Yale 11353395D User Manual
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OPERATION, SERVICE & PARTS MANUAL
Before installing hoist, fill in the
information below. Refer to the Hois
and Motor data plates.
Model No. __________________
Serial No. __________________
Purchase Date __________________
Voltage __________________
Rated Load __________________
GLOBAL KING
TM
WIRE ROPE HOISTS
RATED THRU 10 METRIC TONNE
Follow all instructions and warnings
for inspectin
operating this hoist. The use of an
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 shoul
ecome 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.
, maintaining, and
®
LIFT-TECH INTERNATI ONAL, Di vision of
®
COLUMBUS McKI NNON CORPORATI ON
MUSKEGON, MI 49443-0769
JANUARY, 2002 COPYRIGHT 2001, LIFT-TECH INTERNATIONAL, INC. PARTNO. 11353395D
PRINTED IN U.S.A.
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 ………………………………………………………………………………………………. 4
Paragraph 2-2 Suspending Hoist …………………………………………………………………………………… 4
Paragraph 2-3 Connecting Hoist to Electrical Service …………………………………………………………… 5
Paragraph 2-4 Pre-Operation Checks ……………………………………………………………………………… 5
.
SECTION III OPERATION
Paragraph 3-1 General ………………………………………………………………………………………………. 6
Paragraph 3-2 Push Button Operation ……………………………………………………….……………………. 6
Paragraph 3-3 Operating Precautions ……………………………………………………………………………… 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 ……………………………………………………………………………………………… 11
Paragraph 5-2 Inspection of Lower Block ………………………………………………………………………… 14
Paragraph 5-3 Inspection of Upper Block …………………………………………………………………………. 14
Paragraph 5-4 Inspection of Electrical Controls ………………………………………………………………… 14
Paragraph 5-5 Inspection of Rope Guide …………………………………………………………………………. 15
Paragraph 5-6 Rope Inspection, Replacement & Maintenance ………………………………………………… 15
Paragraph 5-7 Rope Reeving ………………………………………………………………………………………. 16
Paragraph 5-8 Inspection of Rope Drum & Shaft ………………………………………………………………… 18
Paragraph 5-9 Inspection of Hoist Gearing ……………………………………………………………………… 18
Paragraph 5-10 Inspection of Motor Brake and Actuating Mechanism ………………………………………… 20
Paragraph 5-11 Inspection of Traverse Drive …………………………………………………………………….. 22
Paragraph 5-12 Inspection of Block Operated Limit Switch …………………………………………………….. 22
Paragraph 5-13 Testing Hoist ……………………………………………………………………………………… 23
SECTION VI TROUBLESHOOTING CHART …………………………………………………………………………. 24
SECTION VII ADJUSTMENTS
Paragraph 7-1 Motor Brake Adjustment …………………………………………………………………………… 25
Paragraph 7-2 Block Operated Limit Switch Adjustment ………………………………………………………… 25
Paragraph 7-3 Geared Rotary Limit Switch Adjustment ………………………………………………………… 25
Paragraph 7-4 Shortening of Push Button Cable ………………………………………………………………… 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.
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.
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.
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.
4
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
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.
: For trolleys which
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
connections to collectors or power cord shall
be made only by qualified journeyman
electricians.
, including
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.
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.
(Figure 2-1) The gearcase
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.
(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
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.
connection. Do not change
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
(2) A geared rotary type upper and lower limit
switch is also provided as standard. This
switch is adjustable and although roughly
preset by the factory, it should be adjusted
at time of installation to the desired high
and low limits of lower block travel. Refer
to SECTION VII, Paragraph 7-3.
d) Check Lower Block and Hoisting Cable.
Depress “DOWN” push button and run lower
block to its lowest position. No less than two
wraps shall remain on the drum with the
loaded hook in its lowest position. Also
check to see that the lower block and rope
do not twist excessively. If it does twist to
the extent that two ropes rub against each
other, disengage the swaged rope end from
the frame anchor and twist the rope four or
five turns in a direction opposite to that
which the block turns. Reconnect rope to the
frame anchor, holding firmly to eliminate
rope twisting back to its original position.
Operate hoist up and down a few times. If
lower block still rotates excessively repeat
process until twisting is corrected.
e) Lubricate Hoisting 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.
For longer cable
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.
b) DO be familiar with hoist operating controls,
procedures, and warnings.
c) DO make sure hook travel is in the same
direction as shown on the controls. If
opposite direction occurs, see Pre-Operation
Checks, Section II, Paragraph 2-4.b.
d) DO make sure hoist limit switches function
properly.
e) DO maintain firm footing when operating
hoist.
f) DO make sure that the load slings or other
approved single attachments are properly
sized and seated in the hook saddle.
g) DO make sure that the hook latch is closed
and not supporting the load.
h) DO make sure that load is free to move and
will clear all obstructions.
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 recom-
mended 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.
v) DO NOT use the hoist with twisted, kinked,
damaged, or worn wire rope.
w) DO NOT lift a load unless wire rope is
properly seated in its groove(s).
x) DO NOT use wire rope as a sling or wrap
rope around the load.
y) DO NOT lift a load if any binding prevents
equal loading on all supporting ropes.
z) DO NOT apply the load to the tip of the
hook.
aa) DO NOT operate unless load is centered
under hoist.
bb) DO NOT allow your attention to be diverted
from operating the hoist.
cc) DO NOT operate the hoist beyond limits of
wire rope travel.
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 un-
attended 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) DO provide supporting structure that has an
appropriate design factor based on the load
rating and dead weight of the hoist. If in
8
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.
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
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) 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.
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.
FIGURE 4-2. Gearcase Width Illustration.
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
following actions are required:
(1) Periodically re-grease with MPG
(Paragraph 4-7) using the grease fitting
provided (Figure 5-3, Item 6).
(2) Every 6 months the rope guide should be
removed per Section V, Paragraph 5-5,
cleaned and inspected. When the rope
guide is reassembled, the rope guide
should be thoroughly greased with MPG
(Paragraph 4-7) and the hoist run up and
down to lubricate both the drum and the
wire rope.
. Once properly installed the
NOTES
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9
4-7. LUBRICANT SPECIFICATIONS. AMBIENT TEMPERATURE
GCOH
Gear Case Oil.
Hoist Gear Case.
SG
Spline Grease
WG
Wheel Gear and
Pinion Grease
CL
Cable Lubricant.
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.
AGMA Lubricant No. 6 No. 7 EP No. 7
Viscosity @ 100° F
Viscosity Index 154 95 158
Pour Point
Mobil
Oil Corp. Mobil
Shell
Oil Co. Omala RL 320 Omala
Texaco
ASTM D217 Worked
Dropping Point
Base Lithium
Mobil
Viscosity @ 100° F
Mobil Oil Corp. ---------------------------Mobiltac 375 NC--------------------------
Texaco Inc. ---------------------------------Crater H --------------------------------
Amoco Oil Co. ----------------------------Amovis 5-X ----------------------------Mobil Oil Corp. -------------------------Mobilarma 798---------------------------Sun Oil Co. -------------------Sunoco Wire Rope Lubricant----------------Texaco
Viscosity @ 100° F
Viscosity Index 60 Min. 60 Min.
Pour Point
Amoco Oil Co. Rykon Oil 46 American Industrial Oil
Mobil Oil Corp. ----------------------Mobil DTE Oil Heavy-------------------------
Shell Oil Co. Rotella 10W Rotella 10W-30
Sun Oil Co. Sunvis 932 Sunvis 968
Texaco
6ASTM Worked
Penetration
Dropping Point
Base Lithium Lithium
Amoco Oil Co. Amolith Grease 1 EP Amolith Grease No. 2 EP
Mobil Oil Corp. Mobilith AW 1 Mobilith AW 2
Shell Oil Co.
Sun Oil Co. Prestige 741 EP Sunoco Multipurpose 2 EP
Texaco
Inc. Pinnacle 320 Meropa 460 Pinnacle 460
NLGI Grease No. 1
Penetration
Oil Corp. ---------------------------Mobilux EP 111--------------------------
No Specification
Inc. Crater A Texclad 2
AGMA Lubricant No. 1 No. 2
Inc. Rando Oil 46 Rando Oil 68
NLGI Grease No. 1 No. 2
Inc. Multifak EP 1 Multifak EP 2
-20° to 50°F 50° to 125°F 125° to 250°F
(-29° to +10°C) (10° to 52°C) (52° to 121°C)
1335 - 1632 SUS 1919 - 2346 SUS 1919 - 2346 SUS
-40°F 20°F -37°F
SHC 632 Mobilgear 634 Mobil SHC 634
460 Omala RL 460
310 - 340
320°F (160°C)
25,000 SUS (contains diluent)
193 - 235 SUS 284 - 347 SUS
-20°F (-29°C) 10°F (-12°C)
68
310 - 340 265 – 295
360°F (182°C) 360°F (182°C)
-------------------------Retinax LC-----------------------------------
10
4-7. LUBRICANT SPECIFICATIONS
CONT’D.
GCOT
Gear Case
Oil.
Traverse
Gear Case.
AGMA Lubricant No. 5S No. 8 Compounded
ISO Viscosity Grade 220 680
American Lubricants
Mobil Oil Corp. Mobil SHC
Shell Oil Co. Omala RL
Fiske Brothers
Texaco
Inc. Pinnacle
-20° to 50°F 50° to 100°F 100° to 250°F
(-29° to
+10°C)
SHC 90W AGMA #8 Gear Oil
630
220
SPO-MG SPO-288
220
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
AMBIENT TEMPERATURE
(10° to 38°C) (38° to 121°C)
Refer to Yale Hoist
Field Service
Department for
Extra Hecla Super
Valvata J 680
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.
Gearcase Operating
Temperatures above
200°F.
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
(`). 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
column with a check mark
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 INSPECTION OR MAINTENANCE
Daily or start of
each shift (visual)
1 Month * HOIST CABLE – Inspect per Paragraph 5-6 and lubricate per Paragraph 4-3.
1-3 Months * ELECTRICAL CONTROLS – Inspect per Paragraph 5-4. Check hoist gearcase oil level
6 Months * LOWER BLOCK –Inspect per Paragraph 5-2.
6 Months or 500750 hours “on”
time
Annually * Motor brake and actuating mechanisms. Inspect and adjust per Paragraph 5-10.
5 years elapsed
time or 5000
hours “on” time
* 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.
– add oil as required per Paragraph 4-2.e.
* 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.
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.
12
INSPECTION SCHEDULE AND MAINTENANCE REPORT
_
_
_
HOIST SERIAL NO. (Manufacturer's) ___________________
RATED LOAD ____________________ LOCATION IN PLANT
TYPE ___________________________ THIS INSPECTION IS: MONTHLY
VOLTAGE _______________________ SEMI-ANNUAL
*Recom-
COMPONENT, UNIT OR PART
and location
COMPONENT,
UNIT OR PART
Motor
Motor Br ake
Couplings
Gears, Shafts, & Bearings
Upper Block
Lower Block
Hook & Throat Opening
HOIST
Hoist Rope
Rope Drum
Rope Guide
Guards
Limit Switches
Pushbutton
mended
Inspection
Interval
MONTHLY
SEMI-ANNUAL
(Check column best indicating condition when part or
unit is inspected. Use note column to the right if
condition is not listed below.)
GOOD
ANNUAL
X
REQUIRED
ADJUSTMENT
REPAIR REQUIRED
CUSTOMER CRANE IDENTITY NO. __________________________
INSPECTED BY:_____________________________
CONDITION
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. W hen
REQUIRED
REPLACEMENT
(Loose Parts or Wires)
REQUIRED
LUBRICATION
Rust or Corrosion)
(Worn or Damaged)
(Low Oil or Grease,
corrective action is completed, describe and note date
CLEANING OR
in this column.)
PAINTING REQUIRED
Record Hook Throat Opening:
ANNUAL
DATE:_________
DATE
CONTROL
STATION OR
PUSHBUTTON
Wiring
Motor
Brake (when so equipped)
Couplings
Gears, Shafts, & Bearings
Frame
Wheel s
TROLLEY
Bumpers
Guards
Conductors
Collectors
Hoist
Trolley
RESISTORS
Monorail Joints
Monorail
Main Conductors
RUNWAYSMISC. LOCATION
Main Collectors
General Condition
Load Attachment Chains
Rope Slings & Connections
Change Gearcase Lubricant
Grounding Faults
* See text for DAILY & WEEKLY REQUIREMENTS.
INSPECTION INTERVAL.
Typical Inspection Schedule and Maintenance Report form. 12375gwr
User must adjust Inspection Interval and components to suit his individual conditions and usage.
SIGNED & DATED REPORT - OSHA.
X MAGNETIC PARTICLE OR EQUIVALENT EXAMINATION REQUIRED.
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.
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.
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.
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.
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.
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.
14
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.
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
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.
. The rope guide is intended to help
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
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.
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.
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 and inspect all
components.
(6) Follow steps in reverse to reassemble. Be
sure to re-grease the rope guide with MPG
(Paragraph 4-7) after assembling.
5-6. ROPE INSPECTION, MAINTENANCE AND
REPLACEMENT.
. Refer to Figure 5-3. For further
WARNING
WARNING
Figure 5-3. Rope Guide Assembly.
WARNING
Wire Rope improperly handled or
abused can create a SAFETY HAZARD.
Read and comply with inspection,
maintenance and replacement
information given herein.
a) Inspection.
of the most important components requiring
frequent inspection and maintenance. All
Wire rope on your hoist is one
15
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