1 GHB 1123A Slow Speed Gear for 20 1 Ratio GHB 1123B Slow Speed Gear for 30 1 Ratio 24 High Speed Worm on Shaft 1 GHB 1124A High Speed Worm on Shaft for 20 1 Ratio GHB 1124B High Speed Worm on Shaft for 30 1 Ratio 25 GHB 1125 Nameplate 1 45 DIZ 77 78 C A VLE RG amp f Y ky Vy yg y SL NS J Ch ffi i WZ e Figure 9 12 C Frame Trolley Drive Gear Reducer C Frame Trolley Drive Gear Reducer Components for Figure 9 12 Ref Part Qty No Number Description Req d GHC 309A C Gear Reducer 30 1 Ratio 50 FPM Includes Ref Nos 1 25 1 GHC 309B C Gear Reducer 20 1 Ratio 75 FPM Includes Ref Nos 1 25 1 1 GHC 1201 Housing 1 2 GHC 1202 High Speed Bearing 1 3 GHC 1203 Slow Speed Bearing Cone
25. 2 4 GHC 1204 Slow Speed Bearing Cup 2 5 GHC 1205 High Speed Spacer 1 6 GHC 1206 High Speed Ring 1 T GHC 1207 High Speed Retaining Ring 1 8 GHC 1208 High Speed Cap Closed 1 9 GHC 1209 High Speed Gasket 2 10 GHC 1210 Slow Speed Gasket 2 11 GHC 1211 Slow Speed Key 1 12 GHC 1212 Pipe Plug Socket Head Coated and Plated 1 8 27 NPTF 6 13 GHC 1213 Vent Shield 1 14 GHC 1214 Drive Pin 4 x 3 16 Stainless Steel 2 15 GHC 1215 Slow Speed Cover Standard 1 16 GHC 1216 Slow Speed Cover Special 4 17 GHC 1217 Hex Head Cap Screw 5 16 18 x 7 8 Long Coated with Polylock 12 18 GHC 1218 High Speed Seal 1 19 GHC 1219 Slow Speed Seal 2 20 GHC 1220 Motor Adapter 1 21 GHC 1221 Hex Head Cap Screw 5 16 18 x 1 1 4 Long Coated with Polylock 4 22 GHC 1222 Hollow Slow Speed Shaft with Hex 1 23 Slow Speed Gear 1 GHC 1223A Slow Speed Gear for 20 1 Ratio GHC 1223B Slow Speed Gear for 30 1 Ratio 24 High Speed Worm on Shaft 1 GHC 1224A High Speed Worm on Shaft for 20 1 Ratio GHC 1224B High Speed Worm on Shaft for 30 1 Ratio 25 GHC 1225 Nameplate 1 46 NOTES 47 Recommended Spare Parts Certain Parts of your hoist will in time require replacement under normal wear conditions It is suggested that the following parts be purchased for your hoist as spares for future use One Brake Friction Disc One Brake Module One Set of Contactors One Transformer One Wire Rope Assembly Note When ordering parts alw
26. 230 volt 3 phase 60 Hertz GHB 1021B 460 volt 3 phase 60 Hertz GHB 1021C 575 volt 3 phase 60 Hertz 22 Stator Assembly for 7 5 1 25 HP Motor Not Shown 1 GHB 1022A 230 volt 3 phase 60 Hertz GHB 1022B 460 volt 3 phase 60 Hertz GHB 1022C 575 volt 3 phase 60 Hertz Recommended Spare Part Duplicate part numbers indicate parts only sold together as a kit 43 e fll ane Z l y TW EN GRY ud F iy l 7777 SEEN Figure 9 10 Hoist Motor Brake C Frame Hoist Brake Components for Figure 9 10 Ref Part Qty No Number Description Req d 1 GHC 10011 Brake Disc 1 GHC 1002 Brake Fan Kit Includes items 2 4 amp 7 1 2 Fan 1 3 N A 4 External Retaining Ring Fan Hub 1 5 N A 6 N A 7 Key Fan 1 GHC 1008 Brake Hub Kit Includes items 8 thru 11 1 8 External Retaining Ring Brake Hub 1 9 Spacer 1 10 Key Brake Hub 1 11 Brake Hub 1 GHC 1012 Brake Hardware Kit Includes items 12 thru 15 1 12 Hollow Core Bolts 3 13 O Ring 1 14 Bolts Brake Mounting 3 15 Springs 3 16 GHC 1016 Magnet Body Includes GHC 1012 Hardware Kit 1 GHC 1017 Fan Shroud Kit Includes items 17 and 18 1 17 Fan Shroud 4 18 Bolt Brake and Fan Shroud 1 19 GHC 1019 Brake End Bell Assembly for 15 HP Motor 1 20 GHC 1020 Gearca
27. ES LIMIT SWITCHES ARE SAFETY DEVICES AND SHOULD NOT BE USED AS NORMAL OPERATING CONTROL AWARNING Some hoists may be shipped with the electrical controls loose disconnected and will not have the upper and lower limit switches connected DO NOT OPERATE HOIST UNTIL LIMIT SWITCH ES ARE PROPERLY CONNECTED AND ADJUSTED Failure to do so may allow hoist to be operated beyond proper travel limits which can cause load to drop resulting in damage to equipment or injury 2 A geared rotary type upper and lower limit Switch is also provided as standard This Switch is adjustable and although roughly preset by the factory it should be adjusted at time of installation to the desired high and low limits of lower block travel Refer to SECTION VII Paragraph 7 3 d Check Lower Block and Hoisting Cable Depress DOWN push button and run lower block to its lowest position No less than two wraps shall remain on the drum with the loaded hook in its lowest position Also check to see that the lower block and rope do not twist excessively If it does twist to the extent that two ropes rub against each other disengage the swaged rope end from the frame anchor and twist the rope four or five turns in a direction opposite to that which the block turns Reconnect rope to the frame anchor holding firmly to eliminate rope twisting back to its original position Operate hoist up and down a few times If lower block still r
28. Head Cap Screw Plated 7 16 14 x 1 1 4 3 23 GHC 123 Lockwasher Hi Collar 7 16 3 24 GHC 124 Rope Clamp 3 25 Drum 1 GHC 125A Drum 25 Lift GHC 125B Drum 40 Lift 26 GHC 900 Rope Guide See Figure 9 9 for Rope Guide and its components 1 27 GHC 127 Flange Mounted Ball Bearing 1 28 GHC 128 Lockwasher Hi Collar 5 8 4 29 GHC 129 Hex Head Bolt Grade 5 5 8 11 x 2 1 4 Includes Ref No 30 4 31 GHC 131 Outboard End Drum Frame 1 32 GHC 132 Limit Switch Bracket 1 33 GHC 133 Retaining Ring 1 34 GHC 134 Drum Shaft Insert for Geared Limit Switch 1 35 GHC 135 Geared Limit Switch 1 36 Drum Frame Rod GHC 136A Drum Frame Rod 25 Lift 2 GHC 136B Drum Frame Rod 40 Lift 2 31 Figure 9 2 Hoist Gearing B Frame Hoist Gearing for Figure 9 2 Ref Part Qty No Number Description Req d GHB 200 Complete Hoist Gearcase Ass y 94 4 1 Ratio Incl Ref Nos 1 19 1 GHB 201 Oil Seal 1 2 GHB 202 Oil Seal 1 3 GHB 203 Stud 4 4 GHB 204 Nut Hex 5 8 18 4 5 GHB 205 Washer Hardened 5 8 8 6 GHB 206 Lock Nut Hex Thin Grade 5 5 8 18 4 7 GHB 207 Ball Bearing 2 8 GHB 208 Motor Gear 56 Teeth 1 9 GHB 209 Intermediate Pinion Shaft 1 10 GHB 210 Key Chamfered 1 11 GHB 211 Ball Bearing 1 12 GHB 212 Drum Pinion Shaft 1 13 GHB 213 Intermediate Gear 1 14 GHB 214 Retaining
29. NSPECTION SCHEDULE AND MAINTENANCE REPORT HOIST SERIAL NO Manufacturer s CUSTOMER CRANE IDENTITY NO RATED LOAD LOCATION IN PLANT TYPE THIS INSPECTION IS MONTHLY ANNUAL VOLTAGE SEMI ANNUAL INSPECTED BY DATE Baca CONDITION COMPONENT UNIT OR PART mended Check column best indicating condition when part or and location Inspection unit is inspected Use note column to the right if Interval condition is not listed below CORRECTIVE ACTION NOTES Indicate corrective action taken during inspection and note date For corrective action to be done after inspection a designated person must determine that the existing deficiency does not constitute a safety hazard before allowing unit to operate When corrective action is completed describe and note date in this column COMPONENT UNIT OR PART LOCATION ADJUSTMENT REQUIRED REPAIR REQUIRED Loose Parts or Wires REPLACEMENT REQUIRED Worn or Damaged LUBRICATION REQUIRED Low Oil or Grease Rust or Corrosion CLEANING OR PAINTING REQUIRED DATE Eo eerie Hex Throat Opening Mor o Brake when so eaupped o Couptings fo sears snars amp Bearings o Frame EN Wreets ot Bms fot l esas Sdo EF epo f Conductors do b oj qo opo po opo opo p o coectors fot b oj qp TP ERUNT DR FSET DEC em RN iii pue i O S S S a MID MonoraitJoints Pot opo po opo op o p S Monorail Pot J opo po po opo o o
30. OPERATION SERVICE amp PARTS MANUAL Before installing hoist fil in the information below Refer to the Hoist and Motor data plates Model No Serial No Purchase Date Voltage Rated Load Follow all instructions and warnings for inspecting maintaining and operating this hoist The use of any hoist presents some risk of personal injury or property damage That risk is greatly increased if proper instructions and warnings are not followed Before using this hoist each operator should become thoroughly familiar with all warnings instructions and recom mendations in this manual Retain this manual for future reference and use GLOBAL KING Forward this manual to operator Failure to operate equipment as WIRE ROPE HOISTS directed in manual may cause RATED THRU 10 METRIC TONNE LIFT CH E NU m Yale COLUMBUS McKINNON CORPORATION co HOISTS PRINTED IN U S A JANUARY 2002 COPYRIGHT 2001 LIFT TECH INTERNATIONAL INC PARTNO 11353395D FORWARD This book contains important information to help you install operate maintain and service your new Yale electric hoist We recommend that you study its contents thoroughly before putting the hoist into use Read HST 4M performance standard and ANSI B30 16 safety standard for hoists Then through proper installation application of correct operating procedures and by practicing the recommended maintenance suggestions you can expect maximum lifti
31. Ring 1 15 GHB 215 Key Hardened Chamfered 2 16 GHB 216 Ball Bearing 1 17 GHB 217 Ball Bearing 1 18 GHB 218 Output Shaft and Drum Gear Assembly 1 19 GHB 216 Ball Bearing 1 C Frame Hoist Gearing for Figure 9 2 Ref Part Qty No Number Description Req d GHC 200A Complete 10t Hoist Gearcase Ass y 124 5 1 Ratio Incl Ref Nos 1 19 GHC 200B Complete 7 5t Hoist Gearcase Ass y 104 6 1 Ratio Incl Ref Nos 1 19 1 GHC 201 Oil Seal 1 2 GHC 202 Oil Seal 1 3 GHC 203 Stud 4 4 GHC 204 Nut Hex 3 4 16 4 32 C Frame Hoist Gearing for Figure 9 2 Ref Part Qty No Number Description Req d 5 GHC 205 Washer Hardened 3 4 8 6 GHC 206 Lock Nut Hex Thin Grade 5 3 4 16 4 7 GHC 207 Ball Bearing 2 8 GHC 208 Motor Gear 64 Teeth 1 9 Intermediate Pinion Shaft 1 GHC 209A 10t Hoist Intermediate Pinion Shaft GHC 209B 7 1 2t Hoist Intermediate Pinion Shaft 10 GHC 210 Key Chamfered 1 11 GHC 211 Ball Bearing 1 12 Drum Pinion and Gear Assembly 1 GHC 212A 10t Drum Pinion and Gear Assembly Includes Ref Nos 12 15 GHC 212B 7 1 2t Drum Pinion and Gear Assembly Includes Ref Nos 12 15 16 GHC 216 Ball Bearing 1 17 GHC 217 Ball Bearing 1 18 GHC 218 Output Shaft and Drum Gear Assembly 1 19 GHC 219 Ball Bearing 1 NOTES 33
32. Viscosity 100 F 1335 1632 SUS 1919 2346 SUS 1919 2346 SUS Viscosity Index 154 95 158 Hoist Gear Case Pour Point 40 F 20 F 37 F Mobil Oil Corp Mobil SHC 632 Mobilgear 634 Mobil SHC 634 Shell amp Oil Co Omala RL 320 Omala 460 Omala RL 460 Texaco Inc Pinnacle 320 Meropa 460 Pinnacle 460 SG NLGI Grease No 1 Spline Grease ASTM D217 Worked 310 340 Penetration Dropping Point 320 F 160 C Base Lithium Mobil Oil Corp WG Viscosity 100 F Wheel Gear and Mobil Oil Corp Pinion Grease Texaco Inc 7 Crater H CL No Specification Cable Lubricant Amoco Oil Co Amovis B 5 X Mobil amp Oil Corp Wire Rope Sun Oil Co 7 Sunoco Wire Rope Lubricant Lubricant Texaco Inc Crater A Texclad 2 GO AGMA Lubricant No 1 No 2 General Oil Viscosity 100 F 193 235 SUS 284 347 SUS Viscosity Index 60 Min 60 Min General Oiling to Pour Point 20 F 29 C 10 F 12 C Prevent Rusting Amoco Oil Co Rykon Oil 46 American Industrial Oil amp 68 and Provide Limited Lubrication Mobil amp Oil Corp Mobil amp DTE Oil Heavy
33. al conditions in which the hoist operates are also important considerations for the user when adjusting hoist inspection and maintenance programs to local conditions Frequency of inspection and maintenance must be increased if hoist is subjected to severe atmospheric environmental conditions such as corrosive vapors extreme heat or cold cement or dust and other airborne contaminants The user should carefully consider all environmental conditions and adjust frequency and degree of maintenance for his local conditions Consult the factorys Field Service Department for advice regarding unusual environ mental conditions Various codes also regulate inspection and maintenance programs Attention must be given to applicable federal standards OSHA regulations national standards state and local codes which may include mandatory rules relating to hoist inspection and maintenance The user should become familiar with all applicable codes for his area and be guided accordingly Listed on the Recommended Inspection and Maintenance Schedule are inspection frequencies and requirements Perform these inspections regularly as scheduled and additional inspections as may be required for activity service and environ ment of your hoist The hoist operator must be responsible for determining the operating conditions and severity of service Inspection Schedule and Maintenance Report Form Shown on page 13 of this manual is a recommended Inspec
34. alled Verify that the contactor armatures are free to move If binding occurs replace contactor Check for burned out contactor coils d Check push button contacts and wires 6 5 Hoist Will Not Lift Rated Load a Low voltage a See that the power supply current is the same voltage listed on motor data plate Check hoist motor connections Check size of power supply lines 6 6 Hoist Motor Overheats a Excessive load b Excessive duty cycle c Wrong voltage or frequency d Defective motor or bearings in hoist frame worn e Brake not adjusted correctly a Reduce loading to rated load as shown on nameplate b Reduce frequency of lifts or amount of jogging c Check current rating on motor data plate against power supply Check hoist and inspect for defective worn or damaged parts d Disassemble hoist and inspect for defective worn or damaged parts e Adjust brake per Section VII Paragraph 7 1 6 7 Load Drifts Excessively When Hoist is Stopped a Excessive Load b Motor brake not holding a Reduce loading to rated load as shown on nameplate b With No Load check hoist for drift If drifting is excessive inspect motor brake Section V Paragraph 5 10 and adjust as outlined in Section VII Paragraph 7 1 6 8 Hoist Operates Intermittently a Collectors make poor contact b Loose connections a Check collectors for free movement of spring arm weak spring or e
35. ame rod nuts at the outboard drum frame end Figure 5 7 The hardware attaching the drum frame to the hoist and trolley frame may then be removed d Keeping the drum level remove the drum from the splined output shaft at the gear case end 5 9 INSPECTION OF HOIST GEARING OUTPUT DRUM GEAR OUTPUT SHAFT ASSEMBLY r SHOULDER BOLT WITH LOCK WASHER INTERMEDIATE GEAR ___ AND SHAFT ASSEMBLY Ye er 4 e ES P W N SK SOCKET HEAD CAP SCREWS WITH LOCK WASHERS MOTOR INPUT SHAFT Se es it INPUT SHAFT ASSEMBLY DRAINPLUG S SHOULDER BOLT WITH LOCK WASHER Figure 5 8 Hoist Gear Case Assembly a General The hoist gear case is a triple reduction splash lubricated vertically split cast aluminum case and cover The first two high speed reductions are helical and the third low speed output reduction is 1 Lower hook block to the floor and relieve all 2 Make sure power to hoist is off and locked spur The gear shafts are supported with ball bearings housed in the back of the case and in the cover The input helical pinion is cut directly into the motor shaft An oil seal housed in the gear case at the motor input seals the motor shaft as it passes into the gear case Since the entire motor shaft is submerged in oil anytime the motor is removed the oil must be drained from the gear case All pinions are integral with their shafts while the gears are keyed and pressed onto thei
36. aph 5 13 to ensure proper brake operation c Brake Disassembly 1 Lower hook block to the floor and relieve 2 all load from ropes Make sure power to the hoist is off and locked out Remove the four 4 bolts attaching the fan shroud to the motor and remove the fan shroud See Figure 5 9 Remove the snap ring behind the plastic fan Carefully remove the fan from the motor shaft Remove the snap ring in front of where the fan was mounted Disconnect the two wires from the terminal block on the magnetic body Remove the three mounting bolts that attach the brake body to the motor end bell and remove the brake body from the motor Remove the friction disk from the motor shaft Clean and inspect all components and working surfaces Replace all damaged or worn components as necessary Measure friction disk thickness and replace if less than the minimum thickness shown in Table 5 1 d Brake Re assembly 1 Install the friction disk on the splined hub The friction disk must slide on the splined hub and seat against the end bell of the motor Install the brake body to the motor end bell using the three 3 mounting bolts The air gap must be reset as described in Section V Paragraph 5 10 b Torque the mounting bolts to the values shown in Table 5 1 Install the large O ring in the groove over the air gap Ensure this O ring is not pinched in the air gap 21 3 Connect the brake leads
37. are two basic frame sizes each with two standard lifts the B Frame handles capacities up to 5 tonne and the C Frame handles capacities up to 10 tonne The B Frame has an integral trolley with two different flange width ranges available 4 5 8 through 14 or 14 1 8 through 20 wide with a maximum flange thickness of 1 3 4 The C Frame integral trolley has a flange range of 4 5 8 through 20 with a maximum flange thickness of 2 The hoist motor is 2 speed with a 6 1 ratio between high and low speeds as standard The Motor Driven trolley has two available speeds with 1 speed 2 speed or Variable Frequency control Throughout this manual you will see references to the B or C frame hoists If you are unsure about which frame size you have see Section IV Paragraph 4 2 for a simple gearcase measurement to easily determine the size of your hoist 1 2 BASIC CONSTRUCTION Yale Global King hoists consist of a rugged steel frame which houses a lifting drum and serves as the suspension for carrying the entire hoist load An aluminum gearcase attached to one end of the drum frame houses a triple reduction gear train The first two reductions are helical with the third being spur Attached to the gearcase is a 2 speed hoisting motor with a 6 1 ratio between the high and low speeds A 200 torque DC motor brake is attached to the motor A single NEMA 4 12 control enclosure contains both the hoist and
38. averse drive on the hex traverse drive shaft Also the electrical conduit cable must not be constrained when attempting to adjust the trolley sides in or out AWARNING ANOTICE Only qualified personnel properly supervised shall mount the hoist and trolley on the monorail and perform final pre operation inspection Loosen all electrical cable or conduit attached to the frame and alignment bars before adjusting trolley width Ensure that the electrical cable is not stretched pinched twisted or otherwise damaged when adjusting trolley width The trolley width shall be adjusted by loosening the jam nuts on the traverse drive side of the threaded rods at each end of the hoist If necessary lubricate the frame alignment bars with penetrating oil before attempting to adjust trolley width The trolley side may then be pushed or driven into position by turning the adjusting nuts on the treaded rods Adjust nuts on each side of the hoist simultaneously to avoid binding After adjusting the trolley to the proper width tighten all adjusting nuts and the clamp collar and re secure the electrical conduit cable Verify that the geared wheels mesh properly with the traverse drive pinions Using proper equipment carefully lift the trolley and hoist and install on the end of the beam Lubricate the wheel gear and pinion WG Section IV Paragraph 4 3 b CLOSED END BEAM For trolleys which are to be mo
39. ays furnish Hoist Serial Number Catalog Number Motor Horsepower Voltage Phase Frequency and Rated Load of Hoist on which the parts are to be used Parts for your hoist are available from your local authorized Yale repair station For the location of your nearest repair station write Yale HOISTS 414 West Broadway Avenue P O Box 0769 Muskegon Michigan 49443 0769 Phone 800 999 6318 Fax 800 766 0223 WARRANTY WARRANTY AND LIMITATION OF REMEDY AND LIABILITY A Seller warrants that its products and parts when shipped and its work including installation construction and start up when performed will meet applicable specifications will be of good quality and will be free from defects in material and workmanship All claims for defective products or parts under this warranty must be made in writing immediately upon discovery and in any event within two 2 years or as otherwise provided from shipment of the applicable item unless Seller specifically assumes installation construction or start up responsibility All claims for defective products or parts when Seller specifically assumes installation construction or start up responsibility and all claims for defective work must be made in writing immediately upon discovery and in any event within two 2 years or as otherwise provided from completion of the applicable work by Seller provided however all claims for defective products and parts must b
40. d at regular intervals at least every six 6 months coinciding with spring and fall seasons is recommended The reason for this is that on hoists installed outside or in unheated areas a cold test oil is required in such below freezing climates making seasonal changes necessary 4 2 CHANGING GEARCASE OIL a Add 5 solution of Mobilsol A or equivalent to the oil and run for a short time This will clean components and hold particles in suspension for draining FIGURE 4 1 View of Hoist Showing Location of Name Plates and Oil Plugs b Remove oil drain plug from bottom of gearcase and drain oil out Dispose of oil in accordance with local environmental codes AWARNING Avoid skin contact with Mobilsol A In case of skin contact dry wipe the skin cleanse the area with a waterless hand cleaner and follow by washing thoroughly with soap and water c Reinstall drain plug d Remove oil level plug from front of gearcase cover o tore LEITET FIGURE 4 2 Gearcase Width Illustration e Refill through filler hole to proper level bottom of oil level plug hole using GCOH Paragraph 4 7 The amount of oil required depends on overall size of gearcase two sizes are used for Global King hoists To determine size and amount of oil to add measure width of hoist gearcase see Figure 4 2 The B Frame measures 11 3 4 and requires approximately 6 quar
41. duction hollow shaft gear reducer Ensure that the hoist is properly fitted to the beam The hoist must be centered on the beam with clearance between the sides of the bottom of the beam flange and the inside faces of the wheel flanges Proper clearance must exist along the entire length of beam that the hoist can traverse An amount of 3 32 to 1 8 inch clearance per side is recommended for a total of 3 16 to 1 4 inch wider than the beam flange If too little or too much clearance is determined adjust trolley per Section Il Paragraph 2 2 Inspect wheel treads flanges and gear teeth for wear Check for adequate lubrication WG Section IV Paragraph 4 7 on the wheel gear and pinion mesh Check wheel bearings for any signs of wear including rough rotation and signs of lubricant leakage Replace all damaged or d 5 12 TESTING Examine the drive pinions cross shaft and cross shaft bearings Check pinions for gear tooth wear and proper alignment with wheel gear A spacer washer between the cross shaft bearings and the pinion aligns the gear mesh Clamp collars hold the pinions and spacer washers tight against the bearings Verify that the clamp collars are tight on the cross shaft If it is necessary to adjust or reset the clamp collars verify that the hex shaft surface is free of mechanical damage and oil before tightening the clamp collars Drive pinions must be replaced as sets and should be replaced along with the drive w
42. e e ceases eee eeee e eene 22 Paragraph 5 12 Inspection of Block Operated Limit Switch 0 0 cececcececee ee ects eect esta eeeeeeeeeee eens 22 Paragraph9 13 Testing Holst 25 sess sce seksi oa e ede cope ate aden Oe en cae le ae ee REA 23 SECTION VI TROUBLESHOOTING CHART 0 0c cece memes eerie rennen 24 SECTION VII ADJUSTMENTS Paragraph 7 1 Motor Brake Adjustment sssssssssssss m meme ememememe eee senes 25 Paragraph 7 2 Block Operated Limit Switch Adjustment sss 25 Paragraph 7 3 Geared Rotary Limit Switch Adjustment sss mee 25 Paragraph 7 4 Shortening of Push Button Cable sss mmm meme eene 26 SECTION VIII WIRING DIAGRAMS sssssssIIIII rr emere mener rere nene 26 SECTION IX PARTS LIST Paragraph 9 1 General 5 xn eL Rn ee ADI PEDIR Pel dE Drei prd Pi Pear cater edie 29 Paragraph 9 2 List of Parts Illustrations sssssssssssss mH HH Heer 29 No part of this document may be reproduced in any form in an electronic retrieval system or otherwise without prior written permission of the publisher SECTION I GENERAL DESCRIPTION 1 1 GENERAL Yale Global King electric hoists are wire rope and drum type hoists that are manufactured with an integral trolley These hoists are all low headroom models with the drum and upper block or dead end anchor depending on the reeving type on opposite sides of the beam suspending the trolley There
43. e made in writing no later than thirty 30 months after shipment Defective items must be held for Seller s inspection and returned to the original f o b point upon request THE FOREGOING IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER EXPRESS IMPLIED AND STATUTORY INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS 48 B Upon Buyer s submission of a claim as provided above and its substantiation Seller shall at its option either 1 repair or replace its product part or work at either the original f o b point of delivery or at Seller s authorized service station nearest Buyer or ii refund an equitable portion of the purchase price C This warranty is contingent upon Buyer s proper maintenance and care of Seller s products and does not extend to normal wear and tear Seller reserves the right to void warranty in event of Buyer s use of inappropriate materials in the course of repair or maintenance or if Seller s products have been dismantled prior to submission to Seller for warranty inspection D The foregoing is Seller s only obligation and Buyer s exclusive remedy for breach of warranty and is Buyer s exclusive remedy hereunder by way of breach of contract tort strict liability or otherwise In no event shall Buyer be entitled to or Seller liable for incidental or consequential damages Any action for breach of this warranty must be commenced within two 2 years or as otherwi
44. e rope groove is smooth and free from burrs or other surface defects Check each sheave for freedom of rotation replace bearings if defective Make certain that the spring pin holding the hook nut to the hook is securely in position If hook is equipped with a hook latch or rotational lock check to determine that they are in good operating condition Check throat opening of the hook Refer to Figure 5 2 It is recommended that upon receipt of the hoist a measurement be made and recorded of the hook throat opening OSHA regulations require that the hook be replaced if the throat opening exceeds 15 percent of the original opening or if the hook is twisted more than 10 degrees from the unbent plane We suggest that a gage block properly identified to the hoist similar to the one shown in Figure 5 2 be made for each hook for use in these measurements FIGURE 5 2 Gage Block g Hooks showing signs of cracks must be replaced Hooks should be inspected at least once per year using dye penetrants magnetic particle or other suitable non destructive test methods h Check wear of the hook especially at the saddle and replace if worn more than 10 of original dimensions 5 3 INSPECTION OF UPPER BLOCK a Check upper block sheaves when hoist is so equipped for wear damage and freedom of rotation If sheaves do not rotate freely disassemble block and inspect bearings Replace worn or damaged bearings washers pins
45. filled with oil to the proper level However this should be re checked before operating the hoist Check oil level by removing the plug indicated in Figure 2 1 When properly filled oil should be level with the bottom of the tapped hole Fill to this level with oil as specified in Paragraph 4 2 e Check Push Button Operation and Phasing To properly check the phase of the hoist follow these steps 1 With POWER OFF operate all the push buttons and determine that they do not bind or stick in any position AWARNING AWARNING Be certain that electrical power supply is OFF and locked in the open position before attempting any electrical connections to the hoist This equipment must be effectively grounded according to the National Electric Code ANSI NFPA 70 or other applicable codes If the grounding method used is through the trolley wheels then each section of track must be grounded by metal to metal connection to the building ground Certain environments may prevent proper grounding by this means In this case a separate grounding conductor should be provided If any push button binds or sticks in any position DO NOT TURN POWER ON determine the cause and correct the malfunction before operating 2 Connect hoist to power source AWARNING On three phase hoists it is possible to have Reverse Phasing causing the block to lower when the UP button is depressed Whe
46. g inspection corrective action taken and date in space provided In this manner items requiring further attention will be checked without showing corrective action This will advise the designated person responsible for hoist operation and safety who reviews the reports that deficiencies exist The designated person will check all deficiencies as listed and re examine or otherwise determine whether they constitute a safety hazard AWARNING Deficiencies may be hazardous to personnel and equipment Do not operate a hoist having deficiencies unless a designated qualified person has determined that these deficiencies DO NOT constitute a safety hazard Written dated and signed inspection reports for many items are mandatory under OSHA regulations and many state safety codes It is strongly recommended that the Inspection Schedule and Maintenance Report shown herein be completed by a qualified person designated with the responsibility for hoist operation and safety or an inspector appointed by this person Inspection records can point out the service life of hoist components and help forecast the need for adjustments repairs and ordering of replacement parts File and review these reports after each inspection RECOMMENDED INSPECTION AND MAINTENANCE SCHEDULE TIME INTERVAL INSPECTION OR MAINTENANCE Daily or start of each shift visual Check operation of all functional mechanisms including l
47. harp objects that will scrape nick crush or induce sharp bends in the rope AWARNING Use only factory approved rope with swaged wire rope socket c Replacement When recommended by an authorized inspector the rope should be replaced Replacement rope assemblies are shipped from the factory carefully coiled to prevent damage by kinking Care must be taken to avoid twisting or kinking when uncoiling and handling during reeving Before replacing rope check condition of grooves in sheaves and drums to determine if they are excessively worn When first using hoist after rope replacement break in rope by operating under lighter loads to full travel before applying maximum load 5 7 ROPE REEVING a General Place reel on stand with shaft through the center of reel so rope can be pulled straight out with reel rotating ACAUTION It is imperative that rope reel or coil rotates as rope unwinds If coil or reel does not rotate the wire will be twisted as it is uncoiled and kinking will result A kinked rope may be damaged and unsafe for maximum service b Before removing the old rope refer to reeving diagram Figure 5 6 To assist with re reeving your hoist refer to the reeving diagram and corresponding paragraph that describes the reeving procedure c Removing old rope Please refer to the Section IX Parts lists to assist in locating components referred to in the following paragraphs
48. heating Replace transformer if burned out Verify the transformer secondary is the same voltage as the coils to which it is connected f Replace motor Check input power supply Check hoist motor connections 6 2 Hook Moves in Wrong Direction phase hoists b Hoist wired incorrectly a Reverse phasing on three a Interchange any two power supply line leads Refer to Section II Paragraph 4 b b Check wiring connections with appropriate wiring diagram 6 3 Hook Will Raise But Not Lower a Lower electrical circuit open b Contactor functioning assembly not c Down push button is inoperative a Check for loose connections See that necessary jumper wires are properly installed on contactor b See that necessary jumper wires are properly installed Verify that the contactor armatures are free to move If binding occurs replace contactor Check for burned out contactor coils c Check push button contacts and wires 24 SECTION VI TROUBLE SHOOTING TROUBLE PROBABLE CAUSE REMEDY 6 4 Hook Will Lower But Not Raise a Excessive load b Hoist electrical circuit open c Contactor assembly not functioning d Up down button inoperative a Reduce loading to rated load of hoist as shown on nameplate b Check for loose connections See that necessary jumper wires are properly installed on contactor c See that necessary jumper wires are properly inst
49. heels The cross shaft bearings are sealed for life and should be replaced at any sign of mechanical wear or lubricant leakage Inspect the traverse gearbox and motor Look for signs of rough operation mechanical damage or lubricant leaks Inspect the hollow bore and hexagonal drive shaft for wear Verify that the four bolts that hold the gearbox to the trolley frame and the four bolts that hold traverse motor to the gearbox are all present and tight Replace and tighten as necessary The factory recommends complete replacement of the traverse gearbox However gearbox service may be available from you local authorized Yale repair center BLOCK OPERATED SWITCH a General The block operated limit switch is a secondary upper limit switch actuated when the lower block contacts the limit Switch weight The rotary geared limit switch screw type limit switch is the primary upper limit switch and must be temporarily disconnected to allow the block operated limit switch to be tested LIMIT b Procedure Remove load from the hook To disconnect the geared limit switch refer to Figure 7 2 Remove the limit switch cover then loosen the two 2 screws holding the locking plate in place Allow the locking plate to slide down and disengage from the adjustment discs Do not rotate the adjustment discs AWARNING ACAUTION Check limit switch operation carefully without load before placing hoist in service If
50. hroud Item 2 fits snugly in the rope guide body groove 5 Thoroughly clean and inspect all components 6 Follow steps in reverse to reassemble Be sure to re grease the rope guide with MPG Paragraph 4 7 after assembling 5 6 ROPE INSPECTION MAINTENANCE AND REPLACEMENT AWARNING Wire Rope improperly handled or abused can create a SAFETY HAZARD Read and comply with inspection maintenance and replacement information given herein Figure 5 3 Rope Guide Assembly a Inspection Wire rope on your hoist is one of the most important components requiring frequent inspection and maintenance All 15 wire ropes will eventually deteriorate to a point where they are not safe and will require replacement Wire rope should be thoroughly inspected at regular monthly intervals by an authorized person and a determination made when further use of the rope would constitute a safety hazard Each inspection should include a written dated and signed report of rope condition Reports should be filed and reviewed each month and any rope deterioration carefully noted Inspections revealing but not limited to the following conditions should cause inspector to question remaining strength of rope and consider replacement 1 Twelve randomly distributed broken wires in one rope lay or four broken wires in one strand See Figure 5 4 Lay as a unit of measure ONE ROPE LAY Showing how one r
51. imit switch operation brakes and control Check hoist cable for kinks abrasions corrosion or broken wires or evidence of improper spooling on drum Inspect hooks upper and lower blocks and all load bearing components for damage 1 Month HOIST CABLE Inspect per Paragraph 5 6 and lubricate per Paragraph 4 3 1 3 Months ELECTRICAL CONTROLS Inspect per Paragraph 5 4 Check hoist gearcase oil level add oil as required per Paragraph 4 2 e 6 Months LOWER BLOCK Inspect per Paragraph 5 2 UPPER BLOCK Inspect per Paragraph 5 3 ROPE GUIDE Inspect per Paragraph 5 5 BLOCK OPERATED LIMIT SWITCH Inspect per Paragraph 5 12 6 Months or 500 750 hours on time Inspect electrical controls per Paragraph 5 4 Change hoist gearcase oil Fill with oil per Paragraph 4 2 e Lubricate hoist cable per Paragraph 4 3 Lubricate upper and lower hook block Lubricate limit stop lever per Paragraph 4 4 Add a light film of MPG grease Paragraph 4 7 to the bevel gear in the screw type limit switch Annually Motor brake and actuating mechanisms Inspect and adjust per Paragraph 5 10 Inspect hooks with crack detecting procedures per Paragraph 5 2 Drain and refill hoist gearcase per Paragraph 4 2 5 years elapsed time or 5000 hours on time Complete inspection disassembly and maintenance required It is recommended that your Yale repair Station be contacted for this service 12 I
52. in main power switch is locked in open position OFF before removing brake cover 5 5 INSPECTION OF ROPE GUIDE 8 General The rope guide is intended to help prevent the rope from back winding and to hold the rope in the proper groove Side pulling and excessive load swing will severely damage the rope guide and must be avoided b Disassembly Refer to Figure 5 3 For further assistance in locating components refer to the parts list in Section IX 1 Remove socket head cap screws and lock washers Items 8 and 9 Take off mounting clip Item 7 N Remove shoulder bolts Item 4 and compression springs Item 5 The two halves of the rope guide body Item 1 can now be pulled off the drum separately When reassembling be sure that the half with the rope slot is on the top half of the drum AWARNING AWARNING Once shoulder bolts are removed the halves will separate and if not properly supported the halves could fall Side pulling and excessive load swing will severely damage the rope and rope guide Failure of these components may result in injury 3 Carefully unhook the rope tensioning spring Item 3 which is under tension AWARNING The rope tensioning spring is under considerable tension use caution when unhooking to avoid injury 4 Remove the split plastic shroud Item 2 from the drum When reassembling the rope guide be sure the plastic s
53. ing limit switch are inside cover and are repeated below see Figure 7 2 AWARNING SWITCH LOCKING ADJUSTMENT SWITCH PLATE DISC Check limit switch operation carefully without load before placing hoist in service If misadjusted SEVERE DAMAGE AND OR A DROPPED LOAD COULD RESULT Allow 3 for hook drift in both directions Never allow less than two 2 complete wraps of rope on drum with hook in lowest position Provide a light film of MPG grease Paragraph 4 7 on gear of both limit switches 7 4 SHORTENING OF PUSHBUTTON CABLE AWARNING Be certain that electrical power supply is OFF and locked in the open position before attempting shortening of push button cable Figure 7 2 Screw Type Limit Switch Adjustment Wires Not Shown For Clarity AWARNING Be certain that electrical power supply is OFF and locked in the open position before removing limit switch cover a Remove four screws and lift off switch cover b Loosen locking plate screws Slide locking plate away from adjustment disc c Turn proper adjustment disc right for up left for down toward switch to reduce hook travel or away from switch to increase hook travel d Slide locking plate back into position ensuring slots on adjustment discs are fully engaged tighten locking plate screws to 4 in Ibs e Replace cover f Carefully check limit switch operation without load before placing
54. ion of Geared Limit Switch me 9 Paragraph 4 5 Lubrication of Geared Trolley Wheel ssssssses Hen 9 Paragraph 4 6 Lubrication of Rope Guide ssssssssssssssssssesess sem me eene tree 9 Paragraph 4 7 Lubricant Specifications ccccececec eee eects cece e eee ee neta ene teeeeaeeeeeeeneeaeeeeeeeeaes 10 SECTION V INSPECTION AND PREVENTATIVE MAINTENANCE Paragraph 9 1 Generalll 22 2 datnr to pede trop ved spice actuate inch NR E ETA RaRa a Ralea 11 Paragraph 5 2 Inspection of Lower Block cccecececeeceeee eee ee eens eI em mese n tree rrr 14 Paragraph 5 3 Inspection of Upper Block ssssssssssssssss IH eer 14 Paragraph 5 4 Inspection of Electrical Controls ssssssssssssssssssssse m mem een 14 Paragraph 5 5 Inspection of Rope Guide sssssssssssssssssssseem m emm eme hne 15 Paragraph 5 6 Rope Inspection Replacement amp Maintenance sssssssssssses 15 Paragraph 5 7 Rope Reeving e eter ooh rop e nae AAN E E end Ete ER eee 16 Paragraph 5 8 Inspection of Rope Drum amp Shaft cccccec ee ec ec ee ee eee eee e ee eeee ee ea eee seme 18 Paragraph 5 9 Inspection of Hoist Gearing ssssssssssssseee IH memememee nens 18 Paragraph 5 10 Inspection of Motor Brake and Actuating Mechanism ceeceeeeee ee eeeeeeeeeeeeeeeees 20 Paragraph 5 11 Inspection of Traverse Drive c ccecceeee ee eect eect ee
55. king Nuts 1 4 20 8 16 GHB 416 Capacity Plates 2 17 GHB 417 Hex Washer Head Self Tapping Screws 5 16 18 x 1 1 2 4 C Frame Lower Block Components for Figure 9 4 Ref Part Qty No Number Description Req d GHC 400Y10 10t Lower Block Assembly Includes Ref Nos 1 17 1 GHC 400Y7 5 7 1 2t Lower Block Assembly Includes Ref Nos 1 17 1 1 GHC 401 Lower Block Frame Hook Beam 1 2 GHC 402 Hook 1 3 GHC 403 Thrust Bearing 1 4 GHC 404 Castle Nut 1 5 GHC 405 Spring Pin 1 6 GHC 406Y Sheave Covers 4 36 C Frame Lower Block Components for Figure 9 4 Ref Part Qty No Number Description Req d 7 GHC 407 Flat Head Socket Cap Screws 1 4 20 x 1 2 4 8 GHC 408 Sheave Pin 1 9 GHC 409 Sheaves 2 10 GHC 410 Ball Bearings 2 11 GHC 411 Internal Retaining Rings 2 12 GHC 412 External Retaining Rings 2 13 GHC 413 Socket Head Cap Screws 1 4 20 x 3 1 4 Long 8 14 GHC 414 Hi Collar Lockwashers 1 4 8 15 GHC 415 Self Locking Nuts 1 4 20 8 16 Capacity Plates 2 GHC 416A 10t Capacity Plates GHC 416B 7 1 2t Capacity Plates 17 GHC 417 Hex Washer Head Self Tapping Screws 5 16 18 x 1 2 4 NOTES 37 O Figure 9 5 Upper Block Assembly B Frame Upper Block Components for Figure 9 5 Ref Part Number Description Qty Req d GHB 500 B Frame Hoist Upper Block Assembly Includes Ref Nos 1 10 GHB 501 U
56. lectrical connections b Check all wiring for loose connections SECTION VII ADJUSTMENTS 7 1 MOTOR BRAKE ADJUSTMENT These brakes are designed so that adjustment is seldom required If after a period of service the load hook drifts downward more than usual for your hoist before coming to a stop the motor brake may require adjustment to compensate for brake disc AWARNING Check to be certain main power switch is locked in open position OFF before removing brake cover Refer to Figure 5 9 and proceed as outlined in Section V Paragraph 5 10 7 2 BLOCK OPERATED LIMIT SWITCH The block operated limit stop furnished as standard equipment is non adjustable and designed to stop the lower block at the safest high point of travel to eliminate any possibility of double blocking When the safest high point is reached the limit switch automatically stops hook travel 7 3 GEARED ROTARY LIMIT SWITCH ADJUSTMENT The geared rotary type limit switch is standard equipment and is located on the drum end opposite the gearcase end 25 This limit switch has a rotary screw driven by a gear reduction that is coupled to the end of the drum shaft Adjustment discs operate the contacts of separate switches one for the hoisting circuit and one for the lowering circuit The switch assembly must be wired in accordance with the appropriate wiring diagram which is shipped with the hoist Instructions for adjust
57. ling the motor or seal damage will occur It may be necessary to rotate the rope drum slightly to align the gear teeth to mesh with the teeth on the motor shaft Ensure that the motor seats properly into the rabbet fit machined in the gear case Fasten the motor to the gear case 10 Reconnect the conduit and power leads to the motor See Section VIII and refer to the specific wiring diagrams shipped with your hoist 11 Refill gear case with lubricant per Section IV Paragraph 4 2 12 Test hoist to ensure proper operation per Section V Paragraph 5 13 5 10 INSPECTION OF MOTOR BRAKE AND 8 ACTUATING MECHANISM General Operation The hoist brake is an electro magnetically released spring set non adjustable brake Torque is generated by compressing a friction disk between the stationary motor end bell and the spring loaded brake armature The friction disk is fixed to the motor shaft and rotates with the motor shaft When the magnet coil is energized the armature plate is pulled across the air gap The friction disk is carried by a splined hub that permits axial movement when the brake is released This axial movement releases both sides of the friction disk from their mating stationary surfaces and allows the friction disk to rotate freely when the brake is energized When power is removed from the magnetic coil the compression springs push the armature against the friction disk and the other side of the friction
58. n the load rating and dead weight of the hoist If in doubt of the supporting structure s strength consult a structural engineer AWARNING DO NOT operate hoist with the hoisting rope out of the drum grooves Such operation may result in damage to the rope and or the rope breaking This may result in dropping the load that can cause damage to equipment and injury to operator or other personnel Hoist rope will remain in the drum grooves during operation under normal operating con ditions however slack or kinked rope excessive side pulls swinging or jerking of load or similar abuse may cause the rope to leave the grooves vv ww yy DO NOT use hoist in location that will not allow operator movement to be free of the load DO when starting to lift move the load a few inches at which time the hoist should be checked for proper load holding action The operation shall be continued only after the operator is assured that the hoist is operating properly and that the load is supported in the center of the base bowl saddle of the hook DO Observe recommended inspection and maintenance procedures DO Use common sense and best judgment whenever operating a hoist SECTION IV LUBRICATION 4 1 GENERAL The lubrication services outlined in Paragraphs 4 3 thru 4 6 should be performed before initial operation of the hoist The lubrication services outlined in Paragraphs 4 2 thru 4 6 should be performe
59. n this condition exists the automatic limit switch is inoperative and hoist operation will be dangerous 3 Operate UP button briefly to determine direction of hook travel 4 If hook raises when UP button is depressed phasing is correct 5 If hook lowers when UP button is depressed hoist is Reverse Phased TURN AND LOCK POWER OFF and check the pushbutton wiring If the pushbutton was wired properly correct the problem by interchanging any two leads at power source connection Do not change internal wiring of hoist c Check Limit Switch Operation 1 A block operated upper limit stop is furnished as standard equipment on all Yale Global King hoists This limit stop is factory set to stop the lower block at the safest high position guarding against over travel and possible damage to hoist No adjustment can be made However the hoist should be tested by jogging the lower block against the limit weight to be sure the limit switch is functioning properly When lower block lifts the limit weight the hoist will automatically stop If lower block coasts through the limit switch when lifting a reversing switch will automatically close and reverse direction of motion to lowering AWARNING Damage to the hoist a dropped load and injury may result if limit switches fail due to improper use TO AVOID INJURY UNDER NORMAL OPERATING CONDITIONS STOP HOIST TRAVEL BEFORE ENGAGING LIMIT SWITCH
60. ng service from the hoist It will likely be a long time before parts information found in Section IX is needed Therefore after the hoist is installed and you have completely familiarized yourself with operation and preventative maintenance procedures we suggest that this book be carefully filed for future reference When ordering replacement parts from this book it will be necessary that you include with your order the Hoist Serial Number and Model Number that are found on the nameplate attached to the motor end of hoist Figure 4 1 For your convenience a space has been provided on the front cover of this Manual for entering this information We recommend that you fill it out immediately so it is readily at hand when needed The contents of this manual are of necessity general in nature and may cover features not incorporated on your hoist or you may have ordered features not covered by this manual Therefore the user must exercise care in applying instructions given in this manual If specific information not in this manual is required contact the factory THE INFORMATION CONTAINED IN THIS BOOK IS FOR INFORMATIONAL PURPOSES ONLY AND LIFT TECH DOES NOT WARRANT OR OTHERWISE GUARANTEE IMPLIEDLY OR EXPRESSLY ANYTHING OTHER THAN THE COMPONENTS THAT LIFT TECH MANUFACTURERS AND ASSUMES NO LEGAL RESPONSIBILITY INCLUDING BUT NOT LIMITED TO CONSEQUENTIAL DAMAGES FOR INFORMATION CONTAINED IN THIS MANUAL No part of this documen
61. ope lay is the lengthwise distance in which a strand 12168 makes one complete turn around the rope Figure 5 4 Description of One Rope Lay 2 Wear of one third of the original diameter of outside individual wires 3 Kinking crushing or birdcaging 4 Heat damage from any cause 5 Reductions from nominal diameter of more than 1 32 for 7 16 diameter rope or 3 64 for 9 16 rope See Figure 5 5 for proper measurement techniques 12169 Wrong Way Right Way Figure 5 5 Correct Method of Measuring Rope 6 Rope corrosion internal or external 7 Effects from improper lubrication 16 8 Rope being idle for one month or more due to shutdown or inactivity Special attention should be exercised when inspecting rope normally hidden during inspecting procedures Please refer to the Wire Rope Users Manual for illustrations and definitions when following the above guidelines for rope inspection This manual may be obtained from WRTB Fulfillment 609 North Second Street St Joseph MO 64502 Or by calling 1 888 BUY WRTB 289 9782 b Maintenance Keep rope well lubricated to help reduce internal friction and prevent corrosion Lubricant as described in Paragraph 4 3 should be applied as a part of the regular maintenance program Special attention is required to lubricate sections of rope over equalizing sheaves and other hidden areas Avoid dragging ropes in dirt or around s
62. otates excessively repeat process until twisting is corrected e Lubricate Hoisting Cable For longer cable life it is recommended that the cable be lubricated at time of installation by applying a heavy coating of lubricant CL Paragraph 4 7 as outlined in SECTION IV Paragraph 4 3 f When first using the hoist and trolley operate with lighter loads through full travel before applying maximum load SECTION Ill OPERATION 3 1 GENERAL Operation of Yale Global King hoists is controlled by a convenient pendant push button station With it the hoist can be controlled to give fast lifting and lowering or controlled to lift or lower the load in small increments providing accurate spotting The push button station has a built in interlock to prevent depressing opposing buttons simultaneously When first using the hoist break in by operating under lighter loads to full travel before applying maximum load 3 2 PUSH BUTTON OPERATION a Depress push button marked UP to raise load b Depress push button marked DOWN to lower load c Depress push button marked RIGHT to traverse one direction d Depress push button marked LEFT to traverse in the opposite direction ACAUTION Excessive jogging will cause premature burning of contact tips motor overheating and premature brake wear e On two speed hoist or trolley motions partial depression of a button operates hoist or trolley
63. pper Block Yoke GHB 502 Key Plate GHB 503 Hex Head Bolt 3 8 16 x 5 8 GHB 504 Sheave Pin GHB 505 Lockwasher 3 8 GHB 506 Hex Head Bolt Grade 5 3 8 16 x 3 GHB 507 Spacer Washer GHB 508 Sheave ojlo NIDIA o N gt GHB 509 Ball Bearing GHB 510 Internal Retaining Ring GHB 511 Spacer Washer GHB 512 Self Locking Nut 3 8 GHB 513 Yoke Pin GHB 514 Cotter Pin GHB 515 Flanged Bushing N 2 N IO gt 4 Po Po BR gt IN gt C Frame Upper Block Components for Figure 9 5 Part Number Description Qty Req d GHC 500 C Frame Hoist Upper Block Assembly Includes Ref Nos 1 10 GHC 501 Upper Block Yoke GHC 502 Key Plate GHC 503 Socket Head Cap Screw 3 8 16 x 3 4 GHC 504 Sheave Pin GHC 505 Lockwasher 3 8 GHC 506 Socket Head Cap Screw 3 8 16 x 4 GHC 507 Spacer Washer GHC 508 Sheave ooo On o N gt GHC 509 Ball Bearing a A3lw wm A amp 2 lwA 38 C Frame Upper Block Components for Figure 9 5 Ref Part Qty No Number Description Req d 10 GHC 510 Internal Retaining Ring 1 11 GHC 511 Spacer Washer 4 12 GHC 512 Self Locking Nut 3 8 2 13 GHC 513 Yoke Pin 1 14 GHC 514 Co
64. r shafts The output shaft passes through an oil seal in the back of the gear case and drives the drum by means of a crowned spline One end of the rope drum is supported on this output shaft Inspection and Disassembly Gearcase See Figure 5 8 load from ropes out 5 If it is necessary to remove the output shaft assembly from the gear case the rope drum must first be removed from the hoist See Section V Paragraph 5 7 AWARNING The hoist must be removed from service and repaired on the ground for any maintenance that requires removal of the output shaft assembly or drum AWARNING Before disassembly prevent rope drum from free spinning by wedging drum in place with a block of wood and resting lower block on work surface so all weight is off rope drum Rope may also be removed from hoist drum 3 4 Drain the oil from the gear case per Section IV Paragraph 4 2 Provide adequate means to support the gear case cover Once the cover is supported remove the two 2 shoulder bolts seven 7 socket head cap screws and nine 9 lock washers holding the cover to the gear case Carefully draw the cover directly away from the gear case as damage to this surface will prevent the gasket from sealing properly As the cover is removed ensure that all gear and shaft assemblies remain in the case AWARNING If output shaft assembly is pulled out of the gear
65. red 9 Replace the lower block sheave covers 10 Lubricate cable per Paragraph 4 3 See Figure 9 5 B Frame components for lower block parts with 7 16 diameter wire rope See Figure 9 5 C Frame components for lower block parts with 9 16 diameter wire rope c Checking for and removal of rope twisting 1 To remove rope twist in four part single reeved hoists a Observe direction block tends to rotate b Lower the block to a low position and TURN OFF lock out POWER c Remove swaged fitting from anchor pin and rotate rope several turns in a direction tending to correct block rotation d TURN ON POWER raise and lower the block several times to feed the correcting twist in the rope through the reeving 5 8 INSPECTION OF ROPE DRUM AND SHAFT a To remove the rope drum remove the rope guide and hoisting cable as outlined in Section V Paragraphs 5 5 and 5 7 c respectively 18 AWARNING The hoist must be removed from service and placed on the ground for any maintenance that requires removal of the output shaft assembly or drum S Figure 5 7 Drum Frame amp Geared Limit Switch b Remove the Geared Limit Switch or disconnect the wires so that the electrical cable will not inhibit removal of the drum See Figure 5 7 c Remove the unit from service place it on the ground and provide adequate means to support the drum before removing the fr
66. s Please attempt to remedy your hoist problems by following these steps before contacting the factory Whenever servicing electrical components be sure to shut off and lock out power following proper lockout tagout procedures AWARNING Working in or near exposed energized electrical equipment presents the danger of electric shock TO AVOID INJURY DISCONNECT POWER AND IMPLEMENT LOCKOUT TAGOUT PROCEDURE BEFORE REMOVING COVER OR SERVICING THIS EQUIPMENT SECTION VI TROUBLE SHOOTING TROUBLE PROBABLE CAUSE REMEDY 6 1 Hoist Will Not a No power to hoist a Check switches circuit breakers or fuses and Operate connections in power supply lines Check power b Wrong Voltage c Loose or system d Contactor functioning assembly e No control voltage f Motor burned out broken wire connections in hoist electrical collectors b Check voltage required on motor data plate against power supply c Shut off and lock out power supply remove electrical cover on hoist and check wiring connections Also check connections in push button station and limit switches d See that necessary jumper wires are properly installed Verify that the contactor armatures are free to move If binding occurs replace contactor Check for burned out contactor coils e Check transformer fuse If blown check for grounding and or shorts in the push button station Check the transformer coil for signs of over
67. se provided after the cause of action has accrued
68. se End Bell Assembly for 15 HP Motor Not Shown 1 21 Rotor Assembly for 15 HP Motor Not Shown 1 GHC 1021A 230 volt 3 phase 60 Hertz GHC 1021B 460 volt 3 phase 60 Hertz GHC 1021C 575 volt 3 phase 60 Hertz 22 Stator Assembly for 15 HP Motor Not Shown 1 GHC 1022A 230 volt 3 phase 60 Hertz GHC 1022B 460 volt 3 phase 60 Hertz GHC 1022C 575 volt 3 phase 60 Hertz Recommended Spare Part Duplicate part numbers indicate parts only sold together as a kit 44 A Al ipa K l EN d E KA NAMA UA N VA Ni N reroll ooo Lows A ba A Mf D TAN SASSI KN NNR f N A ceu 2 N WEY N Y s RM 1A RS SANS Figure 9 11 B Frame Trolley Drive Gear Reducer B Frame Trolley Drive Gear Reducer Components for Figure 9 11 Ref Part Qty No Number Description Req d GHB 309A B Gear Reducer 30 1 Ratio 50 FPM Includes Ref Nos 1 25 1 GHB 309B B Gear Reducer 20 1 Ratio 75 FPM Includes Ref Nos 1 25 1 1 GHB 1101 Housing 1 2 GHB 1102 High Speed Bearing 1 3 GHB 1103 Slow Speed Bearing Cone 2 4 GHB 1104 Slow Speed Bearing Cup 2 5 GHB 1105 High Speed Spacer 1 6 GHB 1106 High Speed Ring 1 7 GHB 1107 High Speed Retaining Ring 1 8 GHB 1108 High Speed Cap Closed 1 9 GHB 1109 High Speed Gasket 2 10 GHB 1110 Slow Speed Gasket 2 11 GHB 1
69. switch stopped the hoist before the block operated limit switch was activated If this is not the case see Section VII Paragraph 7 3 for adjusting the geared limit switch Replace geared limit switch cover when testing and adjusting is complete 5 13 TESTING HOIST a General Testing shall be performed in accordance with ANSI B30 16 2 and this manual Before placing hoist in service hoist should be tested to insure safe operation when hoist has been disassembled and reassembled To test suspend hoist from an overhead supporting member of sufficient strength to support the weight of the hoist and the rated load Connect hoist to power supply as shown on hoist nameplate and perform the checks listed in b and c below Check hoist as outlined in PRE OPERATION CHECKS SECTION _ Il Paragraph 2 4 Check hoist with rated load 1 Attach rated load to lower hook 2 Depress UP push button and raise load When push button is released hoist should stop immediately and hold load at that level 3 Depress DOWN push button lower load a short distance and release button Hoist should stop immediately and hold load at that level NOTE If load drifts downward slowly in step 2 or 3 above motor brake requires adjustment see Motor Brake Adjustment SECTION VII Paragraph 7 1 23 SECTION VI TROUBLE SHOOTING 6 1 GENERAL This section contains possible causes and solutions to common hoist problem
70. t may be reproduced in any form in an electronic retrieval system or otherwise without prior written permission of the publisher NOTICE Information contained in this book is subject to change without notice NOTICE Information contained in this book is subject to change without notice INDEX SECTION I GENERAL DESCRIPTION PAGE Paragraph 1 1 General 3 1p etse bbe iy D eese VE Da pasate age d cu E sale e Le eft mies E ae Tu e edis 4 Paragraph 1 2 Basic Construction sssssssssssssssseseeene enemies ene e e enne ne 4 SECTION Il INSTALLATION Paragraph 2 1 General 2 35 21 ere e ie dhe Do toot rea het e odaibelt uu a uale e Dei Minna ee ED TNT 4 Paragraph 2 2 Suspending Hoist 0c e en eee mememesesese ee enses 4 Paragraph 2 3 Connecting Hoist to Electrical Service 0 e eee ee eee eee mee 5 Paragraph 2 4 Pre Operation Checks ccececeee cence cece eee eee ea ee eases esse e meses ete e entree 5 SECTION Ill OPERATION Paragraph S I General tene HR PEE o EH Pe LECCE erga IPIE nrbe ban 6 Paragraph 3 2 Push Button Operation seirinin e ee e eem hse nennen 6 Paragraph 3 3 Operating Precautions cece cece e mmm messes eee esee 7 SECTION IV LUBRICATION Paragrapli4 1 General iue ber pri titel e beeee eae ote eso ed 8 Paragraph 4 2 Changing Gearcase Oil cece nent entree memes eene 8 Paragraph 4 3 Lubrication of Hoist Cable oo eee ee Hememmemememememe eene 9 Paragraph 4 4 Lubricat
71. tion Schedule and Maintenance Report form that lists various components of the hoist The form also includes trolley components runway com ponents and miscellaneous items This form is suggested as a guide for written inspection reports Inspections are recommended each month and should be performed thoroughly enough to inform the hoist user of deficiencies for any item listed This form does not supersede the Inspection and Maintenance Schedule listed on page 12 of this manual but may be used to record scheduled inspection and maintenance services required 11 The user should revise the inspection interval add additional units or provide a similar form to suit particular conditions that may exist However written dated and signed inspection reports should be maintained particularly on critical items such as hoist hooks hoisting rope sheaves drums and brakes Periodic review of old inspection reports can point out service life of hoist components forecasting need for adjustment repair or replacement of these components As a matter of expedience appointed maintenance personnel inspecting hoist can also take care of minor adjustments repairs and cleaning where required Note column on Inspection Schedule and Maintenance Report form headed Corrective Action and Notes When corrective action is made during inspection note condition of part or unit as inspected in appropriate Condition column with a check mark Note durin
72. to the terminal block on the brake body 4 Install the forward fan mounting retaining ring and install the fan Install the rear retaining ring Install the fan shroud and bolts 5 Test hoist per Section V Paragraph 5 13 missing items Wheels must always changed be in opposing pairs and drive wheels should be changed when the drive pinions are replaced ACAUTION 5 11 INSPECTION OF HOIST TRAVERSE DRIVE a P4 l MOTOR B HEX CROSS Sur 7 gt J 5 uu TITLE ET Arm GEAR REDUCER CLAMP COLLARS CROSS SHAFT BEARING if CROSS SHAFT PINIONS SPACER WASHER Ensure that the cross shaft is properly positioned and locked into place by means of the clamp collars Failure to do so may allow the drive shaft to contact the rope on the rope drum B frame or the hoist gearcase C frame hoist 22 Figure 5 10 Traverse Drive Arrangement a General The traverse drive consists of four single flange wheels two on each side of the beam carried directly by the hoist frame These wheels rotate on sealed ball bearings supported by fixed pins Pinions drive two opposing wheels with gear teeth cut into the flange Both pinions are mounted on a hexagonal drive shaft supported by sealed ball bearings at each hoist side The pinions are held in place by means of clamp collars The drive shaft passes through one hoist side and is driven by a single re
73. trolley electrical system controls Hoisting cable and a covered lower block assembly are used for lifting loads A rotary geared limit switch is used to limit travel both up and down A secondary block operated limit switch is used to limit the travel of the lower block when raising A push button control station purchased separately for operating the hoist is suspended on a wire strain cable attached to the hoist SECTION Il INSTALLATION 2 1 GENERAL Yale Global King electric hoists are lubricated and tested before being shipped from the factory To place a hoist in service adjust appropriately for the beam flange width Paragraph 2 2 connect to electrical service Paragraph 2 3 and perform pre operation tests and checks Paragraph 2 4 AWARNING Working in or near exposed energized electrical equipment presents the danger of electric shock TO AVOID INJURY DISCONNECT POWER AND IMPLEMENT LOCKOUT TAGOUT PROCEDURE BEFORE REMOVING COVER OR SERVICING THIS EQUIPMENT 2 2 SUSPENDING HOIST O e m i L e c Uu At Nl FIGURE 2 1 Trolley Wheel Spacing a OPEN END BEAM If the trolley can be installed directly from the end of the supporting beam adjust the spacing between the trolley wheel flanges to be 3 16 1 4 greater than the exact width of the beam flange See Figure 2 1 Before adjusting the width of the trolley frame be sure to loosen the clamp collar nearest the tr
74. ts lists and illustrations in this section of the manual cover parts for models of Yale Global King Electric hoists A typical hoist is shown as the basis for the exploded parts illustrations therefore certain variations may occur from the information given For this reason always give the Hoist Serial Number Catalog Number Motor Horsepower Voltage Phase Frequency and Capacity of Hoist when ordering parts Yale Global King Hoists are built in two basic frame sizes B Frame and C Frame To determine the size of your hoist measure the width of the gearcase see Figure 4 2 The B Frame s gearcase has a width of 11 3 4 and the C Frame has a gearcase width of 14 1 2 Certain parts of your hoist will in time require replacement under normal wear conditions It is suggested that these parts be purchased for your hoist as spares for future use These parts are indicated by a 1 symbol at the side of the parts reference numbers The numbers assigned to parts of our various assemblies in our parts list are not the part numbers used in manufacturing the part They are identification numbers that when given with the model number permit us to identify select or manufacture and ship the correct part needed WHEN ORDERING PARTS OR INFORMATION ON THIS EQUIPMENT ALWAYS INCLUDE MODEL AND SERIAL NUMBER ON ORDER AWARNING Using Commercial or other manu facturer s parts to repair Global King Hois
75. ts may cause load loss TO AVOID INJURY Use only Yale Hoist supplied parts Parts may look alike but Yale Hoist parts are made of specific materials or processed to achieve specific properties LIST OF PART ILLUSTRATIONS TITLE FIGURE No PAGE No Hoist Drum Drum Frame Gearcase Motor Rope Guide and Limit Switch 9 1 30 Hoist Gearing 9 2 32 Motor Driven Trolley Frame and Drive 9 3 34 Lower Block Assembly 9 4 36 Upper Block Assembly 9 5 38 B Frame Rope and Dead End Assembly 9 6 39 C Frame Rope and Dead End Assembly 9 7 40 Block Operated Limit Switch Assembly 9 8 40 Rope Guide Assembly 9 9 42 Hoist Motor Brake 9 10 43 44 B Trolley Drive Gear Reducer 9 11 45 C Trolley Drive Gear Reducer 9 12 46 29 FIGURE 9 1 Hoist Drum Drum Frame Gearcase Motor Rope Guide and Screw Type Limit Switch B Frame Hoist Components for Figure 9 1 Ref Part Qty No Number Description Req d 1 7 HP Hoist Motor 2 Speed with Brake and Fan Note See Figure 9 10 for Parts 1 GHB 101A 230 volt 3 phase 60 Hertz GHB 101B 460 volt 3 phase 60 Hertz GHB 101C 575 volt 3 phase 60 Hertz 2 GHB 102 Heavy Hex Nut 1 2 13 2 3 GHB 103 Lockwasher 1 2 2 4 GHB 104 High Strength Hex Head Bolt ASTM A325 1 2 13 x 2 1 2 2 5 GHB 105 Self Locking Nut ESNA 3
76. ts of oil The C Frame s width is 14 1 2 and requires approximately12 quarts of oil 4 3 LUBRICATION OF HOISTING CABLE Hoists are shipped from the factory without an exterior coating of grease on hoisting cable It is recommended where conditions permit that the cable be thoroughly coated at installation and kept well lubricated with CL Paragraph 4 7 4 4 LUBRICATION OF LIMIT SWITCH Provide a light film of grease MPG Paragraph 4 7 on bevel gear of rotary geared limit switch 4 5 LUBRICATION OF GEARED TROLLEY WHEELS AND PINIONS At installation and periodically apply grease WG Paragraph 4 7 to the traverse drive pinions and the gears of the trolley wheels 4 6 LUBRICATION OF ROPE GUIDE a Maintenance Once properly installed the following actions are required 1 Periodically re grease with MPG Paragraph 4 7 using the grease fitting provided Figure 5 3 Item 6 2 Every 6 months the rope guide should be removed per Section V Paragraph 5 5 cleaned and inspected When the rope guide is reassembled the rope guide should be thoroughly greased with MPG Paragraph 4 7 and the hoist run up and down to lubricate both the drum and the wire rope NOTES 4 7 LUBRICANT SPECIFICATIONS AMBIENT TEMPERATURE 20 to 50 F 50 to 125 F 125 to 250 F 29 to 10 C 10 to 52 C 52 to 121 C GCOH AGMA Lubricant No 6 No 7 EP No 7 Gear Case Oil
77. tter Pin 2 NOTES 2 4 6 1 E gt T lt 2 8 3 E gt J u 5 9 4 Figure 9 6 B Frame Rope and Dead End Assembly B Frame Rope and Dead End Assembly Components for Figure 9 6 Ref Part Qty No Number Description Req d GHB 600 B Frame Hoist Rope and Dead End Assembly 1 GHB 601 Dead End Yoke 1 2 GHB 602 Washer 1 Diameter 18 Gauge 4 3 GHB 603 External Retaining Ring 2 4 GHB 604 Dead End Swage Socket Pin 1 5 Wire Rope and Swaged End Assembly 1 GHB 605A Rope Assembly for 25 lift GHB 605B Rope Assembly for 40 Lift 6 GHB 606 Dead End Pin 1 7 GHB 607 Key Plate 1 8 GHB 608 Socket Head Cap Screw 5 16 18 x 3 4 1 9 GHB 609 Lockwasher 5 16 1 39 Figure 9 7 C Frame Rope and Dead End Assembly C Frame Rope and Dead End Assembly Components for Figure 9 7 Ref Part Qty No Number Description Req d GHC 700 C Frame Hoist Rope and Dead End Assembly 1 GHC 701 Cotter Pin 2 2 GHC 702 Dead End Swaged Socket Pin 1 3 GHC 703 Flanged Bushing 2 4 GHC 704 Washer 1 1 2 Diameter 10 Gauge 2 5 Wire Rope and Swaged End Assembly 1 GHC 705A Rope Assembly for 25 lift GHC 705B Rope Assembly for 40 Lift v L E I 1 JA By 8 d 40 Figure 9 8 Block Operated Limit Switch Assembly B Frame shown B Frame Block Operated Limit Switch Components for figure 9 8
78. unted along the span of a beam not having open ends the trolley must be adjusted in the same manner as described above to a width that allows clearance between the axles and the beam flange Using proper lifting equipment the trolley and hoist must then be lifted to the beam where it is to be installed Once in position adjust the spacing between the trolley wheel flanges to be 3 16 1 4 greater than the exact width of the beam flange See Figure 2 1 After tightening all adjusting bolts the clamp collar and all electrical conduit cable clamps carefully set the trolley on the beam Lubricate the wheel gear and pinion WG Section IV Paragraph 4 3 2 3 CONNECTING HOIST TO ELECTRICAL SERVICE Electrical service to the hoist may be power cable or a guarded system having sliding shoe or wheel type collectors a Follow ANSI NFPA 70 state and local electrical codes including the grounding provisions thereof when providing electrical service to the hoist Make electrical connections using the appropriate wiring diagrams furnished with the hoist All electrical connections including connections to collectors or power cord shall be made only b ualified journeyman electricians ACAUTION Power supply to hoist and trolley must be the same voltage frequency and phase that are specified on the hoist and trolley nameplate 2 4 PRE OPERATION CHECKS a Check Oil Level Figure 2 1 The gearcase has been
79. w inches and check load s holding action before continuing DO avoid swinging of load or load hook DO make sure that all persons stay clear of the suspended load DO warn personnel of an approaching load DO protect wire rope from weld splatter or other damaging contaminants DO promptly report any malfunction unusual performance or damage of the hoist DO inspect hoist regularly replace damaged or worn parts and keep appropriate records of maintenance DO use the hoist manufacturers recom mended parts when repairing a hoist DO use hook latches DO apply lubricant to the wire rope as recommended DO NOT lift more than rated load DO NOT use the hoist load limiting device to measure the load DO NOT use damaged hoist or hoist that is not working properly DO NOT use the hoist with twisted kinked damaged or worn wire rope DO NOT lift a load unless wire rope is properly seated in its groove s DO NOT use wire rope as a sling or wrap rope around the load DO NOT lift a load if any binding prevents equal loading on all supporting ropes DO NOT apply the load to the tip of the hook DO NOT operate unless load is centered under hoist DO NOT allow your attention to be diverted from operating the hoist DO NOT operate the hoist beyond limits of wire rope travel 7 dd ee gg hh nn 00 pp qq rr SS uu DO NOT use limit switches as routine operating

Yale 11353395D User's Manual

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