Global Industrial 298625 User Manual
Air Chain Hoist
User Manual
Model no. 298625, 298626, 298627
Table of Contents
General Data pg. 2
Safety Information pg. 4
Installation & Set up pg. 4
Operation pg. 6
Maintenance & Inspection pg. 7
Disassembly & Reassembly
• Disassembly pg. 8
• Reassembly pg. 11
• Testing Hoist pg. 14
• Pendant Throttle Control Assembly pg. 15
Inspection Schedule & Maintenance Report pg. 16
Parts List pg. 17
Troubleshooting pg. 25
2
Global Industrial Hoists are high quality hoists made with a tough, compact housing for easy
operation, transportation and storage. These are made for long lasting use in industrial
environments. Very ecient with dierent speed controls and ability to lift dierent load
capacities.
PLEASE READ THESE INSTRUCTIONS COMPLETELY AND SAVE FOR REFERENCE. UPON
RECEIVING, INSPECT THE UNIT FOR ANY DAMAGE OR MISSING PARTS. IF DAMAGE IS
EVIDENT, NOTIFY THE CARRIER IMMEDIATELY TO FILE A CLAIM. THESE PRODUCTS MUST
BE HANDLED WITH CAUTION BY TRAINED OPERATORS WITH PROPER SAFETY GEAR AND
EQUIPMENT. FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN SERIOUS INJURY.
PLEASE CONTACT GLOBAL INDUSTRIAL CUSTOMER SERVICE (1-800-645-2986) FOR ANY
ISSUES OR REPLACEMENT PARTS.
GENERAL DATA:
• Rated Loads: 300 lb, 500 lb, 1000 lb.
• Type: Link Chain
• Air Pressure Recommended: 90 PSI
• Air Consumption: 48 SCFM at 90 PSI
• Net Weight (Basic Hoist): 36 lbs
• Suspension: Hook
• Control: Pendant Throttle
• Air Inlet Size: 3/8 NPTF
• Air Supply Hose: 1/2 I.D. min
• Air Exhaust: 1/2 NPTF
Lifting
Model
298625 300 46 84 65 10
Capacity
[lb.]
Wt.
[lb.]
Speed
Max
[fpm]
Lowering
Speed Max
[fpm]
Image 1
Lifting
Height
[Ft.]
298626 500 46 65 95 10
298627 1000 46 45 120 10
Hoist Dimensions
3
Dimensions [inches]
Ref. 298625 298626 298627
A 15.25 15.25 15.25
B 10.25 10.25 10.25
C 4.75 4.75 4.75
D 1.75 1.75 1.75
E 7.0625 7.0625 7.0625
F 5.0625 5.0625 5.0625
G 0.9375 0.9375 0.9375
H 2.1875 2.1875 2.1875
I 5.6875 5.6875 5.6875
1
U D
1 3
2
2
3
1/2TON
4
SAFETY INFORMATION
PLEASE READ THOROUGHLY AND CAREFULLY. IMPROPER OPERATION OR FAILURE TO
FOLLOW THESE PRECAUTIONS COULD RESULT IN SERIOUS INJURY.
DO NOT operate a damaged hoist.
DO NOT modify the hoist in any way.
DO NOT lift more than max capacity.
DO NOT lift over people, or transport people.
DO NOT wrap chain around load.
DO NOT apply the load to the tip of the hook or the hook latch.
DO NOT operate beyond limits of the load chain travel.
DO NOT leave load supported by the hoist unattended.
DO NOT allow the load chain or hook to be used as an electrical or welding ground.
DO NOT use the hoist’s overload limiting clutch to measure load.
DO NOT use the hoist’s limit switches as routine operating stops.
ALWAYS make sure people remain clear during use.
ALWAYS make sure the load is centered under hoist.
ALWAYS make sure the hoist is securely attached to a suitable support.
ALWAYS take up slack carefully – make sure load is balanced.
ALWAYS stop immediately if the hoist malfunctions and inspect carefully.
ALWAYS check brake function by tightening the hoist prior to each lift operation.
ALWAYS use hook latches and make sure they are closed.
ALWAYS make sure the load is free to move and will clear all obstructions.
ALWAYS avoid swinging the load or hook.
ALWAYS make sure hook travel is in the same direction as shown on the controls.
ALWAYS inspect the hoist regularly and replace damage or worn parts.
ALWAYS lubricate load chain per instructions in this manual.
INSTALLATION & SET UP
Suspending/Mounting the Hoist to Supporting Structure:
1. The structure used to support the hoist must have a load rating equal to or greater than
that of the hoist.
2. The supporting structure must be able to eectively suspend both the weight of the hoist
and the rated load.
3. Proper installation requires that the upper hook is seated in the center of the hook saddle
and the spring safety latch is completely closed.
4. The hoist must be in the same straight line with the load to avoid side forces.
5. If trolley is mounted to a beam, make sure the beam has end stops to prevent the trolley
running o the end of the beam, causing serious injury.
5
Connecting Hoist to Air Source:
1. Connect hoist to a ltered and lubricated air source with a least 1/2” I.D (see image 2)
2. If the hoist is connected with trolley, the hose must be long enough to reach from air
source.
3. A lter and lubricator unit must be installed between air source and air hose connected to
the hoist to assure the air hoist will receive consistent, clean air ow. (see image 3)
4. DO NOT use multi-viscosity, detergent-type engine oil. USE air hoist motor oil or 10W
machine oil (approx. viscosity 150 SSU @ 100 deg. F). The lubrication rate for air supply
should be 1 drop for every 50-75 cu. Ft. Recommended air pressure is 90 psi.
Speed Adjustments:
1. For lifting speed, the maximum is pre-set. The lowering speed is adjusted to an average
setting between minimum and maximum.
2. To adjust speed, turn the adjusting screw shown in image 4. The speed will be max or min
when the head slots on the adjusting screws are horizontal. Rotate screws 180 deg. In
either direction for full range of speed adjustment.
3. NOTE the max lowering speed with rated load is very high. Adjusting screws should not
be adjusted beyond outer surface of hoist housing.
Image 2
Image 3
Image 4
6
OPERATION
The operator should be a trained professional and is responsible for safe use with these
hoists. They must follow the safety guidelines mentioned on page 5 to prevent damage or
injury.
1. Inspect all connections between side hoist frame, hooks, and structural support. Check
all parts (brake, hoist, chain, pins) to make sure there is no damage/distortion. DO NOT
use if there is any damage or distortion. Chain should be lubricated.
2. DO NOT lift more than rated capacity. Overloading can cause deformation or breakage in
the chain/hook and can cause serious injury and damage.
3. Guide load so that it is under control at all times and clear of any personnel.
4. Make sure the hoist is properly mounted to a support with proper air pressure applied.
5. This hoist is equipped with a pendant throttle control with lever type control valve handle
suspended from control cylinders shown in image 5.
6. On the pendant throttle control, depress the throttle lever marked “UP” to lift the load.
7. Depress the throttle lever marked “DOWN” to lower the load.
8. Release the lever to stop either lifting or lowering.
9. The lifting/lowering speed varies by the position of the throttle valve lever being
depressed.
10. The strain cable is designed for pulling trolley suspended hoist when empty or lightly
loaded.
11. Push on load or load chain to traverse heavy
loads. Push on one corner of the load to pivot.
The lower hook will swivel 360 deg. to allow load
to swing to desired position. The upper hook may
rotate so that the hoist will be swung by the side
pulls to face the load, reducing side thrust.
12. Theses hoists are equipped with chain stops and
limit blocks to prevent over travel when lifting or
lowering the load. The control lever will be tripped
by the lower block when it reaches highest
position. The control lever will be tripped by the
tail end of the load chain when it reaches the
lowest position, see images 6 and 7. The control
lever is connected to a shaft which controls air
pressure into the air motor by inlet valve. These
limit stops are only designed for preventive
measures and not to be used as a regular device.
Image 6
Image 5
Image 7
7
MAINTENANCE & INSPECTION
Periodic maintenance checks on the hoist components are recommended to make sure
there is no damage. Do not attempt to repair defective parts. Only Global approved that
meet specications for strength and dimensions must be used. Please contact Global
Industrial Customer Service (1-800-645-2986) for replacement chains, hooks, etc.
1. Inspect the chain with load in both chain travel directions. The chain should feed
smoothly into and away from the sprocket. If there are any binds or jumps, apply
lubrication and clean the chain. Check for deformation, distortion or damage to any of the
links at any connection points.
2. Greatest wear usually occurs at high and low lift points. Chain must be replaced before
the case is worn past 0.015” deep as shown in image 8.
3. Check the hooks for bending, twisting or distortion. The hook must be replaced if it is bent
more than the dimension shown in image 9.
4. Check all hook latches, trolley parts, springs, and load bearing components.
Apply lubricant if necessary and replace any parts as necessary.
5. Check brake function when the hoist is operating. The brake needs adjusting if the load
drifts down before the motor starts. To adjust brake, use a hex key through the hole in
the brake cover, and turn counterclockwise to tighten brake or clockwise to loosen brake.
Lubrication
Regular lubrication enables the hoist to operate at high level with long-lasting service.
1. Air Line Lubricator – It is important to monitor the lubricator as it provides lubrication for
the control valve and motor. ONLY motor oil or machine oil (10W) should be used.
2. Load & Coil Chains – Keep chains clean regularly. Small amounts of lubrication routinely
will increase the performance and life of the chains. Avoid letting the chains run dry.
3. Upper Hook & Control Shaft - Small amounts of SAE60 can be used on the upper hook
shank and the control shaft at bearing points.
Image 9
Image 8
Hook Throat Opening
Hoist Rated
Load (lb.)
300 1-1/8” 1-9/32”
500 1-1/8” 1-9/32”
1000 1-1/8” 1-9/32”
Normal
Opening
Replace Hook
if Opening is
Greater Than
8
DISASSEMBLY & REASSEMBLY
For ease of disassembly, the following disassembly steps may not, where conditions permit,
be completed before hoist is removed from its overhead suspension or disconnected from
its air supply. If the hoist is in use, remove the chain container. Remove lower block and load
chain assembly.
Handle the parts with care when disassembling and reassembling the hoist. Carefully apply
pressure evenly when removing and installing parts with press ts. On ball bearing, apply
pressure to the side of the inner or outer race, whichever is adjacent to the mating part. Apply
a thin lm of oil to parts having a tight t when installed.
Diassembly
Removal of Hoist from Overhead Suspension
1. Turn o source of air
2. Operate control to discharge the air from the hoist.
3. Disconnect air hose at inlet swivel
4. Remove hoist from overhead suspension
Removal of Lower Block and Load Chain Assembly
1. Disconnect end of load chain from the tail end. Anchor the side of the hoist frame on
models with single reeved load chain (300, 500, and 1000lb). Remove socket head cap
screw, holding end link to tail end anchor on coil chain. Run the chain out of hoist by
operating control in “lowering” direction when the hoist is connected to an air source. The
chain can be pulled out of the hoist when it is connected to an air source.
2. Run chain out of hoist by operating it in “lowering” direction, and disconnect opposite
end of chain from anchor at side of upper suspension bracket on models with double
reeved chains (2000lb,).
3. Separate load chain from lower block assembly in single reeved 300, 500, and 1000 lb.
models. Drive out small pin securing lower block pin in lower block and push out block pin
to release chain.
4. Lower blocks (300, 500, and 1000lb.) are of a pinned construction, permitting
individual replacement of body, thrust bearing, or hook. To disassemble, drive spring pin
from hook nut: Remove the pin, hold hook nut from turning with drift punch and rotate
hook to unscrew it from nut. Separate hook, bearing shield, needle bearing and tow thrust
washers from body. Hook and nut are drilled at assembly. And they are replaced only as
an assembly.
5. The lower block assembly is disassembled by removing the socket head screws and nuts
holding the body halves together on 2000lb. (double reeved) models.
Removal of Brake Cover, Control Lever and Load Brake
1. For convenience, disconnect control hoses from air cylinders, open strain cable “S” hook
at eye bolt on throttle housing and remove pendant throttle control assembly from hoist on
pendant throttle control. See “Disassembly and Reassembly”, page 8, for disassembly and
reassembly of pendant throttle control.
2. Take out the two screws securing the brake housing cover to frame and lift o the cover.
3. To remove control lever and shaft, drive spring pins from control lever (Image 10) and valve
shifter at end of shaft using a drift punch. Lightly tap valve shifter end of shaft and withdraw
shaft by pulling on brake cam end (Image 11). Valve shifter and control lever will fall free as
shaft is withdrawn.
4. Carefully pry brake spring up evenly with a
screwdriver until spring is about halfway o
to remove it. Using brake spring spreader
(Image 12), take out spring from brake arms.
5. Take out brake shoes. Make sure not to lose
steel fulcrum balls.
6. Take out steel balls from recesses sides of
upper brake.
9
Image 10 Driving spring in from
control lever and shaft
Image 12
Image 11 Removing control shaft
Removing control head assembly
1. Take out six socket head screws and lift assembly from frame to remove control head
assembly.
2. Lift muer and screen from recess in control head housing.
3. Take out control cylinder assemblies from each side of control head housing (Image 20).
Then remove valve springs, spring guides and “O” ring seals from valve bore at each side
of housing.
4. The throttle valve is retained in the control head by the valve shifter pin. The pin is
assembled with Loctite on the threads and should not be removed during routine
servicing. Use a hex key to remove pin from bottom of throttle valve if valve is to be
removed (See Image 19). Then remove the valve from bushing in housing. The throttle
valve bushing is pressed into place and honed to provide a .0001 to .0003-inch clearance
with valve. The housing and bushing assembly should be replaced along with the valve if
bushing is scored, worn, or otherwise damaged.
5. Take out air inlet swivel body and bushing from
top of housing. Retain bushing gasket for reuse.
Pull strainer screen from housing bore.
6. Take out retaining ring from bottom of swivel
body and pull o bushing. Take out “O” ring seal
from its groove in bushing.
7. Remove cylinder lock ring to disassemble control cylinder (pendant throttle control models).
Cylinder and cap will come o with lock ring. Lift
out spring. Then remove piston and seal
assembly from cylinder. Piston shaft “O” ring
seal and retainer washer will drop out as piston
is removed.
Image 13 Removing control head
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