Yale Global King wire rope hoist Manual

OPERATION, SERVICE & PARTS MANUAL
Before installing hoist, fill in the
information below. Refer to the Hoist
and Motor data plates.
Model No.
__________________
Serial No.
__________________
Purchase Date __________________
GLOBAL KING
WIRE ROPE HOISTS
TM
RATED THRU 10 METRIC TONNE
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 recommendations in this manual. Retain this
manual for future reference and use.
Forward this manual to operator.
Failure to operate equipment as
directed in manual may cause
injury.
®
® LIFT-TECH INTERNATIONAL, Division of
COLUMBUS McKINNON CORPORATION
MUSKEGON, MI 49443-0769
PRINTED IN U.S.A.
JANUARY, 2002
COPYRIGHT 2001, LIFT-TECH INTERNATIONAL, INC.
PARTNO. 11353395D
FORWARD
This book contains important information to help you install, operate, maintain and service your
new Yale electric hoist. We recommend that you study its contents thoroughly before putting the
hoist into use. Read HST 4M performance standard and ANSI B30.16 safety standard for hoists.
Then, through proper installation, application of correct operating procedures, and by practicing
the recommended maintenance suggestions you can expect maximum lifting service from the
hoist.
It will likely be a long time before parts information found in Section IX is needed. Therefore, after
the hoist is installed and you have completely familiarized yourself with operation and
preventative maintenance procedures, we suggest that this book be carefully filed for future
reference.
When ordering replacement parts from this book, it will be necessary that you include with your
order: the Hoist Serial Number and Model Number that are found on the nameplate attached to
the motor end of hoist (Figure 4-1). For your convenience, a space has been provided on the
front cover of this Manual for entering this information. We recommend that you fill it out
immediately so it is readily at hand when needed.
The contents of this manual are of necessity, general in nature and may cover features not
incorporated on your hoist; or, you may have ordered features not covered by this manual.
Therefore, the user must exercise care in applying instructions given in this manual. If specific
information not in this manual is required, contact the factory.
THE INFORMATION CONTAINED IN THIS BOOK IS FOR INFORMATIONAL PURPOSES
ONLY AND LIFT-TECH DOES NOT WARRANT OR OTHERWISE GUARANTEE (IMPLIEDLY
OR EXPRESSLY) ANYTHING OTHER THAN THE COMPONENTS THAT LIFT-TECH
MANUFACTURERS AND ASSUMES NO LEGAL RESPONSIBILITY (INCLUDING, BUT NOT
LIMITED TO, CONSEQUENTIAL DAMAGES) FOR INFORMATION CONTAINED IN THIS
MANUAL.
No part of this document may be reproduced in any form, in an electronic retrieval system or
otherwise, without prior written permission of the publisher.
NOTICE: Information contained in this book is subject to change without notice.
2
NOTICE: Information contained in this book is subject to change without notice.
INDEX
SECTION I GENERAL DESCRIPTION
PAGE
Paragraph 1-1 General ………………………………………………………………………………………………. 4
Paragraph 1-2 Basic Construction …………………………………………………………………………………. 4
SECTION II INSTALLATION
Paragraph 2-1 General ……………………………………………………………………………………………….
Paragraph 2-2 Suspending Hoist ……………………………………………………………………………………
Paragraph 2-3 Connecting Hoist to Electrical Service ……………………………………………………………
Paragraph 2-4 Pre-Operation Checks ………………………………………………………………………………
.
SECTION III OPERATION
Paragraph 3-1 General ……………………………………………………………………………………………….
Paragraph 3-2 Push Button Operation ……………………………………………………….…………………….
Paragraph 3-3 Operating Precautions ………………………………………………………………………………
4
4
5
5
6
6
7
SECTION IV LUBRICATION
Paragraph 4-1 General ……………………………………………………………………………………………… 8
Paragraph 4-2 Changing Gearcase Oil …………………………………………………………………………… 8
Paragraph 4-3 Lubrication of Hoist Cable
……………………………………………………………………… 9
Paragraph 4-4 Lubrication of Geared Limit Switch ……………………………………………………………… 9
Paragraph 4-5 Lubrication of Geared Trolley Wheel ……………………………………………………………. 9
Paragraph 4-6 Lubrication of Rope Guide
……………………………………………………………………… 9
Paragraph 4-7 Lubricant Specifications …………………………………………………………………………… 10
SECTION V INSPECTION AND PREVENTATIVE MAINTENANCE
Paragraph 5-1 General ………………………………………………………………………………………………
Paragraph 5-2 Inspection of Lower Block …………………………………………………………………………
Paragraph 5-3 Inspection of Upper Block ………………………………………………………………………….
Paragraph 5-4 Inspection of Electrical Controls …………………………………………………………………
Paragraph 5-5 Inspection of Rope Guide ………………………………………………………………………….
Paragraph 5-6 Rope Inspection, Replacement & Maintenance …………………………………………………
Paragraph 5-7 Rope Reeving ……………………………………………………………………………………….
Paragraph 5-8 Inspection of Rope Drum & Shaft …………………………………………………………………
Paragraph 5-9 Inspection of Hoist Gearing ………………………………………………………………………
Paragraph 5-10 Inspection of Motor Brake and Actuating Mechanism …………………………………………
Paragraph 5-11 Inspection of Traverse Drive ……………………………………………………………………..
Paragraph 5-12 Inspection of Block Operated Limit Switch ……………………………………………………..
Paragraph 5-13 Testing Hoist ………………………………………………………………………………………
11
14
14
14
15
15
16
18
18
20
22
22
23
SECTION VI TROUBLESHOOTING CHART …………………………………………………………………………. 24
SECTION VII ADJUSTMENTS
Paragraph 7-1 Motor Brake Adjustment ……………………………………………………………………………
Paragraph 7-2 Block Operated Limit Switch Adjustment …………………………………………………………
Paragraph 7-3 Geared Rotary Limit Switch Adjustment …………………………………………………………
Paragraph 7-4 Shortening of Push Button Cable …………………………………………………………………
25
25
25
26
SECTION VIII WIRING DIAGRAMS ……………………………………………………………………………………. 26
SECTION IX PARTS LIST
Paragraph 9-1 General ……………………………………………………………………………………………… 29
Paragraph 9-2 List of Parts Illustrations. …………………………………………………………………………. 29
No part of this document may be reproduced in any form, in an electronic retrieval system or otherwise, without
prior written permission of the publisher.
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 drum and
upper block (or dead-end anchor depending on the
reeving type) on opposite sides of the beam
suspending the trolley. There are two basic frame
sizes each with two standard lifts: the “B” Frame
handles capacities up to 5 tonne; and the “C” Frame
handles capacities up to 10 tonne. The “B” Frame
has an integral trolley with two different flange width
ranges available: 4-5/8” through 14” or 14-1/8”
through 20” wide with a maximum flange thickness
of 1-3/4”. The “C” Frame integral trolley has a flange
range of 4 5/8” through 20” with a maximum flange
thickness of 2”. The hoist motor is 2-speed with a 6:1
ratio between high and low speeds as standard. The
Motor Driven trolley has two available speeds with 1speed, 2-speed, or Variable Frequency control.
2-1. GENERAL. Yale “Global King” electric hoists
are lubricated and tested before being shipped from
the factory. To place a hoist in service, adjust
appropriately for the beam flange width (Paragraph
2-2), connect to electrical service (Paragraph 2-3)
and perform pre-operation tests and checks
(Paragraph 2-4).
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.
2-2. SUSPENDING HOIST.
Throughout this manual you will see references to
the “B” or “C” frame hoists. If you are unsure about
which frame size you have, see Section IV,
Paragraph 4-2 for a simple gearcase measurement
to easily determine the size of your hoist.
1-2. BASIC CONSTRUCTION. Yale “Global King”
hoists consist of a rugged steel frame which houses
a lifting drum and serves as the suspension for
carrying the entire hoist load. An aluminum
gearcase, attached to one end of the drum frame,
houses a triple-reduction gear train. The first two
reductions are helical with the third being spur.
Attached to the gearcase is a 2-speed hoisting
motor with a 6:1 ratio between the high and low
speeds. A 200% torque DC motor brake is attached
to the motor. A single NEMA 4/12 control enclosure
contains both the hoist and trolley electrical system
controls. Hoisting cable and a covered lower block
assembly are used for lifting loads. A rotary geared
limit switch is used to limit travel both up and down.
A secondary block operated limit switch is used to
limit the travel of the lower block when raising. A
push button control station (purchased separately)
for operating the hoist is suspended on a wire strain
cable attached to the hoist.
SECTION II – INSTALLATION
WARNING
Only
qualified
personnel
properly
supervised shall mount the hoist and
trolley on the monorail and perform final
pre-operation inspection.
4
FIGURE 2-1. Trolley Wheel Spacing.
a) OPEN-END BEAM: If the trolley can be
installed directly from the end of the
supporting beam, adjust the spacing
between the trolley wheel flanges to be
3/16”-1/4” greater than the exact width of the
beam flange (See Figure 2-1). Before
adjusting the width of the trolley frame be
sure to loosen the clamp collar nearest the
traverse drive on the hex traverse drive
shaft. Also, the electrical conduit/cable must
not be constrained when attempting to
adjust the trolley sides in or out.
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.
The trolley width shall be adjusted by
loosening the jam nuts on the traverse drive
side of the threaded rods at each end of the
hoist. If necessary, lubricate the frame
alignment bars with penetrating oil before
attempting to adjust trolley width. The trolley
side may then be pushed or driven into
position by turning the adjusting nuts on the
treaded rods. Adjust nuts on each side of
the hoist simultaneously to avoid binding.
After adjusting the trolley to the proper
width, tighten all adjusting nuts and the
clamp collar, and re-secure the electrical
conduit/cable. Verify that the geared wheels
mesh properly with the traverse drive
pinions. Using proper equipment, carefully
lift the trolley and hoist and install on the end
of the beam. Lubricate the wheel gear and
pinion (WG, Section IV, Paragraph 4-3).
b) CLOSED-END BEAM: For trolleys which
are to be 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 axles and the beam flange.
Using proper lifting equipment, the trolley
and hoist must then be lifted to the beam
where it is to be installed. Once in position,
adjust the spacing between the trolley wheel
flanges to be 3/16”-1/4”” greater than the
exact width of the beam flange (See Figure
2-1). After tightening all adjusting bolts, the
clamp collar, and all electrical conduit/cable
clamps, carefully set the trolley on the beam.
Lubricate the wheel gear and pinion (WG,
Section IV, Paragraph 4-3).
2-3. CONNECTING HOIST TO ELECTRICAL
SERVICE. Electrical service to the hoist may be
power cable or a guarded system having sliding
shoe or wheel type collectors.
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. If the
grounding method used is through the
trolley wheels, then each section of track
must be grounded by metal-to-metal
connection to the building ground.
Certain environments may prevent
proper grounding by this means. In this
case a separate grounding conductor
should be provided.
a) Follow ANSI/NFPA 70, state, and local
electrical codes including the grounding
provisions thereof when providing electrical
service to the hoist.
b) Make electrical connections using the
appropriate wiring diagrams furnished with
the hoist. All electrical connections, including
connections to collectors or power cord shall
be made only by qualified journeyman
electricians.
CAUTION
Power supply to hoist and trolley must
be the same voltage, frequency, and
phase that are specified on the hoist and
trolley nameplate.
2-4. PRE-OPERATION CHECKS.
a) Check Oil Level. (Figure 2-1) The gearcase
has been filled with oil to the proper level.
However this should be re-checked before
operating the hoist.
Check oil level by removing the plug
indicated in Figure 2-1. When properly filled,
oil should be level with the bottom of the
tapped hole. Fill to this level with oil as
specified in Paragraph 4-2.e.
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.
WARNING
If any push button binds or sticks in any
position – DO NOT TURN POWER ON –
determine the cause and correct the
malfunction before operating.
(2) Connect hoist to power source.
WARNING
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.
5
(3) Operate “UP” button briefly to determine
direction of hook travel.
(2) A geared rotary type upper and lower limit
switch is also provided as standard. This
switch is adjustable and although roughly
preset by the factory, it should be adjusted
at time of installation to the desired high
and low limits of lower block travel. Refer
to SECTION VII, Paragraph 7-3.
(4) If hook raises when “UP” button is
depressed, phasing is correct.
(5) If hook lowers when “UP” button is
depressed, hoist is “Reverse Phased.”
TURN AND LOCK POWER OFF and
check the pushbutton wiring. If the
pushbutton was wired properly, correct the
problem by interchanging any two leads at
power source connection. Do not change
internal wiring of hoist.
c) Check Limit Switch Operation.
(1) A block operated upper limit stop is
furnished as standard equipment on all
Yale “Global King” hoists. This limit stop is
factory set to stop the lower block at the
safest high position, guarding against over
travel and possible damage to hoist. No
adjustment can be made. However, the
hoist should be tested by jogging the lower
block against the limit weight to be sure
the limit switch is functioning properly.
When lower block lifts the limit weight, the
hoist will automatically stop. If lower block
coasts through the limit switch when lifting
a reversing switch will automatically close
and reverse direction of motion to
lowering.
WARNING
Damage to the hoist, a dropped load, and
injury may result if limit switches fail due
to improper use.
TO AVOID INJURY:
UNDER NORMAL OPERATING CONDITIONS,
STOP HOIST TRAVEL BEFORE ENGAGING
LIMIT SWITCHES. LIMIT SWITCHES ARE
SAFETY DEVICES AND SHOULD NOT BE
USED AS NORMAL OPERATING CONTROL.
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.
6
d) Check Lower Block and Hoisting Cable.
Depress “DOWN” push button and run lower
block to its lowest position. No less than two
wraps shall remain on the drum with the
loaded hook in its lowest position. Also
check to see that the lower block and rope
do not twist excessively. If it does twist to
the extent that two ropes rub against each
other, disengage the swaged rope end from
the frame anchor and twist the rope four or
five turns in a direction opposite to that
which the block turns. Reconnect rope to the
frame anchor, holding firmly to eliminate
rope twisting back to its original position.
Operate hoist up and down a few times. If
lower block still rotates excessively repeat
process until twisting is corrected.
e) Lubricate Hoisting Cable. For longer cable
life, it is recommended that the cable be
lubricated at time of installation by applying
a heavy coating of lubricant CL (Paragraph
4-7) as outlined in SECTION IV, Paragraph
4-3.
f)
When first using the hoist and trolley,
operate with lighter loads through full travel
before applying maximum load.
SECTION III – OPERATION
3-1. GENERAL. Operation of Yale “Global King”
hoists is controlled by a convenient pendant push
button station. With it, the hoist can be controlled to
give fast lifting and lowering; or controlled to lift or
lower the load in small increments, providing
accurate spotting. The push button station has a
built-in interlock to prevent depressing opposing
buttons simultaneously.
When first using the hoist, break in by operating
under lighter loads to full travel before applying
maximum load.
3-2. PUSH BUTTON OPERATION.
a) Depress push button marked “UP” to raise
load.
b) Depress push button marked “DOWN” to
lower load.
c) Depress push button marked “RIGHT” to
traverse one direction.
d) Depress push button marked “LEFT” to
traverse in the opposite direction.
CAUTION
Excessive
“jogging”
will
cause
premature burning of contact tips, motor
overheating, and premature brake wear.
e) On two-speed hoist or trolley motions, partial
depression of a button operates hoist or
trolley at slow speed; depressing button
completely operates hoist or trolley at full
speed.
3-3. OPERATING PRECAUTIONS. Safe operation
of an overhead hoist is the operator’s responsibility.
Listed below are some basic rules that can make an
operator aware of dangerous practices to avoid and
precautions to take for his own safety and the safety
of others. Observance of these rules in addition to
frequent examinations and periodic inspection of the
equipment may save injury to personnel and
damage to equipment.
WARNING
Equipment covered herein is not
designed or suitable as a power source
for lifting or lowering persons.
a)
DO read ASME B30.16 Safety Standard for
Overhead Hoists and the Operation, Service
and Parts Manual.
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.
l)
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.
q)
DO use hook latches.
r)
DO apply lubricant to the wire rope as
recommended.
s)
DO NOT lift more than rated load.
t)
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.
b)
DO be familiar with hoist operating controls,
procedures, and warnings.
v)
DO NOT use the hoist with twisted, kinked,
damaged, or worn wire rope.
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.
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.
DO make sure hoist limit switches function
properly.
y)
DO NOT lift a load if any binding prevents
equal loading on all supporting ropes.
DO maintain firm footing when operating
hoist.
z)
DO NOT apply the load to the tip of the
hook.
aa)
DO NOT operate unless load is centered
under hoist.
d)
e)
f)
DO make sure that the load slings or other
approved single attachments are properly
sized and seated in the hook saddle.
g)
DO make sure that the hook latch is closed
and not supporting the load.
bb)
DO NOT allow your attention to be diverted
from operating the hoist.
h)
DO make sure that load is free to move and
will clear all obstructions.
cc)
DO NOT operate the hoist beyond limits of
wire rope travel.
7
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 unattended 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.
jj)
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.
ll)
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)
Personnel not physically fit or properly
qualified, shall not operate hoist.
oo)
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 switch is
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)
8
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.
WARNING
DO NOT operate hoist with the hoisting
rope out of the drum grooves. Such
operation may result in damage to the
rope and/or the rope breaking. This may
result in dropping the load that can
cause damage to equipment and injury to
operator or other personnel. Hoist rope
will remain in the drum grooves during
operation under normal operating conditions, however, slack or kinked rope,
excessive side pulls, swinging or jerking
of load, or similar abuse, may cause the
rope to leave the grooves.
vv)
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.
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 spring and fall seasons is
recommended. The reason for this is that on hoists
installed outside or in unheated areas a “cold test” oil
is required in such (below freezing) climates making
seasonal changes necessary.
4-2. CHANGING GEARCASE OIL.
a)
Add 5% solution of Mobilsol A (or
equivalent) to the oil and run for a short
time. This will clean components and hold
particles in suspension for draining.
e)
FIGURE 4-1. View of Hoist Showing Location of
Name Plates and Oil Plugs.
b)
Remove oil drain plug from bottom of
gearcase and drain oil out. Dispose of oil in
accordance with local environmental codes.
WARNING
Avoid skin contact with Mobilsol A. In
case of skin contact: dry wipe the skin,
cleanse the area with a waterless hand
cleaner
and
follow
by
washing
thoroughly with soap and water.
c)
Reinstall drain plug.
d)
Remove oil level plug from front of gearcase
cover.
Refill through filler hole to proper level
(bottom of oil level plug hole) using GCOH
(Paragraph 4-7). The amount of oil required
depends on overall size of gearcase; two
sizes are used for “Global King” hoists. To
determine size and amount of oil to add,
measure width of hoist gearcase (see Figure
4-2). The “B” Frame measures 11-3/4” and
requires approximately 6 quarts of oil. The
“C” Frame’s width is 14-1/2” and requires
approximately12 quarts of oil.
4-3. LUBRICATION OF HOISTING CABLE. Hoists
are shipped from the factory without an exterior
coating of grease on hoisting cable. It is
recommended, where conditions permit, that the
cable be thoroughly coated at installation and kept
well lubricated with CL (Paragraph 4-7).
4-4. LUBRICATION OF LIMIT SWITCH. Provide a
light film of grease MPG (Paragraph 4-7) on bevel
gear of rotary geared limit switch.
4-5. LUBRICATION OF GEARED TROLLEY
WHEELS AND PINIONS. At installation and
periodically apply grease WG (Paragraph 4-7) to the
traverse drive pinions and the gears of the trolley
wheels.
4-6. LUBRICATION OF ROPE GUIDE
a) Maintenance. Once properly installed the
following actions are required:
(1) Periodically
re-grease
with
MPG
(Paragraph 4-7) using the grease fitting
provided (Figure 5-3, Item 6).
FIGURE 4-2. Gearcase Width Illustration.
(2) Every 6 months the rope guide should be
removed per Section V, Paragraph 5-5,
cleaned and inspected. When the rope
guide is reassembled, the rope guide
should be thoroughly greased with MPG
(Paragraph 4-7) and the hoist run up and
down to lubricate both the drum and the
wire rope.
NOTES
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9
4-7. LUBRICANT SPECIFICATIONS.
GCOH
Gear Case Oil.
Hoist Gear Case.
SG
Spline Grease
NLGI Grease
ASTM D217 Worked
Penetration
Dropping Point
Base
Mobil  Oil Corp.
No. 6
1335 - 1632 SUS
154
-40°F
Mobil  SHC 632
Omala RL 320
Pinnacle 320
No. 7 EP
1919 - 2346 SUS
95
20°F
Mobilgear  634
Omala  460
Meropa  460
No. 7
1919 - 2346 SUS
158
-37°F
Mobil SHC 634
Omala RL 460
Pinnacle 460
No. 1
310 - 340
320°F (160°C)
Lithium
---------------------------Mobilux  EP 111--------------------------
WG
Wheel Gear and
Pinion Grease
Viscosity @ 100° F
Mobil  Oil Corp.
Texaco Inc.
25,000 SUS (contains diluent)
---------------------------Mobiltac  375 NC----------------------------------------------------------Crater H  --------------------------------
CL
Cable Lubricant.
No Specification
Amoco  Oil Co.
Mobil  Oil Corp.
Sun  Oil Co.
Texaco  Inc.
----------------------------Amovis  5-X -----------------------------------------------------Mobilarma  798----------------------------------------------Sunoco  Wire Rope Lubricant----------------Crater A
Texclad  2
AGMA Lubricant
Viscosity @ 100° F
Viscosity Index
Pour Point
Amoco  Oil Co.
Mobil  Oil Corp.
Shell  Oil Co.
Sun  Oil Co.
Texaco  Inc.
No. 1
No. 2
193 - 235 SUS
284 - 347 SUS
60 Min.
60 Min.
-20°F (-29°C)
10°F (-12°C)
Rykon  Oil 46
American Industrial Oil  68
----------------------Mobil  DTE Oil Heavy------------------------Rotella  10W
Rotella  10W-30
Sunvis  932
Sunvis  968
Rando  Oil 46
Rando  Oil 68
Wire Rope
Lubricant
GO
General Oil.
General Oiling to
Prevent Rusting
and Provide
Limited Lubrication
for Points Not
Considered Normal
Wear Points.
MPG
Multipurpose
Grease.
Grease Lubricated
Wear Points
Provided with
Fittings and Grid or
Gear Type Flexible
Couplings.
10
AGMA Lubricant
Viscosity @ 100° F
Viscosity Index
Pour Point
Mobil  Oil Corp.
Shell  Oil Co.
Texaco  Inc.
AMBIENT TEMPERATURE
-20° to 50°F
50° to 125°F
125° to 250°F
(-29° to +10°C)
(10° to 52°C)
(52° to 121°C)
NLGI Grease
6ASTM Worked
Penetration
Dropping Point
Base
Amoco Oil  Co.
Mobil Oil  Corp.
Shell  Oil Co.
Sun  Oil Co.
Texaco  Inc.
No. 1
310 - 340
No. 2
265 – 295
360°F (182°C)
360°F (182°C)
Lithium
Lithium
Amolith  Grease 1 EP
Amolith  Grease No. 2 EP
Mobilith  AW 1
Mobilith  AW 2
-------------------------Retinax LC----------------------------------Prestige  741 EP
Sunoco  Multipurpose 2 EP
Multifak  EP 1
Multifak  EP 2
4-7. LUBRICANT SPECIFICATIONS
CONT’D.
GCOT
Gear Case
Oil.
Traverse
Gear Case.
AGMA Lubricant
ISO Viscosity Grade
American Lubricants 
Mobil  Oil Corp.
Shell  Oil Co.
Fiske Brothers
Texaco  Inc.
AMBIENT TEMPERATURE
-20° to 50°F
(-29° to
+10°C)
50° to 100°F
(10° to 38°C)
100° to 250°F
(38° to 121°C)
No. 5S
220
SHC 90W
Mobil SHC
630
Omala RL
220
SPO-MG
Pinnacle 
220
No. 8 Compounded
680
AGMA #8 Gear Oil
Extra Hecla Super
Refer to Yale Hoist
Field Service
Department for
Gearcase Operating
Temperatures above
200°F.
SECTION V – INSPECTION AND
PREVENTATIVE MAINTENANCE
5-1. GENERAL. All Yale “Global King” hoists are
inspected and tested at the factory. Regular inservice inspection and preventative maintenance
programs not only help reduce overall maintenance
costs but may also prevent service shutdowns by
forewarning of problems that could cause these
shutdowns. Regular inspections, periodic minor
adjustments, regular cleaning and lubrication and
replacement of worn parts can help preserve good
performance and operation of your hoist.
Many factors influence the inspection and
preventative maintenance program required for your
hoist. Frequency and severity of service and material
handled, local environmental conditions and various
applicable codes are some of the factors that the
user must consider to adjust inspection and
maintenance program outlined in this section to
meet his specific conditions.
The inspection and maintenance services outlined in
this
section
are
considered
minimum.
Recommended in the schedule are minimum
inspection and maintenance intervals based on
average daily use in a normal environment. Average
daily use is based on 1000 total operational hours
per year maximum and intermittent operation of the
hoist eight hours per day, five days per week with a
maximum 50 percent “on” time and the average
loading not exceeding 65 percent of rated load. For
more details regarding hoist duty cycles, please
reference ANSI/ASTM HST-4.
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
Valvata J 680
SPO-288
Vanguard  680
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 service.
Inspection Schedule and Maintenance Report Form.
Shown on page 13 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 the Inspection and
Maintenance Schedule listed on page 12 of this
manual but may be used to record scheduled
inspection and maintenance services required.
11
The user should revise the inspection interval, add
additional units or provide a similar form to suit
particular conditions that may exist. However,
written, dated and signed inspection reports should
be maintained particularly on critical items such as
hoist hooks, hoisting rope, sheaves, drums and
brakes. Periodic review of old inspection reports can
point out service life of hoist components,
forecasting need for adjustment, repair or
replacement of these components.
As a matter of expedience, appointed maintenance
personnel inspecting hoist can also take care of
minor adjustments, repairs and cleaning, where
required. Note column on Inspection Schedule and
Maintenance Report form headed Corrective Action
and Notes. When corrective action is made during
inspection, note condition of part or unit as inspected
in appropriate Condition column with a check mark
(`). Note “during inspection” corrective action taken
and date in space provided. In this manner, items
requiring further attention will be checked (`)
without showing corrective action. This will advise
the designated person responsible for hoist
operation and safety, who reviews the reports that
deficiencies exist. The designated person will check
all deficiencies as listed and re-examine or otherwise
determine whether they constitute a safety hazard.
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.
RECOMMENDED INSPECTION AND MAINTENANCE SCHEDULE
TIME INTERVAL
Daily or start of
*
each shift (visual)
1 Month
1-3 Months
*
*
6 Months
*
*
*
*
*
6 Months or 500750 hours “on”
time
Annually
*
5 years elapsed
time or 5000
hours “on” time
*
12
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.
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 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.
BLOCK OPERATED LIMIT SWITCH-Inspect per Paragraph 5-12.
Inspect electrical controls per Paragraph 5-4. Change hoist gearcase oil – Fill with oil
per Paragraph 4-2.e. Lubricate hoist cable per Paragraph 4-3. Lubricate upper and
lower hook block. Lubricate limit stop lever per Paragraph 4-4. Add a light film of MPG
grease (Paragraph 4-7) to the bevel gear in the screw type limit switch.
Motor brake and actuating mechanisms. Inspect and adjust per Paragraph 5-10.
Inspect hooks with crack detecting procedures per Paragraph 5-2. Drain and refill hoist
gearcase per Paragraph 4-2.
Complete inspection, disassembly, and maintenance required. It is recommended that
your Yale repair Station be contacted for this service.
INSPECTION SCHEDULE AND MAINTENANCE REPORT
HOIST SERIAL NO. (Manufacturer's) ____________________
RATED LOAD ____________________
TYPE ___________________________
VOLTAGE _______________________
CLEANING OR
PAINTING REQUIRED
LUBRICATION
REQUIRED
(Low Oil or Grease,
Rust or Corrosion)
REPLACEMENT
REQUIRED
(Worn or Damaged)
REPAIR REQUIRED
(Loose Parts or Wires)
GOOD
ADJUSTMENT
REQUIRED
ANNUAL
SEMI-ANNUAL
COMPONENT,
UNIT OR PART
CONDITION
*Recommended (Check column best indicating condition when part or
Inspection
unit is inspected. Use note column to the right if
Interval
condition is not listed below.)
MONTHLY
LOCATION
COMPONENT, UNIT OR PART
and location
CUSTOMER CRANE IDENTITY NO. __________________________
LOCATION IN PLANT
THIS INSPECTION IS: MONTHLY
ANNUAL
SEMI-ANNUAL
INSPECTED BY:______________________________DATE:__________
CORRECTIVE ACTION NOTES
(Indicate corrective action taken during inspection and
note date. For corrective action to be done after
inspection, a designated person must determine that
the existing deficiency does not constitute a safety
hazard before allowing unit to operate. When
corrective action is completed, describe and note date
in this column.)
DATE
Motor
Motor Brake
Couplings
Gears, Shafts, & Bearings
HOIST
Upper Block
Lower Block
Hook & Throat Opening
Record Hook Throat Opening:
X
Hoist Rope
Rope Drum
Rope Guide
Guards
CONTROL
STATION OR
PUSHBUTTON
Limit Switches
Pushbutton
Wiring
Motor
Brake (when so equipped)
TROLLEY
Couplings
Gears, Shafts, & Bearings
Frame
Wheels
Bumpers
Guards
Conductors
RUNWAYS
RESISTORS
Collectors
Hoist
Trolley
Monorail Joints
Monorail
Main Conductors
Main Collectors
MISC.
General Condition
Load Attachment Chains
Rope Slings & Connections
Change Gearcase Lubricant
Grounding Faults
*
See text for DAILY & WEEKLY REQUIREMENTS.
INSPECTION INTERVAL.
X
SIGNED & DATED REPORT - OSHA.
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
13
WARNING
Do not operate a hoist having unusual
vibrations, sounds, or with anything
wrong or apparently wrong. Danger may
be present that the hoist operator
cannot see. Determine and correct the
cause of unusual conditions and make
certain hoist can be operated safely.
g) Hooks showing signs of cracks must be
replaced. Hooks should be inspected at
least once per year using dye penetrants,
magnetic particle, or other suitable nondestructive test methods.
h) Check wear of the hook, especially at the
saddle and replace if worn more than 10%
of original dimensions.
5-3. INSPECTION OF UPPER BLOCK.
5-2. INSPECTION OF LOWER BLOCK.
a) Check lubrication of all parts. Also lubricate
the shank of the hook that passes through
the crosshead. If the thrust bearing is
removed, apply MPG grease (Section IV,
Para. 4-7).
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.
a) Check upper block sheaves (when hoist is
so equipped) for wear, damage and
freedom of rotation.
If sheaves do not rotate freely, disassemble
block and inspect bearings. Replace worn
or damaged bearings, washers, pins, 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.
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.
Arrangement of electrical control equipment varies
with the type of control, physical space and the
optional control features ordered with the hoist.
Note the location in the electrical enclosure of the
control circuit fuse, transformer, limit stop switches
and the hoist contactors. Trolley contactors and
optional hoist and trolley fuses are also located in
this enclosure.
Use wiring diagrams furnished with hoist to
determine electrical components on your hoist; then
determine component location and identity on your
hoist.
WARNING
Be certain that main power switch is
locked in open position (OFF) before
opening hinged control enclosure cover
mounted to the counterweight.
FIGURE 5-2 Gage Block.
14
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.
WARNING
Check to be certain main power switch
is locked in open position (OFF) before
removing brake cover.
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.
WARNING
Side pulling and excessive load swing
will severely damage the rope and rope
guide. Failure of these components may
result in injury.
b) Disassembly. Refer to Figure 5-3. For further
assistance in locating components refer to the
parts list in Section IX.
(1) Remove socket head cap screws and lock
washers (Items 8 and 9). Take off mounting
clip (Item 7).
(2) Remove shoulder bolts (Item 4) and
compression springs (Item 5). The two
halves of the rope guide body (Item 1) can
now be pulled off the drum separately.
When reassembling be sure that the half
with the rope slot is on the top half of the
drum.
WARNING
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 3), which is under tension.
WARNING
The rope tensioning spring is under
considerable tension; use caution when
unhooking to avoid injury.
(4) Remove the split plastic shroud (Item 2)
from the drum. When reassembling the
rope guide be sure the plastic shroud (Item
2) fits snugly in the rope guide body
groove.
(5) Thoroughly
clean
components.
and
inspect
all
(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.
WARNING
Wire Rope improperly handled or
abused can create a SAFETY HAZARD.
Read and comply with inspection,
maintenance
and
replacement
information given herein.
Figure 5-3. Rope Guide Assembly.
a) Inspection. Wire rope on your hoist is one
of the most important components requiring
frequent inspection and maintenance. All
15
wire ropes will eventually deteriorate to a
point where they are not safe and will
require replacement. Wire rope should be
thoroughly inspected at regular monthly
intervals by an authorized person and a
determination made when further use of the
rope would constitute a safety hazard.
Each inspection should include a written
dated and signed report of rope condition.
Reports should be filed and reviewed each
month and any rope deterioration carefully
noted. Inspections revealing but not limited
to the following conditions should cause
inspector to question remaining strength of
rope and consider replacement:
(1) Twelve randomly distributed broken wires
in one rope lay or four broken wires in
one strand. (See Figure 5-4.)
Figure 5-4. Description of One Rope Lay.
(2) Wear of one-third of the original diameter
of outside individual wires.
(3) Kinking, crushing, or birdcaging.
(8) Rope being idle for one month or more
due to shutdown or inactivity.
Special attention should be exercised when
inspecting rope normally hidden during
inspecting procedures.
Please refer to the Wire Rope Users Manual
–for illustrations and definitions when
following the above guidelines for rope
inspection. This manual may be obtained
from:
WRTB Fulfillment
609 North Second Street
St. Joseph, MO 64502
Or by calling: 1-888-BUY-WRTB (289-9782).
b) Maintenance. Keep rope well lubricated to
help reduce internal friction and prevent
corrosion. Lubricant, as described in
Paragraph 4-3, should be applied as a part
of the regular maintenance program.
Special attention is required to lubricate
sections of rope over equalizing sheaves
and other hidden areas.
Avoid dragging ropes in dirt or around
sharp objects that will scrape, nick, crush,
or induce sharp bends in the rope.
WARNING
Use only factory-approved rope with
swaged wire rope socket.
(4) Heat damage from any cause.
(5) Reductions from nominal diameter of
more than 1/32” for 7/16” diameter rope
or 3/64” for 9/16” rope. See Figure 5-5 for
proper measurement techniques.
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.
Figure 5-5. Correct Method of Measuring Rope.
(6) Rope corrosion, internal or external.
(7) Effects from improper lubrication.
16
5-7. ROPE REEVING.
a) General. Place reel on stand with shaft
through the center of reel so rope can be
pulled straight out with reel rotating.
CAUTION
It is imperative that rope reel or coil
rotates as rope unwinds. If coil or reel
does not rotate the wire will be twisted
as it is uncoiled and kinking will result.
A kinked rope may be damaged and
unsafe for maximum service.
b) Before removing the old rope, refer to
reeving diagram, Figure 5-6. To assist with
re-reeving your hoist, refer to the reeving
diagram and corresponding paragraph that
describes the reeving procedure.
c) Removing old rope. Please, refer to the
Section IX Parts lists to assist in locating
components referred to in the following
paragraphs.
(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.)
(4) Remove
covers.
outer
lower
block
sheave
(5) Remove lower block sheaves and wire
rope.
(6) Remove two (2) rope retention bolts and
nuts from upper block yoke.
(7) Remove two (2) bolts and key plate to
allow removal of upper block sheave pin.
(8) Securely grasp the upper block sheave
before carefully sliding the sheave pin
out. Note that two spacers will also be
released as the pin is removed.
(9) Remove wire rope from sheave.
(10) Remove retaining rings or cotter pins
from dead end anchor pin. Securely
grasp the swaged wire rope and, in some
cases, spacers before removing the pin.
(11) Remove Rope Guide.
(12) Make certain all personnel are clear of
hoist and operate hoist “DOWN” to
completely unwind all wire rope from
drum. Stop hoist so all (3) rope clamps
are accessible. Remove rope clamps and
wire rope from drum.
WARNING
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.
FIGURE 5-6. Reeving Diagram – 4 Part
Single-Reeved. (Note: Arrow on Drum
Indicates Direction of Drum when
Lowering.)
CAUTION
Be certain all personnel are clear of
hoist as components, hardware, and
wire rope are removed from hoist.
(2) Remove block operated limit switch
weight from rope.
(3) Remove retaining rings from lower block
sheave pin.
(1) Thread rope to drum from trolley frame
side then secure with rope clamps as
follows:
(a) Make sure that the rope clamp
groove size utilized as marked
directly above the groove matches
the rope size for your hoist (7/16” on
the “B” Frame and 9/16” on the “C”
Frame).
(b) With the rope lying in the bottom of
the drum groove, begin tightening the
rope clamp at the tail end of the rope.
Torque to 50 ft-lbs.
(c) With tension on the rope keeping it
properly seated in the drum groove,
17
torque the remaining two (2) rope
clamps in sequence to 50 ft-lbs.
(2) With all personnel clear of hoist – TURN
ON POWER.
(3) Operate hoist “UP” guiding six (6) wraps
of new rope into drum grooves with
gloved hand.
(3) Re-install rope guide over rope in rope
drum grooves as shown in Figure 5-3.
and outlined in Section V, Paragraph 5-6.
Continue lubricating as rope is spooled
onto the drum until about 28’-0” remain
unwound.
WARNING
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.
(7) With outer lower block covers removed,
thread the wire rope through the sheaves
of the upper and lower block as shown in
Figure 5-6.
(8) Attach swaged rope end to the dead end
anchor pin fastening cotter pins or
retaining rings as required.
(9) Replace the lower block sheave covers.
(10) Lubricate cable per Paragraph 4-3.
See Figure 9-5 (“B” Frame components) for
lower block parts with 7/16” diameter wire
rope.
See Figure 9-5 (“C” Frame components) for
lower block parts with 9/16” diameter wire
rope.
c) Checking for and removal of rope twisting.
(1) To remove rope twist in four part single
reeved hoists:
(a) Observe direction block tends to
rotate.
Figure 5-7. Drum Frame & Geared Limit Switch.
b) Remove the Geared Limit Switch or disconnect
the wires so that the electrical cable will not
inhibit removal of the drum. (See Figure 5-7).
c) Remove the unit from service, place it on the
ground, and provide adequate means to
support the drum before removing the frame
rod nuts at the outboard drum frame end
(Figure 5-7). The hardware attaching the drum
frame to the hoist and trolley frame may then
be removed.
d) Keeping the drum level, remove the drum from
the splined output shaft at the gear case end.
5-9. INSPECTION OF HOIST GEARING.
(b) Lower the block to a low position
and TURN OFF (lock out) POWER.
(c) Remove swaged fitting from anchor
pin and rotate rope several turns in
a direction tending to correct block
rotation.
(d) TURN ON POWER; raise and
lower the block several times to
feed the correcting twist in the rope
through the reeving.
5-8. INSPECTION OF ROPE DRUM AND SHAFT.
a) To remove the rope drum, remove the rope
guide and hoisting cable, as outlined in Section
V, Paragraphs 5-5 and 5-7.c. respectively.
18
Figure 5-8. Hoist Gear Case Assembly.
a) General. The hoist gear case is a triple
reduction splash lubricated vertically split
cast aluminum case and cover. The first
two high-speed reductions are helical and
the third low speed output reduction is
spur. The gear shafts are supported with
ball bearings housed in the back of the
case and in the cover. The input helical
pinion is cut directly into the motor shaft. An
oil seal housed in the gear case at the
motor input seals the motor shaft as it
passes into the gear case. Since the entire
motor shaft is submerged in oil, anytime the
motor is removed, the oil must be drained
from the gear case. All pinions are integral
with their shafts while the gears are keyed
and pressed onto their shafts. The output
shaft passes through an oil seal in the back
of the gear case and drives the drum by
means of a crowned spline. One end of the
rope drum is supported on this output shaft.
b) Inspection and Disassembly.
Gearcase. (See Figure 5-8.)
(5) If it is necessary to remove the output
shaft assembly from the gear case, the
rope drum must first be removed from the
hoist. See Section V, Paragraph 5-7.
WARNING
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 gear case.
Provide an adequate means to support
this shaft and gear assembly before
removing, as it weighs approximately 80
lbs. (“C” Frame Hoist).
(1) Lower hook block to the floor and relieve all
load from ropes.
(6) The pinion shaft and gear assemblies
may be removed as necessary.
(2) Make sure power to hoist is off and locked
out.
(7) Inspect all gears, pinions, bearings, and
the output shaft spline for wear, pitting, or
mechanical
damage.
Replace
as
necessary. See Section IX, Figure 9-2 for
replacement parts. It is recommended
that gears and pinions only be replaced
as sets. Thoroughly clean the output
shaft external spline teeth before
reassembly.
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.
(4) Provide adequate means to support the
gear case cover. Once the cover is
supported, remove the two (2) shoulder
bolts, seven (7) socket head cap screws,
and nine (9) lock washers holding the
cover to the gear case. Carefully draw
the cover directly away from the gear
case, as damage to this surface will
prevent the gasket from sealing properly.
As the cover is removed, ensure that all
gear and shaft assemblies remain in the
case.
WARNING
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.
(8) Assembly is opposite of removal. Use a
new gasket. Do not attempt to assemble
the cover to the gear case without a
gasket, as the spacing between bearings
will be reduced. Severe damage to the
hoist will occur if no gasket or the wrong
gasket is used. Refill gear case with new
lubricant per Section IV, Paragraph 4-2
before use. Using SG (Paragraph 4-7),
grease the spline teeth on the output
shaft before reinstalling rope drum.
(9) Test hoist per Section V, Paragraph 5-13
to ensure proper lubrication.
Hoist Motor.
(1) Lower hook block to the floor and relieve all
load from ropes.
(2) Make sure power to hoist is off and locked
out.
(3) Drain the oil from the gear case per
Section IV, Paragraph 4-2.
19
(4) Disconnect the wiring and conduit from
the motor junction box.
(12) Test hoist to ensure proper operation
per Section V, Paragraph 5-13.
(5) Provide a means to support the hoist
motor. The hoist motor weighs approximately 250 lbs. And must be held level
while removing and installing.
5-10. INSPECTION OF MOTOR BRAKE AND
ACTUATING MECHANISM.
(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 installing the motor, pack the gear
teeth with MPG grease (Paragraph 4-7)
and wrap the gear teeth with a number of
layers of Teflon tape to protect the seal
lip from being damaged by the gear
teeth. Coat the seal lip and the motor
shaft with MPG grease.
NOTICE
Failure to use a factory replacement seal
will cause premature seal failure due to
specific lip material requirements that
must be met.
a) General Operation. The hoist brake is an
electro-magnetically released, spring set nonadjustable brake. Torque is generated by
compressing a friction disk between the
stationary motor end bell and the spring loaded
brake armature. The friction disk is fixed to the
motor shaft and rotates with the motor shaft.
When the magnet coil is energized, the
armature plate is pulled across the air gap. The
friction disk is carried by a splined hub that
permits axial movement when the brake is
released. This axial movement releases both
sides of the friction disk from their mating
stationary surfaces and allows the friction disk
to rotate freely when the brake is energized.
When power is removed from the magnetic
coil, the compression springs push the
armature against the friction disk and the other
side of the friction 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.
(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 will occur. It
may be necessary to rotate the rope
drum slightly to align the gear teeth to
mesh with the teeth on the motor shaft.
Ensure that the motor seats properly into
the rabbet fit machined in the gear case.
Fasten the motor to the gear case.
(10) Reconnect the conduit and power
leads to the motor. See Section VIII
and refer to the specific wiring
diagrams shipped with your hoist.
(11) Refill gear case with lubricant per
Section IV, Paragraph 4-2.
20
Figure 5-9. Motor Brake.
b) Friction Disk
Adjustment.
Inspection
and
Air
Gap
(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.
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.
(3) Remove the four (4) bolts attaching the
fan shroud to the motor and remove the
fan shroud. See Figure 5-9.
(8) Replace the large O-ring over the air gap
and reassemble the fan shroud to the
motor.
(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.
(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.
(9) Test hoist per Section V, Paragraph 5-13
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.
(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 over the friction surfaces. If the
friction disk thickness is less than the
minimum shown in Table 1, it must be
replaced. See Section IX, Figure 9-10. If
the friction disk thickness is within the
allowable, reassemble the brake body to
the motor end bell and torque the
mounting bolts to the value shown in
Table 5-1. Whenever the friction disk is
replaced, it is necessary to reset the air
gap.
Hoist
Mounting Bolt
Torque
Nominal Air Gap
(3) Remove the four (4) bolts attaching the
fan shroud to the motor and remove the
fan shroud. See Figure 5-9.
(4) Remove the snap ring behind the plastic
fan. Carefully remove the fan from the
motor shaft. Remove the snap ring in
front of where the fan was mounted.
(5) Disconnect the two wires from the
terminal block on the magnetic body.
(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.
"B" Frame "C" Frame
18 ft-lbs.
18 ft-lbs.
0.016 in.
0.016 in.
Maximum Air Gap 0.031 in.
0.035 in.
Minimum Brake
0.453 in. 0.472 in.
Disk Thickness
Table 5-1. Motor Brake Data.
(7) To reset the air gap, begin by releasing
the (3) mounting bolts 1/2 turn. Turn the
hollow spacer bolts into the magnet body
approximately 1/4 turn. Retighten all
three mounting screws. Measure the air
gap at a minimum of three places around
the circumference. Threading the hollow
spacer bolts into the magnet body will
decrease the air gap while backing these
spacer bolts out of the magnet body will
increase the air gap. Repeat this step as
necessary until the required air gap is
d)
Brake Re-assembly.
(1) Install the friction disk on the splined hub.
The friction disk must slide on the splined
hub and seat against the end bell of the
motor.
(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 Oring is not pinched in the air gap.
21
(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 5-13.
5-11. INSPECTION
DRIVE.
OF
HOIST
TRAVERSE
Figure 5-10. Traverse Drive Arrangement.
a) General. The traverse drive consists of four
single flange wheels, two on each side of
the beam, carried directly by the hoist
frame. These wheels rotate on sealed ball
bearings supported by fixed pins. Pinions
drive two opposing wheels with gear teeth
cut into the flange. Both pinions are
mounted on a hexagonal drive shaft
supported by sealed ball bearings at each
hoist side. The pinions are held in place by
means of clamp collars. The drive shaft
passes through one hoist side and is driven
by a single reduction hollow shaft gear
reducer.
b) Ensure that the hoist is properly fitted to the
beam. The hoist must be centered on the
beam with clearance between the sides of
the bottom of the beam flange and the
inside faces of the wheel flanges. Proper
clearance must exist along the entire length
of beam that the hoist can traverse. An
amount of 3/32 to 1/8 inch clearance per
side is recommended for a total of 3/16 to
1/4 inch wider than the beam flange. If too
little or too much clearance is determined,
adjust trolley per Section II, Paragraph 2-2.
c) 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
22
missing items. Wheels must always be
changed in opposing pairs and drive
wheels should be changed when the drive
pinions are replaced.
CAUTION
Ensure that the cross shaft is properly
positioned and locked into place by
means of the clamp collars. Failure to
do so may allow the drive shaft to
contact the rope on the rope drum (B
frame) or the hoist gearcase (C frame
hoist).
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
cross shaft bearings and the pinion aligns
the gear mesh. Clamp collars hold the
pinions and spacer washers tight against
the bearings. Verify that the clamp collars
are tight on the cross shaft. If it is
necessary to adjust or reset the clamp
collars, verify that the hex shaft surface is
free of mechanical damage and oil before
tightening the clamp collars. Drive pinions
must be replaced as sets and should be
replaced along with the drive 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 hollow bore and hexagonal
drive shaft for wear. Verify that the four
bolts that hold the gearbox to the trolley
frame and the four bolts that hold traverse
motor to the gearbox are all present and
tight. Replace and tighten as necessary.
The
factory
recommends
complete
replacement of the traverse gearbox.
However, gearbox service may be
available from you local authorized Yale
repair center.
5-12. TESTING
SWITCH.
BLOCK
OPERATED
LIMIT
a) General. The block operated limit switch is
a secondary upper limit switch actuated
when the lower block contacts the limit
switch weight. The rotary geared limit
switch (screw type limit switch) is the
primary upper limit switch and must be
temporarily disconnected to allow the block
operated limit switch to be tested.
b) Procedure. Remove load from the hook. To
disconnect the geared limit switch refer to
Figure 7-2. Remove the limit switch cover
then loosen the two (2) screws holding the
locking plate in place. Allow the locking
plate to slide down and disengage from the
adjustment discs. Do not rotate the
adjustment discs.
CAUTION
Damage to the hoist may occur if the
block operated limit switch fails during
testing.
Damage can be avoided by immediately
releasing the pushbutton once the lower
block has traveled through the limit
switch weight.
The block operated limit switch may now be
tested by slowly and carefully raising the
hook until the limit switch weight contacts
the lower block. If the hook does not stop
when the limit switch weight is lifted,
immediately release the pushbutton before
damage to your hoist occurs. If the block
operated switch functions properly, proceed
by testing in the same manner with rated
load on the hook.
Once it has been determined that the block
operated limit switch is functioning properly,
the geared limit switch must be
reconnected and tested.
Position the lower block three inches (3”)
below the point where the block operated
limit switch is activated. The geared limit
switch shall be reconnected by sliding the
locking plate back into position ensuring
slots on adjustment discs are fully engaged
and tightening locking plate screws to 4 inlbs. (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.
WARNING
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 HOIST.
a) General. Testing shall be performed in
accordance with ANSI B30.16-2 and this
manual. Before placing hoist in service,
hoist should be tested to insure safe
operation
when
hoist
has
been
disassembled and reassembled. To test,
suspend hoist from an overhead supporting
member of sufficient strength to support the
weight of the hoist and the rated load.
Connect hoist to power supply as shown on
hoist nameplate and perform the checks
listed in b) and c) below.
b) Check hoist as outlined in PREOPERATION 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.
(3) Depress “DOWN” push button, lower
load a short distance and release
button. Hoist should stop immediately
and hold load at that level.
NOTE:
If load drifts downward slowly in step 2 or 3 above,
motor brake requires adjustment – see Motor Brake
Adjustment – SECTION VII, Paragraph 7-1.
23
SECTION VI – TROUBLE SHOOTING
WARNING
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.
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.
Whenever servicing electrical components be sure
to shut off and lock out power following proper
lockout/tagout procedures.
TROUBLE
6-1 Hoist Will Not
Operate.
6-2 Hook Moves in
Wrong Direction.
SECTION VI – TROUBLE SHOOTING
PROBABLE CAUSE
REMEDY
a. Check switches, circuit breakers or fuses and
a. No power to hoist.
connections in power supply lines. Check power
collectors.
b. Wrong Voltage.
b. Check voltage required on motor data plate
against power supply.
c. Loose
or
broken
wire
connections in hoist electrical
system.
c. Shut off and lock out power supply; remove
electrical cover on hoist and check wiring
connections. Also check connections in push
button station and limit switches.
d. Contactor
assembly
functioning.
d. See that necessary jumper wires are properly
installed. Verify that the contactor armatures are
free to move. If binding occurs, replace
contactor. Check for burned out contactor coils.
not
e. No control voltage.
e. Check transformer fuse. If blown, check for
grounding and/or shorts in the push button
station. Check the transformer coil for signs of
overheating. Replace transformer if burned out.
Verify the transformer secondary is the same
voltage as the coils to which it is connected.
f. Motor burned out.
f. Replace motor. Check input power supply.
Check hoist motor connections.
a. Interchange any two power supply line leads.
Refer to Section II, Paragraph 4.b.
a. Reverse phasing on threephase hoists.
b. Hoist wired incorrectly.
6-3 Hook Will Raise
But Not Lower.
a. Lower electrical circuit open.
b. Contactor
functioning
assembly
c. Down,
push
inoperative.
24
button
not
is
b. Check wiring connections with appropriate
wiring diagram.
a. Check for loose connections. See that necessary
jumper wires are properly installed on contactor.
b. See that necessary jumper wires are properly
installed. Verify that the contactor armatures are
free to move. If binding occurs, replace contactor.
Check for burned out contactor coils.
c. Check push button contacts and wires.
TROUBLE
6-4 Hook Will Lower,
But Not Raise.
6-5 Hoist Will Not
Lift Rated Load.
6-6 Hoist Motor
Overheats.
6-7 Load Drifts
Excessively
When Hoist is
Stopped.
6-8 Hoist Operates
Intermittently.
SECTION VI – TROUBLE SHOOTING
PROBABLE CAUSE
REMEDY
a. Reduce loading to rated load of hoist as shown on
a. Excessive load.
nameplate.
b. Hoist electrical circuit open.
b. Check for loose connections. See that necessary
jumper wires are properly installed on contactor.
c. Contactor assembly not
functioning.
c. 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.
d. Up, down button inoperative.
a. Low voltage.
d. Check push button contacts and wires.
a. See that the power supply current is the same
voltage listed on motor data plate. Check hoist
motor connections. Check size of power supply
lines.
a. Reduce loading to rated load as shown on
nameplate.
a. Excessive load.
b. Excessive duty-cycle.
b. Reduce frequency of lifts or amount of jogging.
c. Wrong voltage or frequency.
c. Check current rating on motor data plate against
power supply. Check hoist and inspect for
defective, worn or damaged parts.
d. Defective motor or worn
bearings in hoist frame.
d. Disassemble hoist and inspect for defective, worn
or damaged parts.
e. Brake not adjusted correctly.
a. Excessive Load.
e. Adjust brake per Section VII, Paragraph 7-1.
a. Reduce loading to rated load as shown on
nameplate.
b. Motor brake not holding.
b. With No Load, check hoist for drift. If drifting is
excessive, inspect motor brake (Section V,
Paragraph 5-10) and adjust as outlined in Section
VII, Paragraph 7-1.
a. Check collectors for free movement of spring arm,
weak spring or electrical connections.
a. Collectors make poor contact.
b. Loose connections.
SECTION VII – ADJUSTMENTS
7-1. MOTOR BRAKE ADJUSTMENT. These
brakes are designed so that adjustment is seldom
required. If, after a period of service, the load hook
“drifts” downward more than usual for your hoist
before coming to a stop, the motor brake may
require adjustment to compensate for brake disc
wear.
WARNING
Check to be certain main power switch
is locked in open position (OFF) before
removing brake cover.
b. Check all wiring for loose connections.
Refer to Figure 5-9 and proceed as outlined in
Section V, Paragraph 5-10.
7-2. BLOCK OPERATED LIMIT SWITCH. The
block operated limit stop, furnished as standard
equipment, is non-adjustable and designed to stop
the lower block at the safest high point of travel to
eliminate any possibility of double-blocking. When
the safest high point is reached, the limit switch
automatically stops hook travel.
7-3. GEARED
ROTARY
LIMIT
SWITCH
ADJUSTMENT. The geared rotary type limit switch
is standard equipment and is located on the drum
end opposite the gearcase end.
25
This limit switch has a rotary screw driven by a gear
reduction that is coupled to the end of the drum
shaft. Adjustment discs operate the contacts of
separate switches, one for the hoisting circuit and
one for the lowering circuit. The switch assembly
must be wired in accordance with the appropriate
wiring diagram, which is shipped with the hoist.
Instructions for adjusting limit switch are inside
cover and are repeated below (see Figure 7-2).
WARNING
Check limit switch operation carefully,
without load, before placing hoist in
service.
If
misadjusted,
SEVERE
DAMAGE AND/OR A DROPPED LOAD
COULD RESULT. Allow 3” for hook drift
in both directions. Never allow less than
two (2) complete wraps of rope on drum
with hook in lowest position.
Provide a light film of MPG grease (Paragraph 4-7)
on gear of both limit switches.
7-4. SHORTENING OF PUSHBUTTON CABLE.
WARNING
SWITCH
LOCKING ADJUSTMENT SWITCH
PLATE
DISC
Figure 7-2. Screw-Type Limit Switch Adjustment
(Wires Not Shown For Clarity.)
WARNING
Be certain that electrical power supply
is OFF and locked in the open position
before removing limit switch cover.
Be certain that electrical power supply
is OFF and locked in the open position
before attempting shortening of push
button cable.
a) Loosen screws at cable connectors and
clamps at top of cable.
b) Adjust steel support cable to proper length
and tighten screws.
c) Loosen upper cable grip and pull excess
cable into connection box at hoist.
d) Tighten cable grip and cut off excess cable.
a) Remove four screws and lift off switch
cover.
b) Loosen locking plate screws. Slide locking
plate away from adjustment disc.
c) Turn proper adjustment disc (right for up,
left for down) toward switch to reduce hook
travel or away from switch to increase hook
travel.
d) Slide locking plate back into position
ensuring slots on adjustment discs are fully
engaged, tighten locking plate screws to 4
in-lbs.
e) Replace cover.
f)
26
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.
e) Strip cable sheath and connect wires with
the same type of terminals previously
furnished (care must be taken to match
previous wire color coding with wire
markers in accordance with wiring diagram
furnished with hoist.)
SECTION VIII – WIRING DIAGRAMS
8-1. GENERAL. Comprehensive wiring diagrams for
Yale electric hoists have been omitted from this
book because of the many possible variations. This
is due to different currents and types of electrical
components used in their construction. Figures 8-1
and 8-2 are examples of typical two-speed hoist
and trolley wiring diagrams respectively. However,
please consult the exact wiring diagrams for your
hoist. A print of the correct wiring diagram for each
hoist is furnished as a separate insert and shipped
with the hoist. We suggest you carefully file the
wiring diagram with this book for future reference.
Figure 8-1. Elementary Wiring Diagram for a Two-Speed Hoist and Two-Speed Trolley with TAS, Hoist
Block Operated Limit Switch, Geared Upper & Lower Limit Switches, and Optional Fuses.
27
Figure 8-2. Component Diagram for a Two-Speed Hoist and Two-Speed Trolley with TAS, Hoist Block
Operated Limit Switch, Geared Upper & Lower Limit Switches, and Optional Fuses.
28
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.
Yale “Global King” Hoists are built in two basic
frame sizes, “B” Frame and “C” Frame. To
determine the size of your hoist, measure the width
of the gearcase (see Figure 4-2.) The “B” Frame’s
gearcase has a width of 11 3/4” and the “C” Frame
has a gearcase width of 14 1/2”.
Certain parts of your hoist will, in time, require
replacement under normal wear conditions. It is
suggested that these parts be purchased for your
hoist as spares for future use. These parts are
indicated by a (†) symbol at the side of the parts
reference numbers.
The numbers assigned to parts of our
various assemblies in our parts list are not
the part numbers used in manufacturing the
part. They are identification numbers, that
when given with the model number, permit
us to identify, select or manufacture, and
ship the correct part needed.
WHEN ORDERING PARTS OR INFORMATION
ON THIS EQUIPMENT, ALWAYS INCLUDE
MODEL AND SERIAL NUMBER ON ORDER.
WARNING
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 processed to
achieve specific properties
LIST OF PART ILLUSTRATIONS
TITLE
Hoist Drum, Drum Frame, Gearcase, Motor, Rope Guide, and Limit Switch
Hoist Gearing
Motor Driven Trolley Frame and Drive
Lower Block Assembly
Upper Block Assembly
“B” Frame Rope and Dead End Assembly
“C” Frame Rope and Dead End Assembly
Block Operated Limit Switch Assembly
Rope Guide Assembly
Hoist Motor Brake
“B” Trolley Drive Gear Reducer
“C” Trolley Drive Gear Reducer
FIGURE No.
9-1
9-2
9-3
9-4
9-5
9-6
9-7
9-8
9-9
9-10
9-11
9-12
PAGE No.
30
32
34
36
38
39
40
40
42
43, 44
45
46
29
FIGURE 9-1. Hoist Drum, Drum Frame, Gearcase, Motor, Rope Guide, and Screw Type Limit Switch.
“B” Frame: Hoist Components for Figure 9-1.
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
30
Part
Number
GHB-101A
GHB-101B
GHB-101C
GHB-102
GHB-103
GHB-104
GHB-105
GHB-106
GHB-107
GHB-108
GHB-109
GHB-110
GHB-111
GHB-112
GHB-113
GHB-114
GHB-115
GHB-116
GHB-117
GHB-118
GHB-119
GHB-120
GHB-121
GHB-122
GHB-123
GHB-124
GHB-125A
GHB-125B
GHB-900
GHB-127
Description
7 ½ HP Hoist Motor (2-Speed with Brake and Fan) Note: See Figure 9-10 for Parts.
230 volt, 3-phase, 60 Hertz
460 volt, 3-phase, 60 Hertz
575 volt, 3-phase, 60 Hertz
Heavy Hex Nut (1/2-13)
Lockwasher (1/2)
High Strength Hex Head Bolt – ASTM A325 (1/2-13 x 2 1/2)
Self-Locking Nut, ESNA (3/4-10)
High Strength Hex Head Bolt – Grade 5 (3/4-10 x 2 1/2)
Heavy Hex Self-Locking Nut (5/8-11)
Gearcase
Gearcase Gasket
Gearcase Cover
Lockwasher, Hi-Collar (1/2)
Socket Head Cap Screw (1/2-13 x 2 1/4)
Hex Shoulder Bolt (3/8-16 x 2 Long, 1/2 shoulder)
Vent Plug with Sealant (1/2-14 NPT)
Pipe Plug (1/2-14 NPT)
Heavy Hex Lock Nut (1/2-13)
Hardened Flat Washer (1/2)
Gearcase End Drum Frame
Hex Head, Grade 5 Bolt (1/2-13 x 1 1/4)
Hardened Flat Washer (5/8)
Thin Hex Self-Locking Nut – Grade 5 (5/8-18)
Socket Head Cap Screw, Plated (7/16-14 x 1 1/4)
Lockwasher, Hi-Collar (7/16)
Rope Clamp
Drum
Drum 25’ Lift
Drum 40’ Lift
Rope Guide (See Figure 9-9 for Rope Guide and its components.)
Flange Mounted Ball Bearing
Qty.
Req’d.
1
2
2
2
6
6
4
1
1
1
9
7
2
1
2
2
2
1
4
4
4
3
3
3
1
1
1
“B” Frame: Hoist Components for Figure 9-1.
Ref.
No.
28
29
30
31
32
33
34
35
36
Part
Number
GHB-128
GHB-129
GHB-130
GHB-131
GHB-132
GHB-133
GHB-134
GHB-135
GHB-136A
GHB-136B
Description
Lockwasher (7/16)
High Strength Hex Head Bolt – Grade 5 (7/16-14 x 1 1/2)
High Strength Hex Head Bolt – Grade 5 (7/16-14 x 1 3/4)
Outboard End Drum Frame
Limit Switch Bracket
Retaining Ring
Drum Shaft Insert for Geared Limit Switch
Geared Limit Switch
Drum Frame Rod
Drum Frame Rod, 25’ Lift
Drum Frame Rod, 40’ Lift
Qty.
Req’d.
4
2
2
1
1
1
1
1
2
2
“C” Frame: Hoist Components for Figure 9-1.
Ref.
No.
1
2
3
4
5
6
6
7
8
9
10
11
12
13
14
15
16
17
18
20
21
22
23
24
25
26
27
28
29
31
32
33
34
35
36
Part
Number
GHC-101A
GHC-101B
GHC-101C
GHC-102
GHC-103
GHC-104
GHC-105
GHC-106A
GHC-106B
GHC-107
GHC-108
GHC-109
GHC-110
GHC-111
GHC-112
GHC-113
GHC-114
GHC-115
GHC-116
GHC-117
GHC-118
GHC-117
GHC-121
GHC-122
GHC-123
GHC-124
GHC-125A
GHC-125B
GHC-900
GHC-127
GHC-128
GHC-129
GHC-131
GHC-132
GHC-133
GHC-134
GHC-135
GHC-136A
GHC-136B
Description
15 HP Hoist Motor (2-Speed with Brake and Fan) Note: See Figure 9-10 for Parts.
230 volt, 3-phase, 60 Hertz
460 volt, 3-phase, 60 Hertz
575 volt, 3-phase, 60 Hertz
Heavy Hex Nut (3/4-10)
Lockwasher (3/4)
High Strength Hex Head Bolt – Grade 5 (3/4-10 x 3 1/4)
Self-Locking Nut, ESNA (1-8)
Socket Head Cap Screw (1-8 x 3)
Socket Head Cap Screw (1-8 x 4)
Heavy Hex Self-Locking Nut (7/8-9)
Gearcase
Gearcase Gasket
Gearcase Cover
Lockwasher, Hi-Collar (5/8)
Socket Head Cap Screw (5/8-11 x 2 3/4)
Hex Shoulder Bolt (1/2-13 x 2 1/4 Long, 5/8 shoulder)
Vent Plug with Sealant (1/2-14 NPT)
Pipe Plug (1/2-14 NPT)
Heavy Hex Self-Locking Nut (3/4-10)
Hardened Flat Washer (3/4)
Gearcase End Drum Frame
Hardened Flat Washer (3/4)
Thin Hex Self-Locking Nut – Grade 5 (3/4-16)
Socket Head Cap Screw, Plated (7/16-14 x 1 1/4)
Lockwasher, Hi-Collar (7/16)
Rope Clamp
Drum
Drum, 25’ Lift
Drum, 40’ Lift
Rope Guide (See Figure 9-9 for Rope Guide and its components.)
Flange Mounted Ball Bearing
Lockwasher, Hi-Collar (5/8)
Hex Head Bolt – Grade 5 (5/8-11 x 2 1/4) *Includes Ref. No. 30*
Outboard End Drum Frame
Limit Switch Bracket
Retaining Ring
Drum Shaft Insert for Geared Limit Switch
Geared Limit Switch
Drum Frame Rod
Drum Frame Rod, 25’ Lift
Drum Frame Rod, 40’ Lift
Qty.
Req’d.
1
2
2
2
6
2
2
4
1
1
1
9
7
2
1
2
2
2
1
4
4
3
3
3
1
1
1
4
4
1
1
1
1
1
2
2
31
Figure 9-2. Hoist Gearing.
“B” Frame: Hoist Gearing for Figure 9-2.
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Part
Number
GHB-200
GHB-201
GHB-202
GHB-203
GHB-204
GHB-205
GHB-206
GHB-207
GHB-208
GHB-209
GHB-210
GHB-211
GHB-212
GHB-213
GHB-214
GHB-215
GHB-216
GHB-217
GHB-218
GHB-216
Description
Complete Hoist Gearcase Ass’y. - 94.4:1 Ratio (Incl. Ref Nos. 1-19+)
Oil Seal
Oil Seal
Stud
Nut - Hex (5/8-18)
Washer - Hardened (5/8)
Lock Nut - Hex, Thin, Grade 5 (5/8-18)
Ball Bearing
Motor Gear - 56 Teeth
Intermediate Pinion Shaft
Key - Chamfered
Ball Bearing
Drum Pinion Shaft
Intermediate Gear
Retaining Ring
Key - Hardened, Chamfered
Ball Bearing
Ball Bearing
Output Shaft and Drum Gear Assembly
Ball Bearing
Qty.
Req’d.
1
1
4
4
8
4
2
1
1
1
1
1
1
1
2
1
1
1
1
“C” Frame: Hoist Gearing for Figure 9-2.
Ref.
No.
1
2
3
4
32
Part
Number
GHC-200A
GHC-200B
GHC-201
GHC-202
GHC-203
GHC-204
Description
Complete 10t Hoist Gearcase Ass’y. – 124.5:1 Ratio (Incl. Ref Nos. 1-19+)
Complete 7.5t Hoist Gearcase Ass’y. – 104.6:1 Ratio (Incl. Ref Nos. 1-19+)
Oil Seal
Oil Seal
Stud
Nut - Hex (3/4-16)
Qty.
Req’d.
1
1
4
4
“C” Frame: Hoist Gearing for Figure 9-2.
Ref.
No.
5
6
7
8
9
10
11
12
16
17
18
19
Part
Number
GHC-205
GHC-206
GHC-207
GHC-208
GHC-209A
GHC-209B
GHC-210
GHC-211
GHC-212A
GHC-212B
GHC-216
GHC-217
GHC-218
GHC-219
Description
Washer - Hardened (3/4)
Lock Nut - Hex, Thin, Grade 5 (3/4-16)
Ball Bearing
Motor Gear - 64 Teeth
Intermediate Pinion Shaft
10t Hoist - Intermediate Pinion Shaft
7 1/2t Hoist – Intermediate Pinion Shaft
Key - Chamfered
Ball Bearing
Drum Pinion and Gear Assembly
10t Drum Pinion and Gear Assembly (Includes Ref. Nos. 12-15)
7 1/2t Drum Pinion and Gear Assembly (Includes Ref. Nos. 12-15)
Ball Bearing
Ball Bearing
Output Shaft and Drum Gear Assembly
Ball Bearing
Qty.
Req’d.
8
4
2
1
1
1
1
1
1
1
1
1
NOTES
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33
Figure 9-3. Motor Driven Trolley Frame and Drive (“B” Frame Shown).
“B” Frame: Trolley Frame and Drive Components for Figure 9-3.
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
34
Part
Number
GHB-301A
GHB-301B
GHB-302A
GHB-302B
GHB-303A
GHB-303B
GHB-304
GHB-305
GHB-306A
GHB-306B
GHB-307A
GHB-307B
GHB-308
GHB-309A
GHB-309B
GHB-310
GHB-311
GHB-312
Description
Side Plate
Drum Side – 25’ Lift Frame
Drum Side – 40’ Lift Frame
Side Plate
Drive Side – 25’ Lift Frame
Drive Side – 40’ Lift Frame
Counterweight
Counterweight, 25’ Lift Frame
Counterweight, 40’ Lift Frame
Lockwasher (5/8)
Hex Head Bolt, Grade 5 (5/8-11 x 1 1/2)
Alignment Bar
Alignment Bar, 4” Thru 14” Trolley Beam Flange Width
Alignment Bar, 14 1/8” Thru 20” Trolley Beam Flange Width
Hex Cross Shaft
Hex Cross Shaft, 4” Thru 14” Trolley Beam Flange Width
Hex Cross Shaft, 14 1/8” Thru 20” Trolley Beam Flange Width
Motor (Specify HP, Phase, Voltage, Frequency, & Number of Speeds)
Traverse Gear Reducer (See Figure 9-11 for Components)
50 FPM
75 FPM
Hex Head Bolt, Grade 5 (3/8-16 x 1)
Lockwasher (3/8)
Hex Head Bolt, Grade 5 (5/16-18 x 7/8)
Qty.
Req’d
1
1
1
2
2
2
1
1
1
4
4
4
“B” Frame: Trolley Frame and Drive Components for Figure 9-3.
Ref.
No.
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Part
Number
GHB-313
GHB-314A
GHB-314B
GHB-315
GHB-316
GHB-317
GHB-318
GHB-319
GHB-320
GHB-321
GHB-322
GHB-323
GHB-324
GHB-325
GHB-326
GHB-327
Description
Lockwasher, (5/16)
Threaded Rod
Threaded Rod, 4” Thru 14” Trolley Beam Flange Width
Threaded Rod, 14 1/8” Thru 20” Trolley Beam Flange Width
Heavy Hex Nut (3/4-10)
Flat Washer (3/4)
Hex Clamp Collar
Cross Shaft Pinion
Flat Washer
Hex Bore Ball Bearing
Driver Wheel (6 1/2” Diameter Tread)
Trailer Wheel (6 1/2” Diameter Tread)
External Retaining Ring
Ball Bearing
Internal Retaining Ring
Axle
External Retaining Ring
Qty.
Req’d
4
2
12
8
2
2
4
2
2
2
4
8
4
4
4
“C” Frame: Trolley Frame and Drive Components for Figure 9-3.
Ref.
No.
1
2
Part
Number
GHC-301A
GHC-301B
GHC-302A
GHC-302B
3
*
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
GHC-303A
GHC-303B
GHC-303C
GHC-304
GHC-305
GHC-306
GHC-307
GHC-308
GHC-309A
GHC-309B
GHC-310
GHC-311
GHC-312
GHC-313
GHC-314
GHC-315
GHC-316
GHC-317
GHC-318
GHC-319
GHC-320
GHC-321
GHC-322
GHC-323
GHC-324
GHC-325
GHC-326
GHC-327
Description
Side Plate
Drum Side – 25’ Lift Frame
Drum Side – 40’ Lift Frame
Side Plate
Drive Side – 25’ Lift Frame
Drive Side – 40’ Lift Frame
Counterweight
Counterweight, 25’ Lift Frame
Counterweight, 40’ Lift Frame
Counterweight Mounting Cap *(Not Shown)
Lockwasher (3/4)
Hex Head Bolt, Grade 5 (3/4-10 x 2)
Alignment Bar
Hex Cross Shaft
Motor (Specify HP, Phase, Voltage, Frequency, & Number of Speeds)
Traverse Gear Reducer (See Figure 9-12 for Components)
50 FPM
75 FPM
Hex Head Bolt, Grade 5 (3/8-16 x 1)
Lockwasher (3/8)
Socket Head Cap Screw (5/16-18 x 1)
Lockwasher, (5/16)
Threaded Rod
Heavy Hex Nut (3/4-10)
Flat Washer (3/4)
Hex Clamp Collar
Cross Shaft Pinion
Flat Washer
Hex Bore Ball Bearing
Driver Wheel (8” Diameter Tread)
Trailer Wheel (8” Diameter Tread)
External Retaining Ring
Ball Bearing
Internal Retaining Ring
Axle
External Retaining Ring
Qty.
Req’d
1
1
1
4
4
2
2
1
1
1
4
4
4
4
2
12
8
2
2
4
2
2
2
4
8
4
4
4
35
Figure 9-4. Lower Block Assembly.
“B” Frame: Lower Block Components for Figure 9-4.
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part
Number
GHB-400Y
GHB-401
GHB-402
GHB-403
GHB-404
GHB-405
GHB-406Y
GHB-407
GHB-408
GHB-409
GHB-410
GHB-411
GHB-412
GHB-413
GHB-414
GHB-415
GHB-416
GHB-417
Description
Lower Block Assembly (Includes Ref. Nos. 1-17)
Lower Block Frame – Hook Beam
Hook
Thrust Bearing
Castle Nut
Spring Pin
Sheave Covers - Yellow
Flat Head Socket Cap Screws (1/4-20 x 1/2)
Sheave Pin
Sheaves
Ball Bearings
Internal Retaining Rings
External Retaining Rings
Socket Head Cap Screws (1/4-20 x 2 3/4 Long)
Hi-Collar Lockwashers (1/4)
Self-Locking Nuts (1/4-20)
Capacity Plates
Hex Washer Head Self-Tapping Screws (5/16-18 x 1 1/2)
Qty.
Req’d
1
1
1
1
1
1
4
4
1
2
2
2
2
8
8
8
2
4
“C” Frame: Lower Block Components for Figure 9-4.
Ref.
No.
1
2
3
4
5
6
36
Part
Number
GHC-400Y10
GHC-400Y7.5
GHC-401
GHC-402
GHC-403
GHC-404
GHC-405
GHC-406Y
Description
10t Lower Block Assembly (Includes Ref. Nos. 1-17)
7 1/2t Lower Block Assembly (Includes Ref. Nos. 1-17)
Lower Block Frame – Hook Beam
Hook
Thrust Bearing
Castle Nut
Spring Pin
Sheave Covers
Qty.
Req’d
1
1
1
1
1
1
1
4
“C” Frame: Lower Block Components for Figure 9-4.
Ref.
No.
7
8
9
10
11
12
13
14
15
16
17
Part
Number
GHC-407
GHC-408
GHC-409
GHC-410
GHC-411
GHC-412
GHC-413
GHC-414
GHC-415
GHC-416A
GHC-416B
GHC-417
Description
Flat Head Socket Cap Screws (1/4-20 x 1/2)
Sheave Pin
Sheaves
Ball Bearings
Internal Retaining Rings
External Retaining Rings
Socket Head Cap Screws (1/4-20 x 3 1/4 Long)
Hi-Collar Lockwashers (1/4)
Self-Locking Nuts (1/4-20)
Capacity Plates
10t Capacity Plates
7 1/2t Capacity Plates
Hex Washer Head Self-Tapping Screws (5/16-18 x 1/2)
Qty.
Req’d
4
1
2
2
2
2
8
8
8
2
4
NOTES
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__________________________________________________________________________________
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37
Figure 9-5. Upper Block Assembly.
“B” Frame: Upper Block Components for Figure 9-5.
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Part
Number
GHB-500
GHB-501
GHB-502
GHB-503
GHB-504
GHB-505
GHB-506
GHB-507
GHB-508
GHB-509
GHB-510
GHB-511
GHB-512
GHB-513
GHB-514
GHB-515
Description
“B” Frame Hoist Upper Block Assembly (Includes Ref. Nos. 1-10)
Upper Block Yoke
Key Plate
Hex Head Bolt (3/8-16 x 5/8)
Sheave Pin
Lockwasher (3/8)
Hex Head Bolt, Grade 5 (3/8-16 x 3)
Spacer Washer
Sheave
Ball Bearing
Internal Retaining Ring
Spacer Washer
Self-Locking Nut (3/8)
Yoke Pin
Cotter Pin
Flanged Bushing
Qty.
Req’d
1
1
1
2
1
4
2
2
1
1
1
6
2
1
2
1
“C” Frame: Upper Block Components for Figure 9-5.
Ref.
No.
1
2
3
4
5
6
7
8
9
38
Part
Number
GHC-500
GHC-501
GHC-502
GHC-503
GHC-504
GHC-505
GHC-506
GHC-507
GHC-508
GHC-509
Description
“C” Frame Hoist Upper Block Assembly (Includes Ref. Nos. 1-10)
Upper Block Yoke
Key Plate
Socket Head Cap Screw (3/8-16 x 3/4)
Sheave Pin
Lockwasher (3/8)
Socket Head Cap Screw (3/8-16 x 4)
Spacer Washer
Sheave
Ball Bearing
Qty.
Req’d
1
1
1
2
1
4
2
2
1
1
“C” Frame: Upper Block Components for Figure 9-5.
Ref.
No.
10
11
12
13
14
Part
Number
GHC-510
GHC-511
GHC-512
GHC-513
GHC-514
Description
Internal Retaining Ring
Spacer Washer
Self-Locking Nut (3/8)
Yoke Pin
Cotter Pin
Qty.
Req’d
1
4
2
1
2
NOTES
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Figure 9-6. “B” Frame Rope and Dead End Assembly.
Ref.
No.
1
2
3
4
5
6
7
8
9
“B” Frame: Rope and Dead End Assembly Components for Figure 9-6.
Part
Number
Description
GHB-600
“B” Frame Hoist Rope and Dead End Assembly
GHB-601
Dead End Yoke
GHB-602
Washer (1” Diameter, #18 Gauge)
GHB-603
External Retaining Ring
GHB-604
Dead End Swage Socket Pin
Wire Rope and Swaged End Assembly
GHB-605A
Rope Assembly for 25’ lift
GHB-605B
Rope Assembly for 40’ Lift
GHB-606
Dead End Pin
GHB-607
Key Plate
GHB-608
Socket Head Cap Screw (5/16-18 x 3/4)
GHB-609
Lockwasher (5/16)
Qty.
Req’d
1
4
2
1
1
1
1
1
1
39
Figure 9-7. “C” Frame: Rope and Dead End Assembly.
Ref.
No.
1
2
3
4
5
“C” Frame: Rope and Dead End Assembly Components for Figure 9-7.
Part
Number
Description
GHC-700
“C” Frame Hoist Rope and Dead End Assembly
GHC-701
Cotter Pin
GHC-702
Dead End Swaged Socket Pin
GHC-703
Flanged Bushing
GHC-704
Washer (1 1/2" Diameter, #10 Gauge)
Wire Rope and Swaged End Assembly
GHC-705A
Rope Assembly for 25’ lift
GHC-705B
Rope Assembly for 40’ Lift
Figure 9-8. Block Operated Limit Switch Assembly (“B” Frame shown).
40
Qty.
Req’d
2
1
2
2
1
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
“B” Frame Block Operated Limit Switch Components for figure 9-8.
Part
Number
Description
GHB-800 “B” Frame Hoist Limit Switch Assembly (Includes Ref. Nos. 1-16)
GHB-801 Limit Switch
GHB-802 Pan Head Machine Screw, Phillips (#10-32 x 1 1/4 Long)
GHB-803 Lockwasher (#10)
GHB-804 Limit Switch Bracket
GHB-805 Limit Switch Rod
GHB-806 Dowel Pin (3/16 Diameter x 1/2 Long)
GHB-807 S-Hook (1/2 Eye)
GHB-808 Coil Chain
GHB-809 Hex Head Bolt (1/4-20 x 1 3/4)
GHB-810 1/4 Diameter Flat Washer
GHB-811 Limit Switch Weight Half
GHB-812 Self-Locking Nut (1/4-20)
GHB-813 Hex Socket Head Cap Screw (#10-32)
GHB-814 Limit Switch Hub
GHB-815 Hex Head Bolt (1/4-20 x 1 1/4)
GHB-812 Self-Locking Nut (1/4-20)
“C” Frame Block Operated Limit Switch Components for Figure 9-8.
Part
Number
Description
GHC-800 “B” Frame Hoist Limit Switch Assembly (Includes Ref. Nos. 1-16)
GHC-801 Limit Switch
GHC-802 Pan Head Machine Screw, Phillips (#10-32 x 1 1/4 Long)
GHC-803 Lockwasher (#10)
GHC-804 Limit Switch Bracket
GHC-805 Limit Switch Rod
GHB-806 Dowel Pin (3/16 Diameter x 1/2 Long)
GHB-807 S-Hook (1/2 Eye)
GHB-808 Coil Chain
GHB-809 Hex Head Bolt (1/4-20 x 1 3/4)
GHB-810 1/4 Diameter Flat Washer
GHB-811 Limit Switch Weight Half
GHB-812 Self-Locking Nut (1/4-20)
GHB-813 Hex Socket Head Cap Screw (#10-32)
GHB-814 Limit Switch Hub
GHC-815 Hex Head Bolt (1/2-13 x 2)
GHC-816 Self-Locking Nut (1/2-13)
GHC-817 Lockwasher (1/2) *Not Shown*
GHC-818 Flat Washer (1/2) *Not Shown*
Qty.
Req’d
1
2
2
1
1
1
1
1
2
2
2
2
2
1
2
2
Qty.
Req’d
1
2
2
1
1
1
1
1
2
2
2
2
2
1
2
2
2
2
41
Figure 9-9. Rope Guide Assembly
“B” Frame Rope Guide Components for Figure 9-9.
Ref.
No.
1
2
3
4
5
6
7
8
9
Part
Number
GHB-900
GHB-901
GHB-902
GHB-903
GHB-904
GHB-905
GHB-906
GHB-907
GHB-908
GHB-909
Description
“B” Frame Rope Guide Assembly (Includes Ref. Nos. 1-9)
Rope Guide Frame (Machined)
Plastic Shroud
Extension Spring
Shoulder Bolt (1/4-20 x 1 1/2 Long, 5/16 Shoulder)
Compression Spring
Grease Fitting
Anti-Rotation Clip
Lockwasher (1/4)
Socket Head Cap Screw (1/4-20 x 3/4)
Qty.
Req’d
1
1
1
1
2
2
1
1
4
4
“C” Frame Rope Guide Components for Figure 9-9.
Ref.
No.
1
2
3
4
5
6
7
8
9
42
Part
Number
GHC-900
GHC-901
GHC-902
GHC-903
GHC-904
GHC-905
GHC-906
GHC-907
GHC-908
GHC-909
Description
“C” Frame Rope Guide Assembly (Includes Ref. Nos. 1-9)
Rope Guide Frame (Machined)
Plastic Shroud
Extension Spring
Shoulder Bolt (5/16-18 x 1 1/2 Long, 3/8 Shoulder)
Compression Spring
Grease Fitting
Anti-Rotation Clip
Lockwasher (1/4)
Socket Head Cap Screw (1/4-20 x 3/4)
Qty.
Req’d.
1
1
1
1
2
2
1
1
4
4
Figure 9-10. Hoist Motor Brake.
“B” Frame: Hoist Brake Components for Figure 9-10.
Ref.
No.
1
Part
Number
GHB-1001†
GHB-1002*
2
3
4
5
6
7
GHB-1008*
8
9
10
11
GHB-1012*
12
13
14
15
16
17
18
19
20
21
GHB-1016
GHB-1017*
GHB-1019
GHB-1020
GHB-1021A
GHB-1021B
GHB-1021C
22
Description
Brake Disc
Brake Fan Kit (Includes items 2 thru 7)
Fan
External Retaining Rings (Fan)
External Retaining Ring (Fan Hub)
Fan Hub
Key (Hub)
Key (Fan)
Brake Hub Kit (Includes items 8 thru 11)
External Retaining Ring (Brake Hub)
Spacer
Key (Brake Hub)
Brake Hub
Brake Hardware Kit (Includes items 12 thru 15)
Hollow Core Bolts
O-Ring
Bolts (Brake Mounting)
Springs
Magnet Body (Includes GHB-1012 Hardware Kit)
Fan Shroud Kit Includes items 17 and 18)
Fan Shroud
Bolt (Brake and Fan Shroud)
Brake End Bell Assembly for 7.5/1.25 HP Motor
Gearcase End Bell Assembly for 7.5/1.25 Motor (Not Shown)
Rotor Assembly for 7.5/1.25 HP Motor (Not Shown)
Qty.
Req’d.
1
1
1
2
1
1
1
1
1
1
1
1
1
1
3
1
3
3
1
1
4
1
1
1
1
230 volt, 3-phase, 60 Hertz
460 volt, 3-phase, 60 Hertz
575 volt, 3-phase, 60 Hertz
Stator Assembly for 7.5/1.25 HP Motor (Not Shown)
GHB-1022A 230 volt, 3-phase, 60 Hertz
GHB-1022B 460 volt, 3-phase, 60 Hertz
GHB-1022C 575 volt, 3-phase, 60 Hertz
† Recommended Spare Part
*Duplicate part numbers indicate parts only sold together as a kit.
1
43
Figure 9-10. Hoist Motor Brake.
“C” Frame: Hoist Brake Components for Figure 9-10.
Ref.
No.
1
Part
Number
GHC-1001†
GHC-1002*
2
3
4
5
6
7
GHC-1008*
8
9
10
11
GHC-1012*
12
13
14
15
16
17
18
19
20
21
GHC-1016
GHC-1017*
GHC-1019
GHC-1020
GHC-1021A
GHC-1021B
GHC-1021C
22
Description
Brake Disc
Brake Fan Kit (Includes items 2,4 & 7)
Fan
N/A
External Retaining Ring (Fan Hub)
N/A
N/A
Key (Fan)
Brake Hub Kit (Includes items 8 thru 11)
External Retaining Ring (Brake Hub)
Spacer
Key (Brake Hub)
Brake Hub
Brake Hardware Kit (Includes items 12 thru 15)
Hollow Core Bolts
O-Ring
Bolts (Brake Mounting)
Springs
Magnet Body (Includes GHC-1012 Hardware Kit)
Fan Shroud Kit Includes items 17 and 18)
Fan Shroud
Bolt (Brake and Fan Shroud)
Brake End Bell Assembly for 15 HP Motor
Gearcase End Bell Assembly for 15 HP Motor (Not Shown)
Rotor Assembly for 15 HP Motor (Not Shown)
1
1
1
1
1
1
1
1
3
1
3
3
1
1
4
1
1
1
1
230 volt, 3-phase, 60 Hertz
460 volt, 3-phase, 60 Hertz
575 volt, 3-phase, 60 Hertz
Stator Assembly for 15 HP Motor (Not Shown)
GHC-1022A 230 volt, 3-phase, 60 Hertz
GHC-1022B 460 volt, 3-phase, 60 Hertz
GHC-1022C 575 volt, 3-phase, 60 Hertz
† Recommended Spare Part
* Duplicate part numbers indicate parts only sold together as a kit.
44
Qty.
Req’d.
1
1
1
1
Figure 9-11. “B” Frame Trolley Drive Gear Reducer.
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
“B” Frame Trolley Drive Gear Reducer Components for Figure 9-11.
Part
Number
Description
GHB-309A
“B” Gear Reducer, 30:1 Ratio – 50 FPM (Includes Ref. Nos. 1-25)
GHB-309B
“B” Gear Reducer, 20:1 Ratio – 75 FPM (Includes Ref. Nos. 1-25)
GHB-1101
Housing
GHB-1102
High Speed Bearing
GHB-1103
Slow Speed Bearing – Cone
GHB-1104
Slow Speed Bearing – Cup
GHB-1105
High Speed Spacer
GHB-1106
High Speed Ring
GHB-1107
High Speed Retaining Ring
GHB-1108
High Speed Cap (Closed)
GHB-1109
High Speed Gasket
GHB-1110
Slow Speed Gasket
GHB-1111
Slow Speed Key
GHB-1112
Pipe Plug, Socket Head, Coated and Plated 1/8-27 NPTF
GHB-1113
Vent Shield
GHB-1114
Drive Pin (#4 x 3/16 Stainless Steel)
GHB-1115
Slow Speed Cover (Standard)
GHB-1116
Slow Speed Cover (Special)
GHB-1117
Hex Head Cap Screw 5/16-18 x 7/8 Long Coated with Polylock
GHB-1118
High Speed Seal
GHB-1119
Slow Speed Seal
GHB-1120
Motor Adapter
GHB-1121
Hex Head Cap Screw 5/16-18 x 1 1/4 Long Coated with Polylock
GHB-1122
Hollow Slow Speed Shaft with Hex
Slow Speed Gear
GHB-1123A Slow Speed Gear for 20:1 Ratio
GHB-1123B Slow Speed Gear for 30:1 Ratio
High Speed Worm on Shaft
GHB-1124A High Speed Worm on Shaft for 20:1 Ratio
GHB-1124B High Speed Worm on Shaft for 30:1 Ratio
GHB-1125
Nameplate
Qty.
Req’d
1
1
1
1
2
2
1
1
1
1
2
2
1
6
1
2
1
4
12
1
2
1
4
1
1
1
1
45
Figure 9-12. “C” Frame Trolley Drive Gear Reducer.
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
46
“C” Frame Trolley Drive Gear Reducer Components for Figure 9-12.
Part
Number
Description
GHC-309A
“C” Gear Reducer, 30:1 Ratio – 50 FPM (Includes Ref. Nos. 1-25)
GHC-309B
“C” Gear Reducer, 20:1 Ratio – 75 FPM (Includes Ref. Nos. 1-25)
GHC-1201
Housing
GHC-1202
High Speed Bearing
GHC-1203
Slow Speed Bearing – Cone
GHC-1204
Slow Speed Bearing – Cup
GHC-1205
High Speed Spacer
GHC-1206
High Speed Ring
GHC-1207
High Speed Retaining Ring
GHC-1208
High Speed Cap Closed
GHC-1209
High Speed Gasket
GHC-1210
Slow Speed Gasket
GHC-1211
Slow Speed Key
GHC-1212
Pipe Plug, Socket Head, Coated and Plated 1/8-27 NPTF
GHC-1213
Vent Shield
GHC-1214
Drive Pin (#4 x 3/16 Stainless Steel)
GHC-1215
Slow Speed Cover (Standard)
GHC-1216
Slow Speed Cover (Special)
GHC-1217
Hex Head Cap Screw 5/16-18 x 7/8 Long Coated with Polylock
GHC-1218
High Speed Seal
GHC-1219
Slow Speed Seal
GHC-1220
Motor Adapter
GHC-1221
Hex Head Cap Screw 5/16-18 x 1 1/4 Long Coated with Polylock
GHC-1222
Hollow Slow Speed Shaft with Hex
Slow Speed Gear
GHC-1223A Slow Speed Gear for 20:1 Ratio
GHC-1223B Slow Speed Gear for 30:1 Ratio
High Speed Worm on Shaft
GHC-1224A High Speed Worm on Shaft for 20:1 Ratio
GHC-1224B High Speed Worm on Shaft for 30:1 Ratio
GHC-1225
Nameplate
Qty.
Req’d.
1
1
1
1
2
2
1
1
1
1
2
2
1
6
1
2
1
4
12
1
2
1
4
1
1
1
1
NOTES
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47
Recommended Spare Parts
Certain Parts of your hoist will, in time, require replacement under normal wear conditions. It is suggested that the
following parts be purchased for your hoist as spares for future use.
One Brake Friction Disc
One Brake Module
One Set of Contactors
One Transformer
One Wire Rope Assembly
Note: When ordering parts 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 station. For the location of your nearest
repair station, write:
414 West Broadway Avenue
P.O. Box 0769
Muskegon, Michigan 49443-0769
Phone: (800) 999-6318
Fax: (800) 766-0223
WARRANTY
WARRANTY AND LIMITATION OF REMEDY AND LIABILITY
A. Seller warrants that its products and parts, when shipped,
and its work (including installation, construction and start-up),
when performed, will meet applicable specifications, will be of
good quality and will be free from defects in material and
workmanship. All claims for defective products or parts under
this warranty must be made in writing immediately upon
discovery and, in any event, within two (2) years (or as otherwise
provided) from shipment of the applicable item unless Seller
specifically assumes installation, construction or start-up
responsibility. All claims for defective products or parts when
Seller specifically assumes installation, construction or start-up
responsibility, and all claims for defective work must be made in
writing immediately upon discovery and, in any event, within two
(2) years (or as otherwise provided) from completion of the
applicable work by Seller, provided, however, all claims for
defective products and parts must be made in writing no later
than thirty (30) months after shipment. Defective items must be
held for Seller’s inspection and returned to the original f.o.b.
point upon request. THE FOREGOING IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES WHATSOEVER,
EXPRESS, IMPLIED AND STATUTORY, INCLUDING,
WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS.
48
B. Upon Buyer’s submission of a claim as provided above and its
substantiation, Seller shall, at its option, either (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
Seller’s products have been dismantled prior to submission to Seller for
warranty inspection.
D. The foregoing is Seller’s only obligation and Buyer’s exclusive
remedy for breach of warranty, and is Buyer’s exclusive remedy
hereunder by way of breach of contract, tort, strict liability or
otherwise. In no event shall Buyer be entitled to or Seller liable for
incidental or consequential damages. Any action for breach of this
warranty must be commenced within two (2) years (or as otherwise
provided) after the cause of action has accrued.
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