Yale 11353395D manual

GLOBAL KING WIRE ROPE HOISTS RATED THRU 10 METRIC TONNE OPERATION, SERVICE & PARTS MANUAL PRINTED IN U.S. A. JANUARY, 2002 COPYRIGHT 2001, LIFT- TECH INTERNATIONA L, INC. PARTNO. 113 53395D Before installing hoist, fill in the information below. Refer to th e Hois t and Motor data plates. Model No. _____________ _____ Serial No. _____________ _[...]

2 FORWARD This book contains i mportant information to help you install, operate, maintain and service your new Yale electric hoist. We reco mmend that y ou study its contents thoroughl y before putting the hoist into use. Read HST 4M performance standard and ANSI B 30.16 safety standard for hoists. Then, through proper inst allation, application o[...]

3 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 Constructio n ………………………………………… ……?[...]

4 SECTION I – GENERAL DESCRIPTION 1-1. GENERAL. Yale “Global King” electric hoists are wire rope a nd drum type hoi sts that are manufactured with an integral trolley. These hoi sts are all low headro om models with the drum an d upper block (or dead-end ancho r depending on the reeving type) on oppo site sides of the b eam suspending the tro[...]

5 The trolley width shall be adjusted by loosening the jam nuts on the traverse drive side of the threaded ro ds at each end of the hoist. If necessary, lubricate the frame alignment bars with penetrating oil be fore attempting to adjust trolley width. The trolley side may then be pushed or drive n into position by turning the adjusting nuts on the[...]

6 (3) Operate “UP” button briefly to dete rmine direction of hook travel. (4) If hook raises when “UP” button is depressed, phasing is correct. (5) If hook lowers when “UP” butto n is depressed, h oist is “Reverse Phas ed.” TURN AND LOCK POWER O FF and check the pushbutton wiring. If the pushbutton was wired prop erly, correct the p[...]

7 d) Depress push button marked “LEFT ” to traverse in the opposite direction. CAUTION Excessive “jogging” will cause premature burning of contact tip s, motor overheating, and premature brake w ear. e) On two-speed hoist or trolley motions, partial depression of a button operates hoist o r trolley at slow speed; depressing button completel[...]

8 dd) DO NOT use limit swit ches 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 bet ween two hoists[...]

9 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 co des. WARNING Avoid skin contact with Mobilsol A. In case of skin contact: d ry wipe the skin, cleanse the area with a waterless hand cleaner and follo[...]

10 4-7. LUBRICANT SPECIFICATIO NS. AMBIENT TEMPERATURE -20 ° to 50 ° F 50 ° to 125 ° F 125 ° to 250 ° F (-29 ° to +10 ° C) (10 ° to 52 ° C) (52 ° to 121 ° C) GCOH AGMA Lubricant No. 6 No. 7 EP No. 7 Viscosity @ 100 ° F 1335 - 1632 SUS 1919 - 2346 SUS 1919 - 2346 SUS Viscosity Index 154 95 158 Pour Point -40 ° F 20 ° F -37 ° F Mobil [...]

11 4-7. LUBRICANT SPECIFICATIONS CONT’D. AMBIENT TEMPERATU RE -20 ° to 50 ° F 50 ° to 100 ° F 100 ° to 250 ° F (-29 ° to +10 ° C) (10 ° to 38 ° C) (38 ° to 121 ° C) GCOT AGMA Lubricant No. 5S No. 8 Compounded ISO Viscosity Grade 220 680 American Lubri cants  SHC 90W AGMA #8 Gear Oil Mobil  Oil Corp. Mobil  SHC 630 Extra Hecla[...]

12 The user should revise t he inspection interval, add additional units or provide a similar form to suit particular condition s that may exist. Ho wever, written, dated and signed inspection repo rts should be maintained particul arly on critical items such as hoist hooks, hoisting ro pe, sheaves, drums and brakes. Periodic revie w of old inspect[...]

13 INSPECTION SCHEDULE AND M AINTENANCE REPORT HO IST SE RIA L NO . (Manufactur er's) ___________________ _ CU ST O MER C RA NE I DEN T IT Y NO . __________________________ RAT E D LO AD ____________________ LOC AT IO N IN PLAN T T YPE ___________________________ T HIS IN SPEC TIO N IS: MONTH LY  ANNUAL  VOLT AGE _______________________ [...]

14 WARNING Do not operate a hoist having unusual vibrations, sounds, or with anything wrong or apparently wrong. Danger may be present that the hoist o perator cannot see. De termine and correct the cause of unusual conditions and make certain hoist can be operated safely. 5-2. INSPECTION OF LOWER BLOCK. a) Check lubricat ion of all parts. Also lub[...]

15 securely crimped to wi res and insulation sound. Terminal screws should be tight. b) Check condition of contacto r assembly, transformer, and upper limit switches. WARNING Check to be certain main po w er switch is locked in open position (OFF) before removing brake cover. 5-5. INSPECTION OF ROPE GUIDE. a) General . The rope gui de is intended t[...]

16 wire ropes will eventua lly deteriorate to a point where they are not safe and will require replacem ent. Wire rope should be thoroughly inspected at regular mo nthly intervals by an authorized person an d a determination made whe n further use of the rope would constitute a safety hazard. Each inspection should i nclude a written dated and sign[...]

17 CAUTION It is imperative that rope reel or coil rotates as rope un winds. 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 damag ed 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, r[...]

18 torque the remaining tw o (2) rope clamps in sequence to 50 ft-lb s. (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 ove r rope in rope drum grooves as sh own in Figure 5 -3. and outlined in Section V, Paragraph 5-6[...]

19 spur. Th e gear shafts are supp orted with ball bearings housed in the back of the case and in the cover. The inp ut 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 a s it passes into the gear case. Since the entire motor shaft is submerge d in oil, anytime the mot[...]

20 (4) Disconne ct the wiring and co nduit from the motor junction box. (5) Provide a means to support the hoi st motor. The hoist motor weig hs approx- imately 250 lbs. And must be held lev el while removing and installing. (6) Once the motor is properly supported, remove the hardware fastening it to the gear case. Carefully withdraw the motor hor[...]

21 (2) Make sure power to the hoist is off and locked out. (3) Remove the four (4 ) bolts attaching the fan shroud to the motor and remove the fan shroud. See Figure 5-9. (4) Carefully roll the large O-rin g 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 gag[...]

22 (3) Connect the brake leads to the terminal block on the brake body. (4) Install the forward fan mounting retaining ring and inst all the fan. Install the rear retaining ring. Install the f an shroud and bolts. (5) Test hoist per Section V, Paragraph 5-13. 5-11. INSPECTION OF HOIST TRAVERSE DRIVE. Figure 5-10. Traverse Drive Arrangement. a) Gene[...]

23 b) Procedure. Remove load from the hook. To disconnect the geare d limit switch refer to Figure 7-2. Remove the limit switch cover then loosen the two (2) scre ws holding the locking plate in place. Allow the lo cking plate to slide down and di sengage from the adjustment discs. Do not rotate the adjustment discs. CAUTION Damage to the hoist may[...]

24 SECTION VI – TROUBLE SHOOTING 6-1. GENERAL. This section c ontains possible causes and solutions to common hoist problem s. Please attempt to remedy your hoist problems by following these steps before contacting t he factory. Whenever servicing el ectrical components b e sure to shut off and lock out power following prop er lockout/tagout proc[...]

25 SECTION VI – TROUBLE SHOOTING TROUBLE PROBABLE CAUSE REMEDY 6-4 Hook Will Lower, But Not Raise. a. Excessive load. b. Hoist electrical circuit open. c. Contactor assembly not functioning. d. Up, down button inoperativ e. a. Reduce loading to rated load of hoist as shown on nameplate. b. Che ck for loose connecti o ns. See that necessary jumper[...]

26 This limit switch has a rota ry screw d riven by a gear reduction that is coupl ed to the end of the drum shaft. Adjustment discs operate the contacts of separate switches, one for the hoisting circuit and one for the lowerin g circuit. The switch assembly must be wired in accordanc e with the appr opriate wiring diagram, whi ch is shipped wit h[...]

27 Figure 8-1. Elementary Wiring Diagram for a T wo-Speed Hoist and Two-Speed Trolley with TAS, Hoist Block Operated Limit Switch, Geared Upper & Lo wer Limit Switches, and Optional Fuses.[...]

28 Figure 8-2. Component Diagram for a T w o-Speed Hoist and Two-Speed Trolley with TAS, Hoist Block Operated Limit Switch, Geared Upper & Lo w er Limit Switches, and Optional Fuses.[...]

29 SECTION IX – PARTS LIST 9-1. GENERAL. The part s lists and ill ustrations in this section of the manual cover part s for models of Yale “Global King” Electric hoists. A typical ho ist is shown as the basis for the exploded pa rts illustrations; therefore, ce rtain variations may occur from the information given. Fo r this reason, al ways g[...]

30 FIGURE 9-1. Hoist Drum, Drum Frame, Gearcase, Mo tor, Rope Guide, and Screw Type Limit S witch. “B” Frame: Hoist Components for Figure 9-1. Ref. No. Part Number Description Qty. Req’d. 1 - 7 ½ HP Hoist Motor (2-Speed with Brake and Fan) Note: See Figur e 9-10 for Parts. 1 GHB-101A 230 volt, 3-phase, 60 Hertz GHB-101B 460 volt, 3-phase, 60[...]

31 “B” Frame: Hoist Components for Figure 9-1. Ref. No. Part Number Description Qty. Req’d. 28 GHB-128 Lockwasher (7/16) 4 29 GHB-129 High Strength Hex Head Bolt – Grade 5 (7/16-14 x 1 1/2) 2 30 GHB-130 High Strength Hex Head Bolt – Grade 5 (7/16-14 x 1 3/4) 2 31 GHB-131 Outboard End Drum Frame 1 32 GHB-132 Limit S witch Bracket 1 33 GHB-[...]

32 Figure 9-2. Hoist Gearing. “B” Frame: Hoist Gearin g for Figure 9-2. Ref. No. Part Number Description Qty. Req’d. GHB-200 Complete Hoist Gearcase Ass’y. - 94.4:1 Ratio (Incl. Ref Nos. 1-1 9+) 1 GHB-201 Oil Seal 1 2 GHB-202 Oil Seal 1 3 GHB-203 Stud 4 4 GHB-204 Nut - Hex (5/8-18) 4 5 GHB-205 Washer - Hardened (5/8) 8 6 GHB-206 Lock Nut - [...]

33 “C” Frame: Hoist Gearin g for Figure 9-2. Ref. No. Part Number Description Qty. Req’d. 5 GHC-205 Washer - Hardened (3/4) 8 6 GHC-206 Lock Nut - Hex, Thin, Grade 5 (3/4-16) 4 7 GHC-207 Ball Bearing 2 8 GHC-208 Motor Gear - 64 Teeth 1 9 - Intermediate Pinion Shaft 1 GHC-209A 10t Hoist - Intermediate Pinion Shaft GHC-209B 7 1/2t Hoist – Int[...]

34 Figure 9-3. Motor Driven Trolley Frame and Drive (“B” Fram e Shown). “B” Frame: Trolley Fra me and Drive Components for Figure 9-3. Ref. No. Part Number Description Qty. Req’d 1 - Side Plate 1 GHB-301A Drum Side – 25’ Lift Frame GHB-301B Drum Side – 40’ Lift Frame 2 - Side Plate 1 GHB-302A Drive Side – 25’ Lift Frame GHB-30[...]

35 “B” Frame: Trolley Fra me and Drive Components for Figure 9-3. Ref. No. Part Number Description Qty. Req’d 13 GHB-313 Lock washer, (5/16) 4 14 - T hreaded Rod 2 GHB-314A Threaded Rod, 4” Thru 14” T rolley Beam Flange Width GHB-314B Threaded Rod, 14 1/8” T hru 20” Trolley Beam Flange Widt h 15 GHB-315 Heavy Hex N ut (3/4-10) 12 16 G[...]

36 Figure 9-4. Lower Block Assembly . “B” Frame: Lo wer Block Components for Figure 9-4. Ref. No. Part Number Description Qty. Req’d GHB-400Y Lower Block Assembly (Includes Ref. Nos. 1-17) 1 1 GHB-401 Lower Block Frame – Hook Beam 1 2 GHB-402 Hook 1 3 GHB-403 Thrust Bearing 1 4 GHB-404 Castle Nut 1 5 GHB-405 Spring Pin 1 6 GHB-406Y Sheave C[...]

37 “C” Frame: Lo wer Block Components for Figure 9-4. Ref. No. Part Number Description Qty. Req’d 7 GHC-407 Flat Head Socket Cap Screws (1/4-20 x 1/2) 4 8 GHC-408 Sheave Pin 1 9 GHC-409 Sheaves 2 10 GHC-410 Ball Bearings 2 11 GHC-411 Internal Retaining Rings 2 12 GHC-412 External Retaining Rings 2 13 GHC-413 Socket Head Cap Screws (1/4-20 x 3[...]

38 Figure 9-5. Upper Block Assembly. “B” Frame: Upper Block Components for Figure 9-5. Ref. No. Part Number Description Qty. Req’d GHB-500 “B” Frame Hoist Upper Block As sembly (Includes Ref. Nos. 1-10) 1 1 GHB-501 Upper Block Yoke 1 2 GHB-502 Key Plate 1 3 GHB-503 Hex Head Bolt (3/8-16 x 5/8) 2 4 GHB-504 Sheave Pin 1 5 GHB-505 Lockwasher[...]

39 “C” Frame: Upper Block Components for Figure 9-5. Ref. No. Part Number Description Qty. Req’d 10 GHC-510 Internal Retaining Ring 1 11 GHC-511 Spacer Washer 4 12 GHC-512 Self-Locking Nut (3/8) 2 13 GHC-513 Yoke Pin 1 14 GHC-514 Cotter Pin 2 NOTES __________________________________________________________________________________ ____________[...]

40 Figure 9-7. “C” Frame: Rope and Dead End Assembly . “C” Frame: Rope and De ad End As sembly Components for Fig ure 9-7. Ref. No. Part Number Description Qty. Req’d GHC-700 “C” Frame Hoist Rope and Dead End Assem bly 1 GHC-701 Cotter Pin 2 2 GHC-702 Dead End Swaged Socket Pin 1 3 GHC-703 Flanged Bushing 2 4 GHC-704 Washer (1 1/2&quo[...]

41 “B” Frame Block Operated Limit S w itch Components for figure 9-8. Ref. No. Part Number Description Qty. Req’d GHB-800 “B” Frame Hoist Limit Switch Assembly (Includes Ref. Nos. 1-1 6) 1 GHB-801 Limit Switch 1 2 GHB-802 Pan Head Machine Screw, Phillips (#10-32 x 1 1/4 Long) 2 3 GHB-803 Lockwasher (#10) 2 4 GHB-804 Limit Switch Bracket 1[...]

42 Figure 9-9. Rope Guide Assembly “B” Frame Rope Guide Components for Figure 9-9. Ref. No. Part Number Description Qty. Req’d GHB-900 “B” Frame Rope Guide Assembly (Includes Ref. Nos. 1-9) 1 1 GHB-901 Rope Guide Frame (Machined ) 1 2 GHB-902 Plastic Shroud 1 3 GHB-903 Extension Spring 1 4 GHB-904 Shoulder Bolt (1/4-20 x 1 1/2 Long, 5/16 [...]

43 Figure 9-10. Hoist Motor Brake. “B” Frame: Hoist Bra ke Components for Figure 9-10. Ref. No. Part Number Description Qty. Req’d. 1 GHB-1001 † Brake Disc 1 GHB-1002* Brake Fan Kit (Includes items 2 thru 7) 1 2 Fan 1 3 External Retaining Rings (Fan) 2 4 External Retaining Ring (Fan Hub) 1 5 Fan Hub 1 6 Key (Hub) 1 7 Key (Fan) 1 GHB-1008* B[...]

44 Figure 9-10. Hoist Motor Brake. “C” Frame: Hoist Bra ke Components for Figure 9-10. Ref. No. Part Number Description Qty. Req’d. 1 GHC-1001 † Brake Disc 1 GHC-1002* Brake Fan Kit (Includes items 2,4 & 7) 1 2 Fan 1 3 N/A 4 External Retaining Ring (Fan Hub) 1 5 N/A 6 N/A 7 Key (Fan) 1 GHC-1008* Brake Hub Kit (Includes items 8 thru 11) [...]

45 Figure 9-11. “B” Frame Trolley Driv e Gear Reducer. “B” Frame Trolley Driv e Gear Reducer Components fo r Figure 9-11. Ref. No. Part Number Description Qty. Req’d GHB-309A “B” Gear Reducer, 30:1 Ratio – 50 FPM (Include s Ref. Nos. 1-25) 1 GHB-309B “B” Gear Reducer, 20:1 Rati o – 75 FPM (Includes Ref. Nos. 1-25) 1 1 GHB-1101[...]

46 Figure 9-12. “C” Frame Trolley Driv e Gear Reducer. “C” Frame Trolley Driv e Gear Reducer Components fo r Figure 9-12. Ref. No. Part Number Description Qty. Req’d. GHC-309A “C” Gear Reducer, 30:1 Rati o – 50 FPM (Incl udes Ref. Nos. 1-25) 1 GHC-309B “C” Gear Reducer, 20:1 Rati o – 75 FPM (Incl udes Ref. Nos. 1-25) 1 1 GHC-1[...]

47 NOTES _________________________ _______________________ __________________________ _________________________ _______________________ ______________________ ____ _________________________ _______________________ ______________________ ____ _________________________ _______________________ ______________________ ____ _________________________ ____[...]

48 Recommended Spare Parts Certain Parts of your hoist will, in time, requi re replacemen t under norm al wear conditions. It is suggested that the following parts be purchased f or your hoist as spares for future use. One Brak e Frictio n Disc One Brak e Modu le One Set of C ontactors One Tr ansfor mer One Wire Rope Assembly Note: When ordering pa[...]