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Global King Wire Rope Hoist - 1 to 3 Ton

1. WIRE DEVICE CONNECTED L HFU CFU PPD CONNECT PER 2 HFU CFU PPD NAMEPLATE FOR L3 HEU CFU PPD PROPER VOLTAGE HLI ru U D PFU Li 12 HL2 HFU U D PFU HLT HL2 HL3 HFU U D 5 areg CL1 CFU R L 871 C2 CFU R I Flpr CL CFU R L uc 0 2 5 PL1 PFU HCPT pp HEU mu ML PL PL2 PL2 PFU A PRIMARY 4 U 0 F EE C U D F C K2 Ki OA 1A 2 91 E Tom T 0 R L FC 121141 4 HLT HL2 HLS CL1 CL2 CL3 2999999 1 SECONDARY x2 li F R L FC LT 1 KW F HSOL e rT 1 HCFU 2 U D HSOL HFOL 5 9 A 1A 2A e Ce 92 0E OB OA 1A 2A H8 H011 F HFOL 13 F HFOL 92 GE o 0 CFOL OA HL HL2 HL3 1H OH 1A 2A A C CDS FC CSOL M m L LL 0011 FC CFOL CD13 FC CFOL 1 j H BEN Y EN o 8 072 HSQL VU 20 Je HTS HSOL unt HFOL MN m 4 TER L 012 HFOL 0113 HFOL 92 A HO C 1A 0A 92 92 001101 HOS 3 CT CSO CH CSOL 03 CSOL 5 S m HD1 HO2 HOS Du HOII HO2 H013 00 19 19 QE RU prol We q7 g2 toc H91 S Se Ia lid p L 0H o OH J M A gt d 1 V lt i D cd
2. SSS Das NSS NS WLLL 7 WSS SS SS N X d M 1 d 0 Ip 72 Figure 9 8 Standard Hoist Motor Brake A S2 Frame Hoist Brake Components for Figure 9 8 Fan 33295551 External Retaining Rings Fan Hub BRAKE External Retaining Ring Fan FAN Fan Hub KIT Key Fan Hub Key Fan 33295552 External Retaining Ring Brake Hub BRAKE Spacer Brake Hub HUB Key Brake Hub KIT Brake Hub 33295553 Hollow Core Bolts HARD O Ring WARE Bolts Brake Mounting KIT Compression Springs Magnet Body Order Complete Brake Armature Plate Order Complete Brake 18 33295555 Fan Shroud 19 SHROUD KIT Bolts Fan Shroud 1 1 1 1 1 3 1 3 7 1 4 Page 45 x NSS i SS N 3
3. AWARNING On three phase hoists it is possible to have Reverse Phasing causing the block to lower when the UP button is depressed When this condition exists the automatic limit switch is inoperative and hoist operation will be dangerous c Check Lower Block and Hoisting Cable Depress DN 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 rotates excessively repeat process until twisting is corrected d 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 Para 4 7 as outlined in SECTION IV Paragraph 4 3 e Check Limit Switch Operation 1 A geared rotary type upper and lower limit switch is provided as standard equipment on YALE World Series hoists This switch is adjustable and although preset by the factory it should be adjusted
4. Mi hb ch OH OO oO oO Joo Page 2 Figure 9 7 Rope Guide Assembly A Frame Rope Guide Components for Figure 9 7 Part Qty Number Description Req d A Frame Rope Guide Assembly Rope Guide Body Plastic Shroud Socket Head Shoulder Bolt M6 Thread Compression Spring Extension Spring Page 43 44943801C N A N A N A N A N A S fy oe AN N N A SS le B N ES SS AA KY N S d gt d a NN NN SEN Figure 9 8 Standard Hoist Motor Brake A S4 Frame Hoist Brake Components for Figure 9 8 Fan 33295051 External Retaining Rings Fan Hub BRAKE External Retaining Ring Fan FAN Fan Hub KIT Key Fan Hub Key Fan 33313852 External Retaining Ring Brake Hub BRAKE Spacer Brake Hub HUB Key Brake Hub KIT Brake Hub 33313853 Hollow Core Bolts HARD O Ring WARE Bolts Brake Mounting KIT Compression Springs Magnet Body Order Complete Brake Armature Plate Order Complete Brake 18 33295055 Fan Shroud 19 SHROUD KIT Bolts Fan Shroud Kit comes with 7 springs but only 5 are utilized in this assembly 1 1 1 1 1 3 1 3 5 1 4 Page 44
5. See text for DAILY amp WEEKLY REQUIREMENTS SIGNED O INSPECTION INTERVAL X MAGNETIC PARTICLE OR EQUIVALENT EXAMINATION REQUIRED Typical Inspection Schedule and Maintenance Report form User must adjust inspection interval and components to suit his individual conditions and usage 12375gwr Page 12 5 3 INSPECTION OF UPPER BLOCK Refer to the Section IX Figure 9 5 Upper Block Assembly a Check upper block sheaves for wear damage and freedom of rotation If sheaves do not rotate freely disassemble block and inspect bearings Replace worn or damaged bearings washers pins or sheaves b Make certain that all sheaves 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 a
6. Lower Block Assembly Excludes Ref Nos 17 amp 18 Sheave Assembly Incl Ref Nos 12 13 14 Hook Latch Kit Not shown Hook Assembly Incl Ref Nos 2 3 4 Trunnion Crosshead Hook amp Nut Assembly Thrust Bearing Roll Pin Sheave Pin Spacer Tube Lower Block Strap Inner Sheave Cover Flat Washer M8 Socket Head Cap Screw 8 Locknut M8 Rope Sheave Ball Bearing Internal Retaining Ring External Retaining Ring Outer Sheave Cover 3200 kg Capacity Label YALE Brand Label Socket Head Cap Screw M6 Locknut M6 44943601C 33296201 4X1307 23398091 N A N A N A N A N A N A N A 33296501 N A N A N A N A N A N A N A 3329651 1 23382880 23382802 N A N A OONOOARWD Page 39 1 1 1 1 1 2 1 1 2 2 2 4 4 2 2 3 3 Figure 9 45 Lower Block Assembly S2 Reeved A Frame S2 Reeved Lower Block for Figure 9 4b Part Qty Number Description d Lower Block Assembly Excludes Ref Nos 14 amp 15 Sheave Assembly Incl Ref Nos 7 8 9 Hook Latch Kit Not Shown Hook Assembly Incl Ref Nos 2 3 4 Crosshead Weldment Hook amp Nut Assembly Thrust Bearing Roll Pin Sheave Pin External Retaining Ring Rope Sheave Internal Retaining Ring Ball Bearing Spacer Washer Outer Sheave Cover Socket Head Cap Screw M8 Flat Washer M8 YALE Brand Label 1600 kg Capacity Label Socket Head Cap Screw M6 Locknut M6 44944101C 33296201 4X1304 2339869
7. NOTICE 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 CLOSE END BEAM For trolleys which are to be mounted 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 axle ends 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 set screws and all electrical conduit cable clamps carefully set the trolley on the beam Lubricate the wheel gear and all pinions WG Section IV Paragraph 4 5 Example An application requires that a hoist be used to repeatedly lift and move small to medium size loads but occasionally will be required to lift heavy loads equal to 3 2 metric tonne This hoist will be operated daily for a single 8 hour shift and will be required to perform 15 lifting cycles per hour The average height which the load is lifted is 18 ft at a desired speed of 20ft min The average daily operating time can be calculated from the above information i 2x18x15x8
8. a LLL p VZZ ER w 16 Figure 9 9 Outdoor Service Hoist Motor Brake A S4 Frame Hoist Brake Components for Figure 9 9 Part Qty Number Description Req d 33297049 Complete Brake Assembly Includes Ref Nos 1 11 16 17 18 amp P N 33294053 33313850 Brake Friction Disc fd 1 Fan 1 33295051 External Retaining Rings Fan Hub BRAKE External Retaining Ring Fan 1 FAN Fan Hub 2 KIT Key Fan Hub Key Fan 33294052 External Retaining Ring Brake Hub BRAKE Spacer Brake Hub HUB Key Brake Hub KIT Stainless Steel Brake Hub 33294053 Hollow Core Bolts HARD O Ring WARE Bolts Brake Mounting KIT Compression Springs Magnet Body Order Complete Brake Stainless Steel Armature Plate Order Complete Brake Stainless Steel Friction Disc Order Complete Brake 11803105 Spacer Washers 20 33295055 Fan Shroud 21 SHROUD KIT Bolts Fan Shroud Kit comes with 7 springs but only 5 are utilized in this assembly 1 1 1 1 1 3 1 3 5 1 4 Page 46 Ww NC N ee nS 16 GSS gt ZS d 5 Figure 9 9 Outdoor Servic
9. Frame Side Plate 20 Lift Model Frame Side Plate 40 Lift Model Counterweight Plate 1 Counterweight 20 Lift Model Counterweight 40 Lift Model Hoist Trolley Controls Specify HP Voltage Frequency No of Speeds Options 1 Alignment Bar 2 Alignment Bar 4 Thru 8 1 2 Trolley Beam Flange Width Alignment Bar 8 5 8 Thru 14 Trolley Beam Flange Width Hex Head Cap Screw M12 22 Lockwasher M12 12 Threaded Rod M12 2 Threaded Rod 4 Thru 8 1 2 Trolley Beam Flange Width Threaded Rod 8 5 8 Thru 14 Trolley Beam Flange Width Plain Hex Nut M12 12 continued on next page 33295921 33295922 N A N A N A N A 23400201 23400202 N A N A N A N A N A Page 34 A Frame S4 Reeved Trolley Frame and Drive Components for Figure 9 3 continued Part Qty Number Description Req d 9 4 N A Wheel Axle N A Plain Trolley Wheel N A Geared Trolley Wheel N A Ball Bearing N A Internal Retaining Ring N A External Retaining Ring N A External Retaining Ring N A Ball Bearing w Retaining Ring N A Flat Washer N A Traverse Pinion N A Key N A Set Screw M6 Traverse Cross Shaft N A Cross Shaft 4 Thru 8 1 2 Trolley Beam Flange Width N A Cross Shaft 8 5 8 Thru 14 Trolley Beam Flange Width N A Drop Lug Bumper Stop 11680704 Bumper Optional N A Locknut M12 N A External Retaining Ring N A Output Pinion N A Hex Head Cap Screw M8 N A Locknut M8 Traverse Reducer 43907725 Traverse Reducer 50 FPM 43907715 Trav
10. visual 1 Month HOIST CABLE Inspect per Paragraph 5 6 and lubricate per Paragraph 4 3 ELECTRICAL CONTROLS Inspect per Paragraph 5 4 Check hoist gearcase oil level add oil as 1 3 Months required per Paragraph 4 2 e LOWER BLOCK Inspect per Paragraph 5 2 UPPER BLOCK Inspect per Paragraph 5 3 ROPE GUIDE Inspect per Paragraph 5 5 6 Months OVER CAPACITY LIMIT SWITCH Inspect per Paragraph 5 13 BLOCK OPERATED LIMIT SWITCH if equipped Inspect per Paragraph 5 12 Lubricate hoist cable per Paragraph 4 3 Lubricate upper and lower hook block Lubricate outboard bearing cartridge at grease fitting Add a light film of MPG grease to the bevel gear in the screw type limit switch per Paragraph 4 7 Complete inspection Motor brake and actuating mechanisms inspected and adjusted per Paragraph 5 10 Inspect hooks with crack detecting procedures per Paragraph 5 2 Annually Hours of On time Load Hoist Duty 12500 25000 Complete inspection disassembly and maintenance required It is recommended that your YALE repair Station be contacted for this service Notes Page 11 INSPECTION SCHEDULE AND MAINTENANCE REPORT HOIST SERIAL NO MFGRS CUSTOMER CRANE IDENTITY NO RATED LOAD LOCATION IN PLANT TYPE THIS INSPECTION IS MONTHLY O ANNUAL VOLTAGE SEMI ANNUAL O INSPECTED BY DATE Recom CONDITION COMPONENT UNIT OR PART mended Check column best indicating condition when CORRECTIVE ACTION and location I
11. 2 Every 6 months the rope guide should be removed per Section V Paragraph 5 5 cleaned and inspected When 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 c Reinstall drain plug d Remove oil level plug from front of gearcase cover 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 the overall size of the gearcase Both versions of the A Frame hoist utilize the same size gearcase although their contents differ To confirm the version of your gearcase refer to Figure 4 2 Your gearcase should have a similar shape to that shown and will measure 10 in width and requires approximately 3 quarts of oil Notes Page 8 4 7 LUBRICANT SPECIFICATIONS 20 to 50 F 125 to 250 F 29 to 10 C 10 to 52 C 52 to 121 C Gear Case Oil 0 6 NMGoexe RT Spline Grease ASTM D217 Worked 310 340 Penetration Dropping Point 320 F 160 C Mobil Oil Corp WG Viscosity 100 F 25 000 SUS contains diluent Wheel Gear and Mobil Oil Corp i Pinion Grease Cable Lubricant Amoco Oil Co i Mobil Oil Corp Wire Rope Sun Oil Co Go __ AGMA Lubricant General Oil V
12. 2 tonne 3200 kg capacity with a four parts of rope single reeving configuration The S2 designation refers to the 1 6 tonne 1600 kg capacity with a two part of rope single reeving configuration Both hoists feature an integral trolley and are offered with two different flange width ranges 4 5 8 through 8 1 2 and 8 5 8 through 14 on a maximum flange thickness of 1 1 8 The smaller flange range also accommodates patented track beams using an optional trolley wheel arrangement The hoist motor is 2 speed with a 4 1 ratio between high and low speeds as standard The motor driven trolley has two available speeds with 1 2 speed or variable frequency control Throughout this manual you will see references to the S2 and S4 Frame hoists If you are unsure about which frame you have count the number of rope falls that are supporting the lower block and or see Section IV Paragraph 4 2 for a simple gearcase measurement to determine the configuration of your hoist 1 2 BASIC CONSTRUCTION YALE Global King hoists consist of a rugged steel frame made from structural steel and assembled using high strength structural bolts The frame houses a lifting drum and serves as the suspension means for the rated hoist load An aluminum gearcase attached to one end of the drum frame houses a triple reduction helical gear train Applying power to the gearcase is a 2 speed AC hoisting motor with a 4 1 speed ratio coupled with a 250 torque DC br
13. 3 6 hr day 20 x 60 The description of the example application implies that the load spectrum is likely an L1 or L2 Choosing an L2 load spectrum factor and using the calculated average daily operating time one can determine from the Classification of Mechanisms table above the duty classification for this application is 2m for a 3 2 metric ton rated hoist For a more thorough explanation of the determination of mechanism classification refer to FEM 9 511 Classification of Mechanisms Your YALE Global King hoist was designed to meet the duty classifications as described above The standard 3 2 tonne and 1 6 tonne capacity models are rated at 2m duty classification A 3m duty classification is available at a derated capacity SECTION II 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 install onto beam by adjusting appropriately for the flange width connect to electrical service and perform pre operation tests and checks A WARNING Only qualified personnel with proper supervision shall install the hoist on the monorail and perform the final pre operation inspection A WARNING 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 Page 4
14. DOWN CONTACTOR 601 5 TROLLEY MOTOR TEMPERATURE ACTIVATED SWITCH F HOIST FAST SPEED CONTACTOR MC MONITOR CARD HSOL HOIST SLOW SPEED THERMAL OVERLOAD RELAY TB TERMINAL BOARD WARNING HFOL HOIST FAST SPEED THERMAL OVERLOAD RELAY Ge FRAME GROUND THI ENT BE EFFECTIVELY G LSU HOIST UPPER GEAR TYPE LIMIT SWITCH mu Nd MORNE LSD HOIST LOWER GEAR TYPE LIMIT SWITCH SCH De BRAKE CONTROL MODULE ma TIMER DELAY MODULE AVERTISSEMENT HTAS HOIST MOTOR TEMPERATURE ACTUATED SWITCH CET EQUIPMENT DOIT ETRE MIS A LA TERRE EN OLS OVERLOAD LIMIT SWITCH ACCORDANCE AVEC LES NORMES EN VIGUEUR OLC OVERLOAD LIMIT SWITCH CONTACTOR Page 26 The numbers assigned to parts of our various assemblies in our Parts List are the part numbers used in manufacturing Some of these itemized parts are not for individual sale but must be grouped with other related replacement items WHEN ORDERING PARTS OR INFORMATION ON THIS EQUIPMENT ALWAYS INCLUDE MODEL AND SERIAL NUMBER ON ORDER AWARNING Using Commercial or other manufacturer s parts to repair Global King Hoists 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
15. LEVER WIDTH FILLER HOLE 005 Figure 2 1 Trolley Wheel Spacing 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 make sure to loosen the pinion set screws on the keyed cross shaft nearest the traverse drive reducer Do not lose the keys for the pinion during adjustment Also the electrical conduit cable must not be constrained when attempting to adjust the trolley sides in or out The trolley width is 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 threaded 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 setscrews 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 hoist and install on the end of the beam Lubricate the wheel gear and all pinions WG Section IV Paragraph 4 5
16. at time of installation to the desired high and low limits of lower block travel Refer to SECTION VII Paragraph 7 3 2 A block operated upper limit switch can be furnished as optional equipment on 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 Minimal adjustments can be made When equipped with this option the hoist should be tested by jogging the lower block against the limit switch actuator arm to assure the switch is functioning properly When the lower block lifts the actuator the hoist will automatically stop If the lower block coasts through the limit switch when lifting a reversing switch will automatically close and reverse direction of motion to lowering f An overcapacity limit switch is provided as standard equipment on YALE Global King hoists This switch is adjustable and although preset by the factory it should be adjusted at the time of installation to the desired setting Refer to SECTION VII Paragraph 7 4 g When first using the hoist and trolley operate with lighter loads through full travel before applying maximum load Page 5 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 Follow ANSI NFPA 70 state and local electrical codes including the grounding provisions
17. case and cover A helical gear train provides smooth and quiet hoisting operation The gear shafts are supported with ball and roller bearings housed in the back of the case and in the cover The input pinion is integrated onto 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 hoist must be removed from service and repaired on the ground for any maintenance that requires removal of the output shaft assembly or drum Only once the output shaft is free of the rope drum can the output shaft assembly be safely removed from the gearcase Provide an adequate means to support this shaft and gear assembly before removing as it is heavy The A Frame gear assembly weighs 14 Ibs 7 The pinion shaft and gear assemblies may be removed as necessary 8 Inspect all gears pinions bearings and the output shaft spline for wear pitting or mechanical damage Replace the gearcase assembly as necessary Thoroughly clean the output shaft external spline teeth before reassembly 9 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
18. maximum stresses full capacity lifts or whether it is subject to smaller loads only Use the charts below to estimate your load spectrum For an exact means of calculating your load spectrum refer to FEM 9 511 Classification of Mechanisms LOAD 40 LOAD 50 50 90 10 OPERATING TIME OPERATING TIME Once the average daily operating time t is calculated for a specific application the Class of Operating Time can be identified Using the Class of Operating Time along with the Load Spectrum one can determine the duty classification requirement of the application Defining the proposed equipment usage in this manner is critical to selecting the correct hoist for the application Classification of Mechanisms Load Spectrum Average Average Daily Operating Time hr day Time hr day NN NENNEN EE Page 3 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 rope drum and upper block supported on opposite sides of the beam by the trolley frame There is one basic frame configuration for both the two and four part single reeved hoists Both reeving configurations are referred to as A Frame hoists with the distinction made between reeving styles The S4 designation refers to the 3
19. processed to achieve specific properties SECTION IX PARTS LIST 9 1 GENERAL The parts 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 Throughout this manual you will see references to the S2 and S4 Frame hoists If you are unsure about which frame you have count the number of rope falls that are supporting the lower block and or see Section IV Paragraph 4 2 for a simple gearcase measurement to determine the configuration of your hoist Your gearcase should have a similar shape to that shown and will measure 10 in width and requires approximately 3 quarts of oil 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 listed at the end of this manual LIST OF PART ILLUSTRATIONS ate Leen Wire Rope Dead End Assen umm s T Fosi motor rare sarad seves f e o a Hoist Motor Brake Outdoor Service 99 46 Notes Page 27 2 2 4 1 2 2 4 1 1 2 2 4 1 1 1 1 Fig
20. 1 N A N A N A N A N A N A N A N A N A N A 33296701 N A N A 23382802 23382881 N A N A 0 OO ex Lu E ica ck CH Figure 9 5 Upper Block Assembly S4 Reeved Frame Upper Block Components for Figure 9 5 Part Number Description Qty Req d BEEN qn A Frame Hoist Upper Block Assembly Sheave Assembly Incl Ref Nos 10 11 12 Upper Block Yoke Yoke Pin External Retaining Ring Locknut M6 Hex Head Bolt M6 Sheave Pin External Retaining Ring Spacer Washer Internal Retaining Ring Sealed Ball Bearing Rope Sheave 44944001 33296201 N A N A N A N A N A N A N A N A N A N A N A Page 40 Part Qty Number Description Page 41 sch P A A AAPM Figure 9 6 Wire Rope Dead End Assembly A Frame S4 Reeved Dead End for Figure 9 6 A Frame S4 Reeved Rope and Dead end Assembly Excl Ref No 20 Dead End Yoke Yoke Pin Yoke Sleeve External Retaining Ring Overload Beam Plate Overload Spring Retainer Detent Belleville Spring Washer Socket Head Cap Screw M6 Locknut M6 Spacer Dead End Pin Washer External Retaining Ring Overload Spring Base Socket Head Cap Screw M6 Hex Nut M6 Hex Head Cap Screw M6 Locknut M6 Wire Rope and Swaged End Assembly Rope Assembly 20 Lift Model 6 4mm Rope Asse
21. 33295921 33295922 N A N A 23400201 23400202 N A N A N A N A N A N A N A N A N A N A Page 36 A Frame S2 Reeved Trolley Frame and Drive Components for Figure 9 3 continued Part Qty Number Description External Retaining Ring External Retaining Ring Ball Bearing w Retaining Ring Flat Washer Traverse Pinion Key N A Set Screw M6 Traverse Cross Shaft N A Cross Shaft 4 Thru 8 1 2 Trolley Beam Flange Width N A Cross Shaft 8 5 8 Thru 14 Trolley Beam Flange Width N A Drop Lug Bumper Stop 11680704 Bumper Optional N A Locknut M12 External Retaining Ring Output Pinion Hex Head Cap Screw M8 Locknut M8 Traverse Reducer 43907725 Traverse Reducer 50 FPM 43907715 Traverse Reducer 80 FPM N A Traverse Motor Specify HP Voltage Frequency No of Speeds Options N A Hex Head Cap Screw 3 8 N A Lock Washer 3 8 N A Gusset Bracket N A Gusset Shoe N A Gusset Stiffener N A Angle Bracket N A Hex Head Cap Screw Long M12 N A Hex Head Cap Screw Short M12 N A Traverse Stiffener Plate N A Hex Head Cap Screw M12 N A Hex Head Cap Screw 3 8 N A Plain Hex Nut 3 8 N A Locknut 3 8 4 4 26 1 1 4 4 1 SS GO HH Notes Page 37 1 1 1 1 1 2 2 2 4 2 2 2 4 2 2 2 2 2 6 6 Figure 9 43 Lower Block Assembly S4 Reeved A Frame S4 Reeved Lower Block Components for Figure 9 4a Part Qty Number Description
22. 43981305 11593901 N A N A N A N A N A N A 44943901 23397701 N A N A Page 30 A Frame S2 Reeved Hoist Components for Figure 9 1 continued Part Qty Number Description 44943801C Rope Guide See Figure 9 7 for Parts 23385903 Frame Rod pa Lift Model Socket Head Cap Screw M10 Hi Collar Lock Washer M10 Drum Frame Bracket Trolley Frame Side Plate Drum 40 Lift Model Stiffener Bar N A Hex Head Cap Screw M12 Flat Washer M12 N A Locknut M12 N A N A N A N A N A 44944702 YALE Brand label for Gearcase Not Shown gt 4 4 2 1 2 6 1 6 Notes Page 31 Complete 3200kg Hoist Gearcase Ass y 75 14 1 Ratio Gearcase Gasket Seal Kit Incl Ref Nos 3 24 25 Gearcase Gasket Bearings Kit Incl Ref Nos 3 10 15 16 20 21 23 24 25 Gearcase Cover Gasket Vent Plug Drain Fill Level Plug Socket Head Shoulder Screw M6 Hi Collar Lockwasher M8 Socket Head Cap Screw M6 Hi Collar Lockwasher M6 Ball Bearing External Retaining Ring Intermediate Gear Drum Pinion Shaft Key Ball Bearing Ball Bearing Intermediate Pinion Shaft Key Motor Gear Ball Bearing Ball Bearing Output Shaft Roller Bearing Output Shaft Oil Seal Motor Shaft Oil Seal Torque Pin Threaded Stud M10 P bi ch ch CN zl aia a 44943501C 44943590 44943591 N A N A N A N A N A N A N A N A N A N
23. 96 of original dimensions 4 Remove the split plastic shroud Item 2 from the drum When reassembling the rope guide be sure the plastic shroud 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 a Inspection Wire rope on your hoist is one of the most important components requiring frequent inspection and maintenance All 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 Inspections should take place at the most active sections of the rope which may be identifiable through visual insp
24. A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A Part Qty Number Description Page 33 Figure 9 2 Hoist Gearing A Frame S2 Reeved Hoist Gearing for Figure 9 2 Complete 1600kg Hoist Gearcase Ass y 126 3 1 Ratio Gearcase Gasket Seal Kit Incl Ref Nos 3 24 25 Gearcase Gasket Bearings Kit Incl Ref Nos 3 10 15 16 20 21 23 24 25 Gearcase Cover Gasket Vent Plug Drain Fill Level Plug Socket Head Shoulder Screw M6 Hi Collar Lockwasher M8 Socket Head Cap Screw M6 Hi Collar Lockwasher M6 Ball Bearing External Retaining Ring Intermediate Gear Drum Pinion Shaft Key Ball Bearing Ball Bearing Intermediate Pinion Shaft Key Motor Gear Ball Bearing Ball Bearing Output Shaft Roller Bearing Output Shaft Oil Seal Motor Shaft Oil Seal Torque Pin Threaded Stud M10 1 1 1 1 2 2 2 7 7 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 44943502C 44943590 44943591 N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A OONOARWD Figure 9 3 Motor Driven Trolley Frame and Drive A Frame S4 Reeved Trolley Frame and Drive Components for Figure 9 3 Part Qty Number Description Req d Geared Wheel Assembly Pair Incl Ref Nos 9 11 12 13 14 15 Plain Wheel Assembly Pair Incl Ref Nos 9 10 12 13 14 15 Trolley Frame Side Plate Drum 1
25. ARNING 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 is unsafe and must be removed from service b Before removing the old rope refer to reeving diagram Figure 5 5 To assist with re reeving your hoist refer to the reeving diagram and corresponding paragraph that describes the reeving procedure 8 Lubricate cable per Paragraph 4 3 e Checking for and removal of rope twisting 1 To remove rope twist in A Frame 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 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 SW f L e j DRUM ARD IAR Figure 5 6 Drum Frame amp Geared Limit Switch 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 b Remove the geared limit switch or disconnect the wires so that the ele
26. Be certain that electrical power supply is OFF and locked in the open position before attempting shortening of push button cable 8 Loosen screws at cable connectors and clamps at top of cable b Adjust steel support cable to proper length and tighten Screws Notes Page 24 Figure 8 1 Elementary Wiring Diagram for a Two Speed Hoist and Trolley with Standard Features POWER S ROM MAINLINE NU 21 SIAR DAL 3 ELEMENTARY DIAGRAM 2 2 IPO 5 A A 2 L5 L1 12 CFU i HFU 9 PFU 1 HL1 A 31 PPD HCFU 92 th CLI CL2 cL ILt HL2 v LL d LE E 19 R N x J X D A 5 F UP HSO F 0 j ug oc POL gr FOI oto spo Oy a Fe 7 Ed GA 00 013 01 HOZ HOS Hot 015 t 9 J 1 5 o C 4 0 011013 HI HI2 HTS ur un HTS 92 52 2 H2 e 3 2 Lac Len TUR j 1 1 mi 13 TH T3 SLOW FAST 5 0 TROLLEY MOTOR DIST MOTOR et BCM 91 C i H al B2 RKH m 7 4 E 41 Vi 2ND 92 OG 12 FO Page 25 Figure 8 2 Component Diagram for a Two Speed Hoist and Trolley with Standard Features
27. OPERATION SERVICE amp PARTS MANUAL Before installing hoist fill 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 b BAL KI N recommendations in this manual TM Retain this manual for future reference and use WIRE ROPE HOISTS Failure to operate equipment as directed in manual may cause RATED LOADS THRU 3 2 METRIC TONNE injury ao Yale YALE LIF T TECH HOISTS division of Columbus McKinnon Corporation December 2007 Copyright 2007 Yale Lift Tech division of Columbus McKinnon Corporation Part No 118175 05 FOREWORD Number that are found on the nameplate attached to the hoist as shown in Figure 4 1 For your convenience a space has been provided on the front cover of this Manual for entering this information We recommend that you fill it out immediately so it is readily at hand when needed The contents of this manual are of necessity general in nature and may cover features not incorporated on your hoist or you may have orde
28. WARNING 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 All YALE Global King hoists are equipped with a Pulse monitor which is wired into the control circuit in the control enclosure This equipment consists of a circuit board a serial communications port and onboard memory which will retain data even when the hoist is removed from power The Pulse monitor takes the pulse of the equipment by recording the most recent hoist activities including all normal operation events motor starts overcapacity lifts and thermal overload events In addition the monitor records the total cumulative operating time and motor starts for the life of the equipment Each Pulse monitor is programmed with the equipment se
29. able 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 If the block switch is not tripping after contact with the lower block body loosen the limit switch hub retaining screw and rotate the hub and rod downward to ensure earlier contact Retighten and test repeat as needed until switch functions properly 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 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 adjusting limit switch are inside cover and are repeated below see Figure 7 2 12758B Adjustment Discs Switch Locking Plate Figure 7 2 Screw Type Limit Switch Adjustment Wires Not Shown for Clarity a Remove four screws and lift off switch cover AWARNING Be certain that electrical power supply is OFF and locked in the open position before removing limit switch cover c Loosen upper cable grip and pull excess cable into c
30. adjusted 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 OVER CAPACITY LIMIT SWITCH ADJUSTMENT The over capacity limit switch is standard equipment and is integrated into the wire rope dead end assembly see Figure 7 3 The device is designed to prevent overloading of the equipment but is not intended to be used as a load measuring device The limit switch is factory preset to prevent the lifting of loads weighing 125 150 of rated capacity At times it may be necessary to adjust the limit switch setting SPRING BASE Figure 7 3 Over Capacity Limit Switch Page 23 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 wear 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 ADJUSTMENT The block operated limit stop furnished as optional equipment is minimally adjust
31. ake High strength wire rope and a covered lower sheave block act as the load carrying means Standard equipment includes a rope guide a rotary geared limit switch to limit hook travel in both up and down directions and an overload capacity limit switch An optional block operated limit switch can be used to limit the upward travel of the lower block An integral trolley consisting of a 2 speed AC motor and a sealed worm reducer applies torque to the trolley wheels through a cross shaft and pinion arrangement which provides traverse motion to the hoist A single NEMA 4 12 control enclosure houses both the hoist and trolley electrical system controls A push button control station purchased separately for operating the hoist is suspended on a wire strain cable attached to the hoist 1 3 SELECTION amp APPLICATION GUIDE Hoist Duty Classification Your YALE Global King hoist was designed to meet a specific duty classification as described by the FEM Rules for the Design of Serial Lifting Equipment The methodology used to determine the duty class requirements of your specific application is shown below YALE Global King hoists are defined as mechanisms by the FEM and are classified as such by the following factors Class of Operating Time and Load Spectrum Your application must be definable by these two factors in order to determine duty classification 2 2 INSTALLING HOIST ANGE VENT PLUG OIL
32. arcase cover These bolts are not to be removed unless the entire gearcase assembly is being removed from the hoist h Before re assembling by reversing above instructions make sure to apply a liberal amount of SG Paragraph 4 7 spline grease to both the output shaft and drum splines Torque A Frame drum mounting bolts to 60 80 ft lbs 81 108 N m 5 Provide adequate means to support the gearcase cover Remove the smaller socket head cap screws and lockwashers holding the cover to the gearcase Carefully draw the cover directly away from the gearcase as damage to this surface will prevent the gasket from sealing properly If needed lightly tap on the top and bottom cover tabs to release As the cover T Y is removed ensure that all gear and shaft assemblies DRUM PINION 4 R remain in the case and are fully supported by the SHAFT ASSEMBLY gearcase bearings 5 9 INSPECTION OF HOIST GEARING e JP 0 AWARNING If output shaft assembly is pulled out of the gear case with the cover it will disengage from the drum allowing the drum to drop Be certain all shaft assemblies stay in the case 6 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 8 AWARNING Figure 5 7 Hoist Gear Case Assembly a General The hoist gear case is a triple reduction splash lubricated vertically split cast aluminum
33. ce Schedule listed on page 11 of this manual but may be used to record scheduled inspection and maintenance services required 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 o Note during inspection corrective action taken and date in space provided In this manner items requiring further attention will be checked V without showing corrective action This will advise the person responsible for hoist operation and safety or whoever reviews the inspection 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 A
34. ctrical cable will not inhibit removal of the drum see Figure 5 6 c Remove the hoist from the beam place it on the ground and provide adequate means to support the drum before removing the frame rod cap screws and rods at the outboard end drum frame see Figure 5 6 e The hardware attaching the drum frame to the hoist and trolley frame may then be removed f Keeping the drum level remove the drum from the splined output shaft at the gear case end 6 Remove one retaining ring on upper block to allow removal of upper block sheave pin 7 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 8 Remove wire rope from sheave 9 Remove retaining ring s and washer from dead end anchor pin Securely grasp the swaged wire rope before removing the anchor pin 10 Remove rope guide per Section V Paragraph 5 5 11 Make certain all personnel are clear of hoist and operate hoist DN 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 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
35. does not stop when the limit switch rod 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 lbs 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 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 AWARNING 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 5 13 TESTING OVER CAPACITY LIMIT SWITCH The over capac
36. e Hoist Motor Brake A S2 Frame Hoist Brake Components for Figure 9 9 ASS N S NN Part Qty Number Description Req d 33297149 Complete Brake Assembly Includes Ref Nos 1 11 16 17 18 amp P N 33297153 33295550 Brake Friction Disc Fan 1 External Retaining Rings Fan Hub B External Retaining Ring Fan 1 Fan Hub S Key Fan Hub Key Fan External Retaining Ring Brake Hub Spacer Brake Hub Key Brake Hub Stainless Steel Brake Hub Hollow Core Bolts O Ring Bolts Brake Mounting Compression Springs 33295551 BRAKE FAN KIT 33297152 BRAKE HUB KIT 33297153 HARD 20 33295555 Fan Shroud 21 Bolts Fan Shroud SHROUD KIT 1 1 1 1 3 1 3 7 1 4 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 Control Module One Brake Hardware Kit One Set of Contactors One Transformer One Wire Rope Assembly Note When ordering parts always furnish Hoist Serial Number Catalog Number Motor Horsepower Voltage Phase Frequency and Rated Load of Hoist on which the parts are to be used Parts for your hoist are available from your local authorized YALE repair stat
37. earance 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 Page 19 5 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 6 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 thickness across 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 8 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 Mounting Bolt Torque 7 5 ft lbs 7 5 ft lbs 10 Nm 10 Nm Nominal Air Gap 0 012 in 0 016 in 0 3 mm 0 4 mm Maximum Air Gap 0 024 in 0 028 in 0 6 mm 0 7 mm Minimum Brake Disk 0 335 in 0 374 in Thickness 8 5 mm 9 5 mm Table 5 1 Motor Brake Data 7 To reset the air gap begin by releasi
38. eat against the end bell of the motor 2 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 3 Connect the brake leads 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 14 5 11 INSPECTION OF HOIST TRAVERSE DRIVE PINIDN SETSCREWS his Figure 5 9 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 keyed drive shaft supported by sealed ball bearings at each hoist side The pinions are held in place by means of locking setscrews The drive shaft is driven by a single geared trolley wheel which is in turn driven by a pinion mounted to a single reduction worm gear reducer b Ensure that the hoist is properly fitted to the beam The hoist must be centered on the beam with cl
39. ection of rope color Ropes will wear more quickly in areas that are more frequently in contact with the running sheaves and drum 1 Replace wire rope if the number of visible broken wires exceeds 13 over a length of 6 times the nominal diameter 6d or exceeds 26 wires over a length of 30d 2 Replace wire rope if a complete strand has broken 3 Replace wire rope if rope exhibits swelling bruises permanent bends kinks crushing bird caging or especially heavy wear 4 Replace wire rope if rope has suffered heat damage from any cause N Right Way Wrong Way Figure 5 4 Correct Method of Measuring Rope Figure 5 3 Rope Guide Assembly b Disassembly of A Frame Rope Guide Refer to Fig 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 ltems 6 and 7 Remove drum frame rod ltem 8 2 Remove shoulder bolts Item 3 and compression springs Item 4 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 Once shoulder bolts are removed the halves will separate and if not properly supported the halves could fall 3 Carefully unhook the rope tensioning spring Item 5 which is under tension AWARNING The rope tensioning spring is under considerable ten
40. ed unless specific precautions have been taken hh DO NOT allow sharp contact between two hoists or between hoist and obstructions ii DO NOT allow the rope or hook to be used as a ground for welding j DO NOT allow the rope or hook to be touched by a live welding electrode kk DO NOT remove or obscure the warnings on the hoist I DO NOT adjust or repair a hoist unless qualified to perform hoist maintenance mm DO NOT attempt to lengthen the wire rope or repair damaged wire rope nn DO NOT allow personnel not physically fit or properly qualified to operate hoist 00 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 II Paragraph 2 4 b pp DO NOT operate hoist unless limit switches are operating properly qq DO avoid operating hoist when hook is not centered under hoist Avoid side pulls and swinging of load or load hook when traveling hoist rr DO operate hoist within recommended duty cycle and DO NOT jog unnecessarily ss DO conduct regular visual inspections for signs of damage and wear tt DO NOT operate hoist with hooks that have opened up See Section V Paragraph 5 2 f uu DO provide supporting structure that has an appropriate design factor based on the load rating and dead weight of the hoist If in doubt of the supporting structure s strength consult a structural engineer A WARNING DO NOT o
41. erse Reducer 80 FPM N A Traverse Motor Specify HP Voltage Frequency No of Speeds Options N A Hex Head Cap Screw 3 8 N A Lock Washer 3 8 N A Gusset Bracket N A Gusset Shoe N A Gusset Stiffener N A Angle Bracket N A Hex Head Cap Screw Long M12 N A Hex Head Cap Screw Short M12 N A Traverse Stiffener Plate N A Hex Head Cap Screw M12 N A Hex Head Cap Screw 3 8 N A Plain Hex Nut 3 8 N A Locknut 3 8 ONNNN PS RONN 4 4 26 1 1 4 4 1 SS GO OO HH Notes Page 35 Figure 9 3 Motor Driven Trolley Frame and Drive A Frame S2 Reeved Trolley Frame and Drive Components for Figure 9 3 Part Qty Number Description Req d Geared Wheel Assembly Pair Incl Ref Nos 9 11 12 13 14 15 Plain Wheel Assembly Pair Incl Ref Nos 9 10 12 13 14 15 Trolley Frame Side Plate Drum 40 Lift Model Counterweight Plate 40 Lift Model Hoist Trolley Controls Specify HP Voltage Frequency No of Speeds Options Alignment Bar Alignment Bar 4 Thru 8 1 2 Trolley Beam Flange Width Alignment Bar 8 5 8 Thru 14 Trolley Beam Flange Width Hex Head Cap Screw M12 Lockwasher M12 Threaded Rod M12 Threaded Rod 4 Thru 8 1 2 Trolley Beam Flange Width Threaded Rod 8 5 8 Thru 14 Trolley Beam Flange Width Plain Hex Nut M12 Wheel Axle Plain Trolley Wheel Geared Trolley Wheel Ball Bearing Internal Retaining Ring continued on next page
42. ft Model Frame Side Plate 40 Lift Model Stiffener Bar Dead End Support Bar Hex Head Cap Screw M12 Long Flat Washer M12 Hex Head Cap Screw M12 Short Locknut M12 Dead End Support Weldment Hex Head Cap Screw M8 Locknut M8 Hex Head Cap Screw M8 Lock Washer M8 44944702 YALE Brand Label for Gearcase Not Shown ON N Notes Page 29 Frame 52 Reeved Hoist Components for Figure 9 1 Figure 9 1 Hoist Drum Drum Frame Gearcase Motor Rope Guide and Screw Type Limit Switch Part Qty Number Description 2 2 4 1 2 2 4 1 1 2 2 4 1 1 1 1 3 3 3 3 HP Hoist Motor 2 Speed with Brake and Fan See Figure 9 8 for Parts 208 Volt 3 Phase 60 Hertz 230 Volt 3 Phase 60 Hertz 460 Volt 3 Phase 60 Hertz 575 Volt 3 Phase 60 Hertz Hex Head Cap Screw M10 Flat Washer M10 Locknut M10 Not Shown Hoist Gearcase See Figure 9 2 for Parts Socket Head Cap Screw M10 Flat Washer M10 Locknut M10 Not Shown Geared Limit Switch Drum Shaft Insert for Geared Limit Switch Hex Head Cap Screw Long M10 Hex Head Cap Screw Short M10 Lock Washer M10 Limit Switch Bracket Heavy Duty External Retaining Ring Flanged Cartridge Ball Bearing Rope Drum 40 Lift Model Rope Clamp Socket Head Cap Screw M6 Lock Washer M6 continued on next page 33295501 33295502 33295503 33295504 N A N A N A 44943502 N A N A N A
43. 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 10 Test hoist per Section V Paragraph 5 14 to ensure proper lubrication Page 17 the gears are keyed and pressed onto their shafts with exception of the integral output shaft 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 b Inspection and Disassembly Gearcase See Figure 5 7 1 Lower hook block to the floor and relieve all load from ropes 2 Make sure power to hoist is off and locked out A WARNING 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 Drain the oil from the gear case per Section IV Paragraph 4 2 5 10 INSPECTION OF MOTOR BRAKE AND ACTUATING MECHANISM a 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 and rotates with the motor shaft When the magnet coi
44. 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 ACAUTION 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 Page 20 3 Depress DN 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 SECTION VI TROUBLESHOOTING 6 1 GENERAL This section contains possible causes and solutions to common hoist problems 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 than necessary and needs to be adjusted If hoist cannot lift load then the sw
45. he 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 SWITCHES LIMIT SWITCHES ARE SAFETY DEVICES AND SHOULD NOT BE USED AS NORMAL OPERATING CONTROL A WARNING 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 SWITCHES 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 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 positioning capability 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 For the hoist motion depress push button marked UP to raise load b For the hoist motion depress push button marked DN to lower load C For the trolley traverse motion With two speed control depress buttons
46. ing 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 WENT PLUG FILLER HOLE IL LEVEL PLUG ni DRAIN PLUG Figure 4 1 View of Hoist Showing Location of Name Plates and Oil Plugs 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 b Remove oil drain plug from bottom of gearcase and drain oil out Dispose of oil in accordance with local environmental codes A CAUTION 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 Page 7 y DO NOT lift a load if any binding prevents equal loading on all supporting ropes z DO NOT apply the load to the tip of the hook aa DO NOT operate unless load is centered under hoist bb DO NOT allow your attention to be diverted from operating the hoist cc DO NOT operate the hoist beyond limits of wire rope travel dd DO NOT use limit switches as routine operating stops unless recommended They are emergency devices only ee DO NOT use hoist to lift support or transport people ff DO NOT lift loads over people gg DO NOT leave a suspended load unattend
47. ion For the location of your nearest repair station write YaleeLift Tech 414 West Broadway Avenue P O Box 769 Muskegon MI 49443 0769 Phone 800 742 9269 Fax 800 742 9270 WARRANTY WARRANTY AND LIMITATION OF REMEDY AND LIABILITY B Upon Buyer s submission of a claim as provided above and its substantiation Seller shall at its option either i 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 Sellers 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 agreement must be commenced within one 1 year after the cause of action has accrued A Seller warrants that its products and parts when shipped and its work including installa
48. is orientated such that the clamp grooves capture and fully seat the rope in the drum grooves The clamps are designed for use specifically with the 6 4mm wire rope that was supplied with your A Frame hoist b With the rope lying in the bottom of the drum groove begin by tightening the rope clamp at the tail end of the rope Torque the A Frame clamps to 12 15 ft lbs 16 20 N m c Applying tension to the rope and keeping it properly seated in the drum groove install the remaining two clamps to the specified torque above 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 4 Reinstall rope guide over rope in rope drum grooves as shown in Figure 5 3a amp 5 3b and outlined in Section V Paragraph 5 5 Continue lubricating as rope is spooled onto the drum until about 24 0 remain unwound 5 With outer lower block covers removed thread the wire rope through the sheaves of the upper and lower block as shown in Figures 5 5a and 5 5b 6 Attach swaged rope end to the dead end anchor pin and fasten with the retainer rings provided with the hoist 7 Replace the lower block sheave covers Page 16 Inspect the gearcase output shaft and drum splines for 4 On the A Frame hoist the bolts supporting the wear gearcase are installed through tabs on the outside of the housing and do not pass through the ge
49. iscosity 193 235 SUS 284 347 SUS eege Viscosity Index event Pusting and PourPoint 20 F Prevent Rusting and Pour Point 20 F 29 C 10 F 12 C Provide Limited Amoco Oil Co Rykon Oil 46 American Industrial Oil e 68 Lubrication for Points Mobil e Oil Corp i i Not Considered Shell e Oil Co Rotella 10W Rotella e 10W 30 Normal Wear Points Sun Oil Co Sunvis 932 Sunvis 968 Rando Oil 46 Rando Oil 68 MPG NolGese Not CN O Multipurpose Grease 6 11 Worked 310 340 265 295 Penetration Dropping Point 360 F 182 C 360 F 182 C fear Points Provided Wear Points Provided ithium ithium with Fittings and Grid Amoco Oil e Co Amolith Grease 1 EP Amolith e Grease No 2 EP or Gear Type Flexible Mobil Oil Corp Mobilith amp AW 1 Mobilith AW 2 Couplings Shell e Oil Co i Sun Oil Co Prestige 741 EP Sunoco Multipurpose 2 EP Multifak EP 1 Multifak EP 2 No 7 or 7C No 8 or 8C GCOT 611 0091 Compounded Compounded Refer te YALE Hoist 2 5 efer to ois Gear Case Ol SO Viscosity Grade E Amoco 6 Oil Corp Worm Gear Oil Cylinder Oil 680 Department for Mobil SHC 634 Gearcase ONCE 0 SHG Sug Synthetic Extra Hecla Operating Mobil Oil Corp Synthetic Mobil 600W Super Temperatures above Shell 6 Oil Co Valvata 0 Valvata 0 v Meropa e 460 Meropa e 680 Page 9 the Inspection and Maintenan
50. itch setting is correct Refer to SECTION VII Paragraph 7 4 for information regarding the adjustment of the limit switch setting 5 14 TESTING HOIST a General Testing shall be performed in accordance with FEM Section IX Series Lifting Equipment namely Section 9 811 Specification for rope and chain hoists 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 b Check hoist as outlined in PRE OPERATION CHECKS SECTION II Paragraph 2 4 C 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 SECTION VI TROUBLESHOOTING Probable Cause Check switches circuit breakers or fuses and connections in power supply lines Check power collectors Check voltage required on motor data plate against power supply Shut off and lock out power supply remove 6 1 Hoist Will Not Operate No power to hoist Wrong voltage Loose or broken wire connections in hoist electrical electrical cover on hoist and check wiring connections Also chec
51. ity limit switch is provided as standard equipment on YALE Global King hoists This switch is integral to the wire rope dead end assembly and is factory preset to prevent over capacity lifts This device is preset at the time of hoist inspection to prevent the lifting of loads weighing 125 150 of rated capacity To test the function of the over capacity limit switch apply 125 of the rated capacity to load hook If hoist is capable of lifting the load then actual switch setting may be higher 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 missing items Wheels must always be changed in opposing pairs and drive wheels should be changed when the drive pinions are replaced NOTICE Ensure that the cross shaft is properly positioned and O locked into place by means of the setscrews Failure to do so may allow the drive shaft to contact the hoist gearcase d 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 cros
52. k connections in push button station and limit switches 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 Check transformer fuse If blown check for grounding and or shorts in the push button station Check the transformer coil for signs of overheating Replace transformer if burned out Verify the transformer secondary is the same voltage as the coils to which it is connected Replace motor Check input power supply Check hoist motor connections system Contactor assembly not functioning No control voltage Motor burned out 0 Reverse phasing on three Check phase protection device PPD if amber LED is steady interchange any two power supply line leads per Section Il Paragraph 2 4 b Page 21 phase hoists SECTION VI TROUBLESHOOTING Probable Cause Check PPD if green LED is steady interchange any two sets each winding of motor power leads Check wiring connections with appropriate wiring diagram Check for loose connections See that necessary jumper wires are properly installed on contactor 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 Check push button contacts and wires Reduce l
53. l 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 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 HOLLOW SPACER BOLTS AIR GAP MOTOR END BELL BRAKE MOUNTING BOLTS FAN SHROUD RETAINING RINGS SHROUD BOLT BRAKE DISC PLASTIC FAN RING MAGNET BODY Figure 5 8 Motor Brake b Eriction 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 locked out Hoist Motor 1 Lower hook block to the floor and relieve all load from ropes 2 Make sure power to hoist is off and locked out 3 Drain the oil from the gear case per Section IV Paragraph 4 2 4 Di
54. lease reference FEM Section IX Series Lifting Equipment or the Hoist Duty Classification page in this manual Environmental 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 factory s Field Service Department for advice regarding unusual environmental 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 environment of your hoist The hoist operator must be responsible for determining the operating conditions and severity of ser
55. ll 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 AWARNING the rabbet fit machined in the gear case Fasten the motor to the gear case Check to be certain main power switch is locked in open position OFF before removing fan shroud 10 Reconnect the conduit and power leads to the motor See Section VIII and refer to the specific wiring diagrams shipped with your hoist 9 3 Remove the four 4 bolts attaching the fan shroud to 11 Refill gear case with lubricant per Section IV the motor and remove the fan shroud See Figure 5 8 4 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 Paragraph 4 2 12 Test hoist to ensure proper operation per Section V Paragraph 5 14 6 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 7 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 s
56. ly 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 Paragraph 4 7 b Check each sheave to insure rope groove is smooth and free from burrs or other surface defects C Check each sheave for freedom of rotation replace bearings if defective d Make certain that the spring pin holding the hook nut to the hook is securely in position e If hook is equipped with a hook latch or rotational lock check to determine that they are in good operating condition f 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 d L ES GAGE BLOC Figure 5 2 Gage Block 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
57. marked lt lt or N S to activate the trolley traverse motion With one speed control depress buttons marked gt lt or N S to activate the trolley traverse motion d On two speed hoist or trolley motions partial depression of a button operates hoist or trolley at slow speed depressing button completely operates hoist or trolley at full speed NOTICE Excessive jogging will cause premature burning of contact tips motor overheating and premature brake wear Page 6 vv DO NOT use hoist in location that will not allow operator movement to be free of the load ww 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 xx DO observe recommended inspection and maintenance procedures yy DO use common sense and best judgment whenever operating a hoist zz DO NOT remove drop lugs Removal will create an unsafe operating condition 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 performed at regular intervals at least every six 6 months coinciding with spr
58. mbly 40 Lift Model 6 4mm Limit Switch Limit Switch Bracket Socket Head Cap Screw M5 Lockwasher M5 A Frame Block Operated Limit Switch Optional Equipment not shown 44944201C N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A 23397901 23397902 N A N A N A N A 33290505C Joo Figure 9 6 Wire Rope Dead End Assembly A Frame S2 Reeved Dead End for Figure 9 6 Part Qty Number Description i 1 1 2 2 1 1 4 2 2 2 2 4 4 1 1 1 2 2 1 A Frame S2 Reeved Rope and Dead end Assembly Excl Ref No 20 Dead End Yoke Yoke Pin Yoke Spacer External Retaining Ring Overload Beam Plate Overload Spring Retainer Detent Belleville Spring Washer Socket Head Cap Screw M6 Locknut M6 Spacer Dead End Pin Washer External Retaining Ring Overload Spring Base Socket Head Cap Screw M6 Hex Nut M6 Hex Head Cap Screw M6 Locknut M6 Wire Rope and Swaged End Assembly Rope Assembly 40 Lift Model 6 4mm Limit Switch Limit Switch Bracket Socket Head Cap Screw M5 Lockwasher M5 A Frame Block Operated Limit Switch Optional Equipment not shown 44944202C N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A 23397903 N A N A N A N A 33290505C 0 00
59. nd 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 hoist 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 5 5 INSPECTION OF ROPE GUIDE a 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 A WARNING Side pulling and excessive load swing will severely damage the rope and rope guide Failure of these components may result in injury Page 13 A WARNING Do not operate a hoist having unusual vibrations sounds or with anything visibly or otherwise 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 Refer to the Section IX Figure 9 4 Lower Block Assemb
60. ng 2 Connect hoist to power source 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 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 prevent 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 applicable sections of FEM Section IX Series Lifting Equipment 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 II Paragraph 2 4 b d DO make sure hoist limit switches functi
61. ng 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 ata 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 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 8 Replace the large O ring over the air gap and reassemble the fan shroud to the motor 9 Test hoist per Section V Paragraph 5 14 to ensure proper brake operation c Brake Disassembly 1 Lower hook block to the floor and relieve all load from ropes 2 Make sure power to the hoist is off and locked out 3 Remove the four 4 bolts attaching the fan shroud to the motor and remove the fan shroud See Figure 5 8 4 Remove the snap ring behind the plastic fan Carefully remove the fan and key from the motor shaft Remove the snap ring in front of where the fan was mounted 5 Disconnect the two wires from the terminal block on the magnetic body The block operated limit switch may now be tested by slowly and carefully raising the hook until the limit switch rod contacts the lower block If the hook
62. nspection part or unit is inspected Use note column to NOTES Interval the right if condition is not listed below 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 MONTHLY SEMI ANNUAL 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 Motor Motor Brake Mechanical Load Brake Overload Clutch Couplings Gears Shafts amp Bearings Upper Block Lower Block Hook amp Throat Opening Hoist Rope Rope Drum Rope Guide Guards Limit Switches Pushbutton Record Hook Throat Opening 0 CONTROL STATION OR PUSH BUTTON Wiring Motor Brake when so equipped Couplings Gears Shafts amp Bearings Frame Wheels Bumpers Guards Conductors Collectors Hoist Trolley TROLLEY RESISTORS Monorail Joints Monorail Main Conductors Main Collectors General Condition Load Attachment Chains Rope Slings amp Connections Change Gearcase Lub Grounding Faults RUNWAYS DATED REPORT REQUIRED OSHA
63. oading to rated load of hoist as shown on nameplate Check for loose connections See that necessary jumper wires are properly installed on contactor 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 Check push button contacts and wires See that power supply current is the same voltage listed on motor data plate Check hoist motor connections Check size of power supply lines Reduce loading to rated load as shown on nameplate Reduce frequency of lifts or amount of jogging Check current rating on motor data plate against power supply Check hoist and inspect for defective worn or damaged parts Disassemble hoist and inspect for defective worn or damaged parts Adjust brake per Section VII Paragraph 7 1 Reduce loading to rated load as shown on nameplate 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 Check collectors for free movement of spring arm weak spring or electrical connections Check all wiring for loose connections Reverse phasing on three phase hoists Hoist wired incorrectly Lower electrical circuit open Contactor assembly not functioning Down push button inoperative E
64. on properly e DO maintain firm footing when operating hoist f DO make sure that the load slings or other approved 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 i DO take up slack carefully check load balance lift a few inches and check load s holding action before continuing j DO avoid swinging of load or load hook k DO make sure that all persons stay clear of the suspended load I DO warn personnel of an approaching load m DO protect wire rope from weld splatter or other damaging contaminants n DO promptly report any malfunction unusual performance or damage of the hoist o DO inspect hoist regularly replace damaged or worn parts and keep appropriate records of maintenance p DO use the hoist manufacturer s recommended parts when repairing a hoist DO use hock 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 u DO NOT use damaged hoist or hoist that is not working properly v DO NOT use the hoist with twisted kinked damaged or worn wire rope w DO NOT lift a load unless wire rope is properly seated in its groove s X DO NOT use wire rope as a sling or wrap rope around the load A WARNING Damage to t
65. onnection 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 the wiring diagram furnished with the 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 To adjust the limit switch setting simply loosen the locking nut see Figure 7 3 and then either loosen or tighten the adjustment bolt into the overload base to achieve the desired setting Loosening the adjustment bolt will increase the load required to trip the limit switch plunger while tightening will reduce this setting Only very small adjustment is required Adjusting the limit switch setting to increase the capacity limit beyond 125 is not permitted 7 5 SHORTENING OF PUSHBUTTON CABLE A WARNING
66. perate hoist with the hoisting rope out of the drum grooves Such operation may result in damage to the rope guide and rope and could result in 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 conditions however slack or kinked rope excessive side pulls swinging or jerking of load or similar abuse may cause damage to the rope guide causing the rope to leave the grooves 4 3 LUBRICATION OF HOISTING CABLE Hoists are shipped from the factory without an exterior coating of grease on hoisting cable It is recommended 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 The rope guide is made of a molded self lubricated reinforced nylon material It is lubricated prior to installation at the factory and requires only periodic inspection 1 Periodically re grease with MPG Paragraph 4 7 by applying grease to the leading edge of the guide and rope drum
67. red 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 MANUAL IS FOR INFORMATIONAL PURPOSES ONLY AND YALE LIFT TECH DOES NOT WARRANT OR OTHERWISE GUARANTEE IMPLIEDLY OR EXPRESSLY ANYTHING OTHER THAN THE COMPONENTS THAT YALE LIFT TECH MANUFACTURES AND ASSUMES NO LEGAL RESPONSIBILITY INCLUDING BUT NOT LIMITED TO CONSEQUENTIAL DAMAGES FOR INFORMATION CONTAINED IN THIS MANUAL This manual contains important information to help you install operate maintain and service your new YALE electric hoist We recommend that you study its contents thoroughly before putting the hoist into use We also recommend that you read Section IX Series Lifting Equipment of the European Federation of Materials Handling and Storage Equipment FEM and the applicable performance and safety standards referenced therein Then through proper installation application of correct operating procedures and by practicing the recommended maintenance procedures you can expect maximum lifting service from the hoist It will likely be a long time before parts information found in the Parts List is needed Therefore after the hoist is installed and you have completely familiarized yourself with operation and preventative maintenance procedures we suggest that this book be carefully filed for f
68. rial number at the factory SECTION V INSPECTION AND PREVENTIVE 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 intervals outlined in this section are considered a minimum Recommended in the schedule are minimum inspection and maintenance intervals based on average daily use in a normal environment Your YALE Global King hoist was designed to meet a specific duty classification as described by the FEM Rules for the Design of Serial Lifting Equipment and is to be used in accordance with the duty rating identified on the equipment nameplate For more details regarding hoist duty cycles and average daily use p
69. s C 0B g e e iri 01 BM o H 06 B HSOL E ue LL i ll be me 0 HFOL OLC MC QH OLC D BCM HI2 3 00 HII 3 OE 92 Q OH 1 B HB 9 HB2 TO HOIST 1A U D MC D C BRAKE 0 B BM SOLENOID SA E pr MC 40 CLI CL2 CL3 41 40D 41A 42 D F 19 B 06 L m DNE 7 40 8 40A L R LA 1 L 408 B CSO 400 CSOL CFOL ij SE ct i 400 CFOL L 4 8 Z E z E L E 41A R L 42 B FC 92 D 002 406 92 92 0011001 CO3 3 H91 B PPD BCM MC HCFU PPO 92 B HCPT OLC U D F R L FC BON MeL L PE C01 C02 CO3 408 C011 C012 0013 40C CB B R L EE ae ttt petty HB2 80 NS 3 ee M CTI 02 3 40C CU CTI2 13 400 1B 1B ro c2 2 mim e o s 10 aa Koz SIM 82 DANGER SYMBOL DESIGNATIONS PPD PHASE REVERSAL LOSS PROTECTION PD PHASE REV LOSS PROTECTION DEVICE CFU TROLLEY MOTOR CIRCUIT FUSING iE SHOWS A a 1s LED WHEN IN HFU HOIST MOTOR CIRCUIT FUSING R TROLLEY RIGHT CONTACTOR BHASE REVERSAL CONDITIO PFU TRANSFORMER PRIMARY FUSING L TROLLEY LEFT CONTACTOR CORRECT IMPROPER PHASING BY INTER HCPT CONTROL CIRCUIT TRANSFORMER FC TROLLEY FAST CONTACTOR CHANGING INPUT POWER LEADS LT AND 2 HCFU CONTROL CIRCUIT FUSING CSOL TROLLEY SLOW SPEED THERMAL OVERLDAD RELAY DO NOT CHANGE PUSHBUTION OR MOTOR U HOIST UP CONTACTOR CFOL TROLLEY FAST SPEED THERMAL OVERLOAD RELAY CIRCUIT WIRING HOIST
70. s shaft bearings and the pinion aligns the gear mesh Setscrews hold the pinions and spacer washers tight against the bearings Verify that the setscrews are tight on the cross shaft If it is necessary to adjust or reset the pinions verify that the cross shaft surface is free of mechanical damage and oil before tightening the setscrews Drive pinions must be replaced as sets and should be replaced along with the drive wheels The cross shaft bearings are sealed for life and should be replaced at any sign of mechanical wear or lubricant leakage e Inspect the traverse gearbox and motor Look for signs of rough operation mechanical damage or lubricant leaks Inspect the reducer and driving pinion for wear Verify that all hardware that mounts the reducer to the trolley frame and the motor to the gear reducer 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 your local authorized YALE repair center 5 12 TESTING BLOCK OPERATED LIMIT SWITCH a General The optional block operated limit switch is a secondary upper limit switch actuated when the lower block contacts the actuator rod The rotary geared limit switch screw type limit switch is the primary upper limit switch and must be temporarily bypassed to allow the block operated limit switch to be tested b Procedure Remove load from the hook To disconnect the
71. sconnect the wiring and conduit from the motor junction box 5 Provide a means to support the hoist motor The A Frame S4 hoist motor weighs approximately 70 Ibs and the S2 hoist motor weighs approximately 50 Ibs The motor must be adequately supported and held horizontally while removing and installing to avoid input seal damage 6 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 7 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 8 Before reinstalling 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 NOTICE Failure to use a factory replacement seal will cause premature seal failure due to specific lip material requirements that must be met 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 installing the motor or seal damage wi
72. sion use caution when unhooking to avoid injury Page 14 Figure 5 53 Reeving Diagram 4 Part Single Reeved Note Arrow on Drum Indicates Direction of Drum when Lowering DEAD EN LOWER BLOCK Figure 5 5b Reeving Diagram 2 Part Single Reeved c Removing old rope Please refer to Section IX to assist in locating components referred to in the following paragraphs 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 ACAUTION Be certain all personnel are clear of hoist as components hardware and wire rope are removed from hoist 2 Remove the cap screws and hex nuts that retain the lower block sheave covers Remove covers 3 Remove retaining rings from lower block sheave pin 4 Slide out lower block sheave s and remove wire rope 5 Remove two 2 rope retention bolts and nuts from the upper block yoke as needed Page 15 5 Rope corrosion and or rust formation internal or external 6 Effects from improper lubrication 7 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 FEM Section IX Series Lifting Eq
73. tch Adjustment 7 4 Over Capacity Limit Switch Adjustment 7 5 Shortening of Push Button Station SECTION I Paragraph Paragraph Paragraph SECTION II Paragraph Paragraph Paragraph Paragraph SECTION III Paragraph Paragraph Paragraph SECTION IV Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph SECTION V Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph Paragraph SECTION VI SECTION VII Paragraph Paragraph Paragraph Paragraph Paragraph SECTION VIII WIRING DIAGRAMS PARTS LIST 9 1 General 9 2 List of Parts Illustrations SECTION IX Paragraph Paragraph 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 Page2 Class of Operating Time Class of Operating Time indicates the average period per day during which the mechanism is in operation which is anytime the equipment is in motion The Class of Operating Time is determined by calculation of the average daily operating time average daily use Where t Average Daily Operating Time hr day H Average Hoist Height ft N Number of Cycles Per Hour cycles hr T Daily Working Time hr day V Hoisting Speed ft min 2xHxNxT V x 60 t Load Spectrum Load Spectrum indicates the extent of which the mechanism is subjected to
74. thereof when providing electrical service to the hoist Make electrical connections using the appropriate wiring diagrams furnished with the hoist Only qualified journeyman electricians shall make any electrical connections including connections to collectors or power cord A WARNING 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 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 OPERATIONAL CHECKS a Check Oil Level Figure 2 1 The gearcase has been filled with oil to the proper level However this should be rechecked 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 b 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 A WARNING If any push button binds or sticks in any position DO NOT TURN POWER ON determine the cause and correct the malfunction before operati
75. tion 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 one 1 year 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 one 1 year from completion of the applicable work by Seller provided however all claims for defective products and parts made in writing no later than eighteen 18 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 Yale HOISTS
76. uipment namely Section 9 661 Dimensions and Design of Rope Reeving Components and ISO 4309 Wire Ropes Care Maintenance Installation Examination and Discard for illustrations and definitions when following the above guidelines for rope inspection b Maintenance Keep rope well lubricated to help reduce internal friction and prevent corrosion Lubricant as described in Paragraph 4 3 should be applied as a part of the regular maintenance program Special attention is required to lubricate sections of rope over equalizing sheaves and other hidden areas Avoid dragging ropes in dirt or around sharp objects 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 General Place reel on stand with shaft through the center of reel so rope can be pulled straight out with reel rotating m A W
77. ure 9 1 Hoist Drum Drum Frame Gearcase Motor Rope Guide and Screw Type Limit Switch A Frame S4 Reeved Hoist Components for Figure 9 1 5 HP Hoist Motor 2 Speed with Brake and Fan See Figure 9 8 for Parts 208 Volt 3 Phase 60 Hertz 230 Volt 3 Phase 60 Hertz 460 Volt 3 Phase 60 Hertz 575 Volt 3 Phase 60 Hertz Hex Head Cap Screw M10 Flat Washer M10 Locknut M10 Not Shown Hoist Gearcase See Figure 9 2 for Parts Socket Head Cap Screw M10 Flat Washer M10 Locknut M10 Not Shown Geared Limit Switch Drum Shaft Insert for Geared Limit Switch Hex Head Cap Screw Long M10 Hex Head Cap Screw Short M10 Lock Washer M10 Limit Switch Bracket Heavy Duty External Retaining Ring Flanged Cartridge Ball Bearing Rope Drum Rope Drum 20 Lift Model Rope Drum 40 Lift Model Rope Clamp continued on next page 33295001 33295002 33295003 33295004 N A N A N A 44943501 N A N A N A 43981305 11593901 N A N A N A N A N A N A 44943901 44943902 23397701 Page 28 A Frame 54 Reeved Hoist Components for Figure 9 1 continued Part Qty Number Description N A Socket Head Cap Screw M6 N A Lock Washer M6 44943801C Rope Guide See Figure 9 7 for Parts Frame Rod 23385903 Frame Rod 20 Lift Model 23385904 Frame Rod 40 Lift Model Socket Head Cap Screw M10 Hi Collar Lock Washer M10 Drum Frame Bracket Trolley Frame Side Plate Drum Frame Side Plate 20 Li
78. uture reference When ordering replacement parts from this book it will be necessary that you include with your order the Hoist Serial Number and Model NOTICE Information contained in this book is subject to change without notice Inspection of Motor Brake amp Actuating Mechanism GENERAL DESCRIPTION 1 1 General 1 2 Basic Construction 1 3 Selection amp Application Guide INSTALLATION 2 1 General 2 2 Installing Hoist 2 3 Connecting Hoist to Electrical Service 2 4 Pre Operational Checks OPERATION 3 1 General 3 2 Push Button Operation 3 3 Operating Precautions LUBRICATION 4 1 General 4 2 Changing Gear Case Oil 4 3 Lubrication of Hoist Cable 4 4 Lubrication of Limit Switch 4 5 Lubrication of Geared Trolley Wheels and Pinions 4 6 Lubrication of Rope Guide 4 7 Lubricant Specifications INSPECTION AND PREVENTIVE MAINTENANCE 5 1 Genera 5 2 Inspection Lower Block 5 3 Inspection Upper Block 5 4 Inspection Electrical Controls 5 5 Inspection of Rope Guide 5 6 Rope Inspection Maintenance amp Replacement 5 7 Rope Reeving 5 8 Inspection of Rope Drum amp Shaft 5 9 Inspection of Hoist Gearing 5 10 5 11 5 12 Inspection of Traverse Drive Testing Block Operated Limit Switch 5 13 Testing Over Capacity Limit Switch 5 14 Testing Hoist TROUBLESHOOTING CHART ADJUSTMENTS 7 1 Motor Brake Adjustment 7 2 Block Operated Limit Switch Adjustment 7 3 Geared Rotary Limit Swi
79. vice Inspection Schedule and Maintenance Report Form Shown on page 12 of this manual is a recommended Inspection Schedule and Maintenance Report form that lists various components of the hoist The form also includes trolley components runway components 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 Page 10 helpful in establishing and scheduling preventative maintenance as well as an aid in troubleshooting the equipment For additional information refer to the Pulse monitor manual P N 11817503 sent with this manual Data may be downloaded from the monitor via the serial communications link by a certified technician Pulse monitor data may be used to determine equipment usage and to verify that the application does not exceed the hoist duty rating as identified on the equipment nameplate The data can also be RECOMMENDED INSPECTION AND MAINTENANCE SCHEDULE INSPECTION OR MAINTENANCE Check operation of all functional mechanisms including limit 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 TIME INTERVAL Daily or start of each shift
80. xcessive load Hoist electrical circuit open Contactor assembly not functioning Up down button inoperative Low voltage Excessive load Excessive duty cycle Wrong voltage or frequency Defective motor or worn bearings in hoist frame Brake not adjusted properly Excessive load Motor brake not holding Collectors make poor contact Loose connections Hook Moves in Wrong Direction Hook Will Raise But Not Lower Hook Will Lower But Not Raise Hoist Will Not Lift Rated Load Hoist Motor Overheats Load Drifts Excessively When Hoist Is Stopped Hoist Operates Intermittently 6 2 6 3 6 4 6 5 6 6 6 7 6 8 Page 22 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 lbs e Replace cover f Carefully check limit switch operation without load before placing 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 AWARNING Check limit switch operation carefully without load before placing hoist in service If mis

Global King Wire Rope Hoist - 1 to 3 Ton

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