December, 2007 Copyright 2007, Yale�Lift-Tech, division of Columbus McKinnon Corporation Part No. 118175-05

OPERATION, SERVICE & PARTS MANUAL

GLOBAL KING™

WIRE ROPE HOISTSRATED LOADS THRU 3.2 METRIC TONNE

Before installing hoist, fill in theinformation below. Refer to the Hoistand Motor data plates.

Model No. _________________

Serial No. _________________

Purchase Date _____________

Voltage ___________________

Rated Load ________________

Follow all instructions andwarnings for inspecting,maintaining, and operating thishoist. The use of any hoist presentssome risk of personal injury orproperty damage. That risk is greatlyincreased if proper instructions andwarnings are not followed. Beforeusing this hoist, each operator shouldbecome thoroughly familiar with allwarnings, instructions, andrecommendations in this manual.Retain this manual for futurereference and use.

Forward this manual to operator.Failure to operate equipment asdirected in manual may causeinjury.

Page 2

INDEXSECTION I GENERAL DESCRIPTION Page

Paragraph 1-1 General ................................................................................................................................................................................. 3Paragraph 1-2 Basic Construction ............................................................................................................................................................... 3Paragraph 1-3 Selection & Application Guide ............................................................................................................................................. 3

SECTION II INSTALLATIONParagraph 2-1 General ................................................................................................................................................................................. 4Paragraph 2-2 Installing Hoist ...................................................................................................................................................................... 4Paragraph 2-3 Connecting Hoist to Electrical Service ............................................................................................................................... 5Paragraph 2-4 Pre-Operational Checks ...................................................................................................................................................... 5

SECTION III OPERATIONParagraph 3-1 General ................................................................................................................................................................................. 6Paragraph 3-2 Push Button Operation ........................................................................................................................................................ 6Paragraph 3-3 Operating Precautions ......................................................................................................................................................... 6

SECTION IV LUBRICATIONParagraph 4-1 General ................................................................................................................................................................................. 7Paragraph 4-2 Changing Gear Case Oil ...................................................................................................................................................... 7Paragraph 4-3 Lubrication of Hoist Cable ................................................................................................................................................... 8Paragraph 4-4 Lubrication of Limit Switch .................................................................................................................................................. 8Paragraph 4-5 Lubrication of Geared Trolley Wheels and Pinions ............................................................................................................. 8Paragraph 4-6 Lubrication of Rope Guide ................................................................................................................................................... 8Paragraph 4-7 Lubricant Specifications ...................................................................................................................................................... 9

SECTION V INSPECTION AND PREVENTIVE MAINTENANCEParagraph 5-1 General ............................................................................................................................................................................... 10Paragraph 5-2 Inspection Lower Block ...................................................................................................................................................... 13Paragraph 5-3 Inspection Upper Block ...................................................................................................................................................... 13Paragraph 5-4 Inspection Electrical Controls ............................................................................................................................................ 13Paragraph 5-5 Inspection of Rope Guide .................................................................................................................................................. 13Paragraph 5-6 Rope Inspection, Maintenance & Replacement ............................................................................................................... 14Paragraph 5-7 Rope Reeving ..................................................................................................................................................................... 15Paragraph 5-8 Inspection of Rope Drum & Shaft ..................................................................................................................................... 16Paragraph 5-9 Inspection of Hoist Gearing ............................................................................................................................................... 17Paragraph 5-10 Inspection of Motor Brake & Actuating Mechanism ......................................................................................................... 18Paragraph 5-11 Inspection of Traverse Drive .............................................................................................................................................. 19Paragraph 5-12 Testing Block Operated Limit Switch ................................................................................................................................ 20Paragraph 5-13 Testing Over-Capacity Limit Switch .................................................................................................................................. 20Paragraph 5-14 Testing Hoist ....................................................................................................................................................................... 21

SECTION Vl TROUBLESHOOTING CHART .................................................................................................................................................... 21

SECTION Vll ADJUSTMENTSParagraph 7-1 Motor Brake Adjustment .................................................................................................................................................... 23Paragraph 7-2 Block Operated Limit Switch Adjustment .......................................................................................................................... 23Paragraph 7-3 Geared Rotary Limit Switch Adjustment ........................................................................................................................... 23Paragraph 7-4 Over-Capacity Limit Switch Adjustment ........................................................................................................................... 23Paragraph 7-5 Shortening of Push Button Station .................................................................................................................................... 24

SECTION VIII WIRING DIAGRAMS .................................................................................................................................................................. 24-26

SECTION IX PARTS LISTParagraph 9-1 General ............................................................................................................................................................................... 27Paragraph 9-2 List of Parts Illustrations .................................................................................................................................................... 27

FOREWORDNumber that are found on the nameplate attached to the hoist asshown in Figure 4-1. For your convenience, a space has been providedon the front cover of this Manual for entering this information. Werecommend that you fill it out immediately so it is readily at hand whenneeded.

The contents of this manual are of necessity, general in nature andmay cover features not incorporated on your hoist; or, you may haveordered features not covered by this manual. Therefore, the user mustexercise care in applying instructions given in this manual. If specificinformation not in this manual is required, contact the factory.

THE INFORMATION CONTAINED IN THIS MANUAL IS FORINFORMATIONAL PURPOSES ONLY AND YALE•LIFT-TECH DOESNOT WARRANT OR OTHERWISE GUARANTEE (IMPLIEDLY OREXPRESSLY) ANYTHING OTHER THAN THE COMPONENTS THATYALE•LIFT-TECH MANUFACTURES AND ASSUMES NO LEGALRESPONSIBILITY (INCLUDING, BUT NOT LIMITED TOCONSEQUENTIAL DAMAGES) FOR INFORMATION CONTAINED INTHIS 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.

This manual contains important information to help you install, operate,maintain and service your new YALE electric hoist. We recommendthat you study its contents thoroughly before putting the hoist into use.We also recommend that you read Section IX - Series Lifting Equipmentof the European Federation of Materials Handling and StorageEquipment (FEM) and the applicable performance and safety standardsreferenced therein. Then, through proper installation, application ofcorrect operating procedures, and by practicing the recommendedmaintenance procedures, you can expect maximum lifting service fromthe hoist.

It will likely be a long time before parts information found in the PartsList is needed. Therefore, after the hoist is installed and you havecompletely familiarized yourself with operation and preventativemaintenance procedures, we suggest that this book be carefully filedfor future reference.

When ordering replacement parts from this book, it will be necessarythat you include with your order: the Hoist Serial Number and Model

NOTICE: Information contained in this book is subject to change without notice.

Page 3

SECTION I - GENERAL DESCRIPTION

1-1. GENERAL. YALE "Global King" electric hoists are wirerope and drum type hoists that are manufactured with an integraltrolley. These hoists are all low headroom models with the ropedrum and upper block supported on opposite sides of thebeam, by the trolley frame. There is one basic frameconfiguration for both the two and four part single reeved hoists.Both reeving configurations are referred to as "A" Frame hoistswith the distinction made between reeving styles. The S4designation refers to the 3.2 tonne (3200 kg) capacity with afour parts of rope single reeving configuration. The S2designation refers to the 1.6 tonne (1600 kg) capacity with atwo part of rope single reeving configuration. Both hoists featurean integral trolley and are offered with two different flangewidth ranges; 4-5/8" through 8-1/2" and 8-5/8" through 14" ona maximum flange thickness of 1-1/8". The smaller flange rangealso accommodates patented track beams using an optionaltrolley wheel arrangement. The hoist motor is 2-speed with a4:1 ratio between high and low speeds, as standard. The motordriven trolley has two available speeds with 1, 2 speed, orvariable frequency control.

Throughout this manual, you will see references to the "S2"and "S4" Frame hoists. If you are unsure about which frameyou have, count the number of rope falls that are supportingthe lower block and/or see Section IV, Paragraph 4-2 for asimple gearcase measurement to determine the configurationof your hoist.

1-2. BASIC CONSTRUCTION. YALE "Global King" hoistsconsist of a rugged steel frame, made from structural steel andassembled using high strength structural bolts. The framehouses a lifting drum and serves as the suspension means forthe rated hoist load. An aluminum gearcase, attached to oneend of the drum frame, houses a triple-reduction, helical geartrain. Applying power to the gearcase is a 2-speed, AC hoistingmotor with a 4:1 speed ratio coupled with a 250% torque DCbrake. High strength wire rope and a covered lower sheaveblock act as the load carrying means. Standard equipmentincludes a rope guide, a rotary-geared limit switch to limit hooktravel in both up and down directions and an overload capacitylimit switch. An optional block operated limit switch can beused to limit the upward travel of the lower block. An integraltrolley, consisting of a 2-speed AC motor and a sealed wormreducer, applies torque to the trolley wheels through a cross-shaft and pinion arrangement, which provides traverse motionto the hoist. A single NEMA 4/12 control enclosure housesboth the hoist and trolley electrical system controls. A pushbutton control station (purchased separately) for operating thehoist is suspended on a wire strain cable attached to the hoist.

1-3. SELECTION & APPLICATION GUIDE.

Hoist Duty Classification

Your YALE “Global King” hoist was designed to meet a specificduty classification as described by the FEM “Rules for the Designof Serial Lifting Equipment”. The methodology used to determinethe duty class requirements of your specific application is shownbelow.

YALE “Global King” hoists are defined as “mechanisms” by theFEM and are classified as such by the following factors: Classof Operating Time and Load Spectrum. Your application mustbe definable by these two factors in order to determine dutyclassification.

Load SpectrumLoad Spectrum indicates the extent of which the mechanism issubjected to maximum stresses (full capacity lifts) or whether itis subject to smaller loads only. Use the charts below to estimateyour load spectrum. For an exact means of calculating yourload spectrum, refer to FEM 9.511 "Classification ofMechanisms".

2 x H x N x T

V x 60t =

Once the average daily operating time, "t", is calculated for aspecific application, the Class of Operating Time can be identified.Using the Class of Operating Time along with the Load Spectrum,one can determine the duty classification requirement of theapplication. Defining the proposed equipment usage in thismanner is critical to selecting the correct hoist for the application.

Classification of Mechanisms

LoadSpectrum

Class of Operating Time

T2 T3 T4 T5 T6

Average Daily Operating Time (hr/day)

¼- ½ ½-1 1-2 2-4 4-8

L1 1Dm 1Cm 1Bm 1Am 2m

L2 1Cm 1Bm 1Am 2m 3m

L3 1Bm 1Am 2m 3m 4m

L4 1Am 2m 3m 4m 5m

Where:t = Average Daily Operating Time (hr/day)H = Average Hoist Height (ft)N = Number of Cycles Per Hour (cycles/hr)T = Daily Working Time (hr/day)V = Hoisting Speed (ft/min)

Class of Operating TimeClass of Operating Time indicates the average period per dayduring which the mechanism is in operation, which is anytimethe equipment is in motion. The Class of Operating Time isdetermined by calculation of the average daily operating time(average daily use):

Page 4

Example:An application requires that a hoist be used to repeatedly liftand move small to medium size loads, but occasionally will berequired to lift heavy loads equal to 3.2 metric tonne. This hoistwill be operated daily for a single 8-hour shift and will be requiredto perform 15 lifting cycles per hour. The average height, whichthe load is lifted, is 18 ft. at a desired speed of 20ft/min.

The average daily operating time can be calculated from theabove information:

The description of the example application implies that the loadspectrum is likely an L1 or L2. Choosing an L2 load spectrumfactor and using the calculated average daily operating time,one can determine from the "Classification of Mechanisms" tableabove, the duty classification for this application is 2m for a 3.2metric ton rated hoist.

For a more thorough explanation of the determination ofmechanism classification, refer to FEM 9.511 "Classification ofMechanisms".

Your YALE "Global King" hoist was designed to meet the dutyclassifications as described above. The standard 3.2 tonne and1.6 tonne capacity models are rated at 2m duty classification. A3m duty classification is available at a derated capacity.

SECTION II - INSTALLATION

2-1. GENERAL. YALE "Global King" electric hoists arelubricated and tested before being shipped from the factory. Toplace a hoist in service, install onto beam by adjustingappropriately for the flange width, connect to electrical serviceand perform pre-operation tests and checks.

2 x 18 x 15 x 8

20 x 60t = = 3.6 hr/day

Working in or near exposed energized electricalequipment presents the danger of electric shock.

TO AVOID INJURY:DISCONNECT POWER AND IMPLEMENT LOCKOUT/TAGOUT PROCEDURE BEFORE REMOVING COVER ORSERVICING THIS EQUIPMENT.

WARNING

Only qualified personnel with proper supervision shallinstall the hoist on the monorail and perform the finalpre-operation inspection.

WARNING

Figure 2-1. Trolley Wheel Spacing

OPEN-END BEAM: If the trolley can be installed directly fromthe end of the supporting beam, adjust the spacing betweenthe trolley wheel flanges to be 3/16"-1/4" greater than the exactwidth of the beam flange (See Figure 2-1). Before adjustingthe width of the trolley frame, make sure to loosen the pinionset screws on the keyed cross shaft nearest the traverse drivereducer. Do not lose the keys for the pinion during adjustment.Also, the electrical conduit/cable must not be constrained whenattempting to adjust the trolley sides, in or out. The trolleywidth is adjusted by loosening the jam nuts on the traversedrive side of the threaded rods at each end of the hoist. Ifnecessary, lubricate the frame alignment bars with penetratingoil before attempting to adjust trolley width. The trolley sidemay then be pushed or driven into position by turning theadjusting nuts on the threaded rods. Adjust nuts on each sideof the hoist simultaneously, to avoid binding. After adjustingthe trolley to the proper width, tighten all adjusting nuts andsetscrews, and re-secure the electrical conduit/cable. Verifythat the geared wheels mesh properly with the traverse drivepinions. Using proper equipment, carefully lift the hoist andinstall on the end of the beam. Lubricate the wheel gear andall pinions (WG, Section IV, Paragraph 4-5).

2-2. INSTALLING HOIST

Loosen all electrical cable or conduit attached to theframe and alignment bars before adjusting trolleywidth. Ensure that the electrical cable is not stretched,pinched, twisted or otherwise damaged whenadjusting trolley width.

NOTICE

CLOSE-END BEAM: For trolleys which are to be mountedalong the span of a beam not having open ends, the trolleymust be adjusted in the same manner as described above to awidth that allows clearance between the axle ends and thebeam flange. Using proper lifting equipment, the trolley andhoist must then be lifted to the beam where it is to be installed.Once in position, adjust the spacing between the trolley wheelflanges to be 3/16"-1/4"" greater than the exact width of thebeam flange (See Figure 2-1). After tightening all adjustingbolts, set screws, and all electrical conduit/cable clamps,carefully set the trolley on the beam. Lubricate the wheel gearand all pinions (WG, Section IV, Paragraph 4-5).

Page 5

Power supply to hoist and trolley must be the samevoltage, frequency, and phase that are specified onthe hoist and trolley nameplate.

CAUTION

2-4. PRE-OPERATIONAL CHECKS

a)Check Oil Level. (Figure 2-1) The gearcase has beenfilled with oil to the proper level. However, this should berechecked before operating the hoist.

Check oil level by removing the plug indicated in Figure2-1. When properly filled, oil should be level with thebottom of the tapped hole. Fill to this level with oil asspecified in Paragraph 4-2.e.

b)Check Push Button Operation and Phasing. To properlycheck the phase of the hoist, follow these steps:

(1) With "POWER OFF", operate all the push buttons anddetermine that they do not bind or stick in any position.

If any push button binds or sticks in any position - DONOT TURN POWER ON - determine the cause andcorrect the malfunction before operating.

WARNING

(2) Connect hoist to power source.

(3) Operate "UP" button briefly to determine direction ofhook travel.

(4) If hook raises when "UP" button is depressed, phasingis correct.

(5) If hook lowers when "UP" button is depressed, hoistis "Reverse Phased." TURN AND LOCK POWER OFFand check the pushbutton wiring. If the pushbuttonwas wired properly, correct the problem byinterchanging any two leads at power sourceconnection. Do not change internal wiring of hoist.

On three phase hoists, it is possible to have "ReversePhasing" causing the block to lower when the "UP"button is depressed. When this condition exists, theautomatic limit switch is inoperative and hoistoperation will be dangerous.

WARNING

c) Check Lower Block and Hoisting Cable. Depress "DN"push button and run lower block to its lowest position. Noless than two wraps shall remain on the drum with theloaded hook in its lowest position. Also check to see thatthe lower block and rope do not twist excessively. If itdoes twist to the extent that two ropes rub against eachother, disengage the swaged rope end from the frameanchor and twist the rope four or five turns in a directionopposite to that which the block turns. Reconnect rope tothe frame anchor, holding firmly to eliminate rope twistingback to its original position. Operate hoist up and down afew times. If lower block still rotates excessively, repeatprocess until twisting is corrected.

d) Lubricate Hoisting Cable. For longer cable life, it isrecommended that the cable be lubricated at time ofinstallation by applying a heavy coating of lubricant CL(Para. 4-7) as outlined in SECTION IV, Paragraph 4-3.

e) Check Limit Switch Operation.

(1) A geared rotary type upper and lower limit switch isprovided as standard equipment on YALE "World

Series" hoists. This switch is adjustable and althoughpreset by the factory, it should be adjusted at time ofinstallation to the desired high and low limits of lowerblock travel. Refer to SECTION VII, Paragraph 7-3.

(2) A block operated upper limit switch can be furnishedas optional equipment on YALE "Global King"

hoists. This limit stop is factory set to stop the lowerblock at the safest high position, guarding againstover travel and possible damage to hoist. Minimaladjustments can be made. When equipped with thisoption, the hoist should be tested by jogging the lowerblock against the limit switch actuator arm to assurethe switch is functioning properly. When the lower blocklifts the actuator, the hoist will automatically stop. Ifthe lower block coasts through the limit switch whenlifting, a reversing switch will automatically close andreverse direction of motion to lowering.

f) An overcapacity limit switch is provided as standardequipment on YALE "Global King" hoists. This

switch is adjustable and although preset by the factory, itshould be adjusted at the time of installation to the desiredsetting. Refer to SECTION VII, Paragraph 7-4.

g) When first using the hoist and trolley, operate with lighterloads through full travel before applying maximum load.

2-3. CONNECTING HOIST TO ELECTRICAL SERVICE.Electrical service to the hoist may be power cable or a guardedsystem having sliding shoe or wheel type collectors.

Follow ANSI/NFPA 70, state, and local electrical codes includingthe grounding provisions thereof when providing electricalservice to the hoist.

Make electrical connections using the appropriate wiringdiagrams furnished with the hoist. Only qualified journeymanelectricians shall make any electrical connections, includingconnections to collectors or power cord.

Be certain that electrical power supply is OFF andlocked in the open position before attempting anyelectrical connections to the hoist. This equipment mustbe effectively grounded according to the NationalElectric Code ANSI/NFPA 70, or other applicable codes.

WARNING

Page 6

Some hoists may be shipped with the electrical controlsloose (disconnected) and will not have the upper andlower limit switches connected. DO NOT OPERATEHOIST UNTIL LIMIT SWITCHES ARE PROPERLYCONNECTED AND ADJUSTED. Failure to do so mayallow hoist to be operated beyond proper travel limits,which can cause load to drop, resulting in damage toequipment or injury.

WARNING

SECTION III - OPERATION

3-1. GENERAL. Operation of YALE "Global King" hoists iscontrolled by a convenient pendant push button station. With it,the hoist can be controlled to give fast lifting and lowering; orcontrolled to lift or lower the load in small increments, providingaccurate positioning capability. The push button station has abuilt-in interlock to prevent depressing opposing buttonssimultaneously.

When first using the hoist, break in by operating under lighterloads to full travel before applying maximum load.

3-2. PUSH BUTTON OPERATION

a.) For the hoist motion depress push button marked "UP" toraise load.

b.) For the hoist motion depress push button marked "DN" tolower load.

c.) For the trolley traverse motion:

With two speed control depress buttons marked "<<" ,">>" or "N", "S" to activate the trolley traverse motion

With one speed control depress buttons marked "<" , ">"or "N", "S" to activate the trolley traverse motion.

d.) On two-speed hoist or trolley motions, partial depressionof a button operates hoist or trolley at slow speed;depressing button completely operates hoist or trolley atfull speed.

Excessive "jogging" will cause premature burning ofcontact tips, motor overheating and premature brakewear.

NOTICE

a) DO read applicable sections of FEM Section IX, SeriesLifting Equipment and the Operation, Service and PartsManual.

b) DO be familiar with hoist operating controls, procedures,and warnings.

c) DO make sure hook travel is in the same direction asshown on the controls. If opposite direction occurs, seePre-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 approvedattachments are properly sized and seated in the hooksaddle.

g) DO make sure that the hook latch is closed and notsupporting the load.

h) DO make sure that load is free to move and will clear allobstructions.

i) DO take up slack carefully, check load balance, lift a fewinches 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 suspendedload.

l) DO warn personnel of an approaching load.

m) DO protect wire rope from weld splatter or other damagingcontaminants.

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 whenrepairing 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 theload.

u) DO NOT use damaged hoist or hoist that is not workingproperly.

v) DO NOT use the hoist with twisted, kinked, damaged, orworn wire rope.

w) DO NOT lift a load unless wire rope is properly seated inits groove(s).

x) DO NOT use wire rope as a sling or wrap rope around theload.

Equipment covered herein is not designed or suitableas a power source for lifting or lowering persons.

WARNING

3-3. OPERATING PRECAUTIONS. Safe operation of anoverhead hoist is the operator's responsibility. Listed below aresome basic rules that can make an operator aware of dangerouspractices to avoid and precautions to take for his own safetyand the safety of others. Observance of these rules, in additionto frequent examinations and periodic inspection of theequipment, may prevent injury to personnel and damage toequipment.

Damage to the hoist, a dropped load, and injury mayresult if limit switches fail due to improper use.

TO AVOID INJURY:

UNDER NORMAL OPERATING CONDITIONS, STOPHOIST TRAVEL BEFORE ENGAGING LIMIT SWITCHES.LIMIT SWITCHES ARE SAFETY DEVICES AND SHOULDNOT BE USED AS NORMAL OPERATING CONTROL.

WARNING

Page 7

DO NOT operate hoist with the hoisting rope out of thedrum grooves. Such operation may result in damage tothe rope guide and rope and could result in the ropebreaking. This may result in dropping the load that cancause damage to equipment and injury to operator orother personnel. Hoist rope will remain in the drumgrooves during operation under normal operatingconditions, however, slack or kinked rope, excessiveside pulls, swinging or jerking of load, or similar abuse,may cause damage to the rope guide causing the ropeto leave the grooves.

WARNING

vv) DO NOT use hoist in location that will not allow operatormovement to be free of the load.

ww) DO, when starting to lift, move the load a few inches atwhich time the hoist should be checked for proper loadholding action. The operation shall be continued only afterthe operator is assured that the hoist is operating properlyand that the load is supported in the center of the base/bowl/saddle of the hook.

xx) DO observe recommended inspection and maintenanceprocedures.

yy) DO use common sense and best judgment wheneveroperating a hoist.

zz) DO NOT remove drop lugs. Removal will create an unsafeoperating condition.

SECTION IV - LUBRICATION

4-1. GENERAL. The lubrication services outlined in Paragraphs4-3 thru 4-6 should be performed before initial operation of thehoist. The lubrication services outlined in Paragraphs 4-2 thru4-6 should be performed at regular intervals at least every six(6) months, coinciding with spring and fall seasons isrecommended. The reason for this is that on hoists installedoutside or in unheated areas a "cold test" oil is required insuch (below freezing) climates making seasonal changesnecessary.

4-2. CHANGING GEARCASE OIL

Figure 4-1. View of Hoist Showing Location of NamePlates and Oil Plugs

a) Add 5% solution of Mobilsol A (or equivalent) to the oiland run for a short time. This will clean components andhold particles in suspension for draining.

b) Remove oil drain plug from bottom of gearcase and drainoil out. Dispose of oil in accordance with localenvironmental codes.

y) DO NOT lift a load if any binding prevents equal loading onall 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 operatingthe hoist.

cc) DO NOT operate the hoist beyond limits of wire rope travel.

dd) DO NOT use limit switches as routine operating stopsunless 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 unlessspecific precautions have been taken.

hh) DO NOT allow sharp contact between two hoists or betweenhoist and obstructions.

ii) DO NOT allow the rope or hook to be used as a ground forwelding.

jj) DO NOT allow the rope or hook to be touched by a livewelding electrode.

kk) DO NOT remove or obscure the warnings on the hoist.

ll) DO NOT adjust or repair a hoist unless qualified to performhoist maintenance.

mm) DO NOT attempt to lengthen the wire rope or repairdamaged wire rope.

nn) DO NOT allow personnel not physically fit or properlyqualified, to operate hoist.

oo) DO NOT operate hoists unless hook moves in the samedirection as indicated on the push button. If oppositedirection occurs, see pre-operation checks, Section IIParagraph 2-4.b.

pp) DO NOT operate hoist unless limit switches are operatingproperly.

qq) DO avoid operating hoist when hook is not centered underhoist. Avoid side pulls and swinging of load or load hookwhen traveling hoist.

rr) DO operate hoist within recommended duty cycle and DONOT "jog" unnecessarily.

ss) DO conduct regular visual inspections for signs of damageand 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 appropriatedesign factor based on the load rating and dead weight ofthe hoist. If in doubt of the supporting structure's strength,consult a structural engineer.

Avoid skin contact with Mobilsol A. In case of skincontact: dry wipe the skin, cleanse the area with awaterless hand cleaner and follow by washingthoroughly with soap and water.

CAUTION

Page 8

c) Reinstall drain plug.

d) Remove oil level plug from front of gearcase cover.

Figure 4-2. Gearcase Width Illustration

e) Refill through filler hole to proper level (bottom of oil levelplug hole) using GCOH (Paragraph 4-7). The amount ofoil required depends on the overall size of the gearcase.Both versions of the "A" Frame hoist utilize the same sizegearcase, although their contents differ. To confirm theversion of your gearcase refer to Figure 4-2. Your gearcaseshould have a similar shape to that shown and willmeasure 10 in width and requires approximately 3 quartsof oil.

4-3. LUBRICATION OF HOISTING CABLE. Hoists are shippedfrom the factory without an exterior coating of grease on hoistingcable. It is recommended that the cable be thoroughly coatedat installation and kept well lubricated with CL (Paragraph 4-7).

4-4. LUBRICATION OF LIMIT SWITCH. Provide a light film ofgrease MPG (Paragraph 4-7) on bevel gear of rotary gearedlimit switch.

4-5. LUBRICATION OF GEARED TROLLEY WHEELS ANDPINIONS. At installation and periodically, apply grease WG(Paragraph 4-7) to the traverse drive pinions and the gears ofthe trolley wheels.

4-6. LUBRICATION OF ROPE GUIDE

a) Maintenance. The rope guide is made of a molded self-lubricated reinforced nylon material. It is lubricated priorto installation at the factory and requires only periodicinspection.

(1) Periodically re-grease with MPG (Paragraph 4-7) byapplying grease to the leading edge of the guide andrope drum.

(2) Every 6 months, the rope guide should be removedper Section V, Paragraph 5-5, cleaned and inspected.When reassembled, the rope guide should bethoroughly greased with MPG (Paragraph 4-7) andthe hoist run up and down to lubricate both the drumand the wire rope.

Notes

Page 9

AMBIENT TEMPERATURE

-20° to +50° F(-29° to +10°C)

50° to 125° F(10° to 52°C)

125° to 250° F(52° to 121°C)

GCOH AGMA Lubricant No. 6 No. 7 EP No. 7

Gear Case Oil

Hoist Gearcase

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 ® Oil Corp. Mobil ® SHC 632 Mobilgear ® 634 Mobil ® SHC 634

Shell ® Oil Co. Omala ® RL 320 Omala ® 460 Omala ® RL 460

Texaco ® Inc. Pinnacle ® 320 Meropa ® 460 Pinnacle ® 460

SG NLGI Grease No. 1

Spline Grease ASTM D217 WorkedPenetration

310 - 340

Dropping Point 320°F (160°C)

Base Lithium

Mobil ® Oil Corp. ---------------------------------------- Mobilux ® EP 111 ---------------------------------------

WG Viscosity @ 100° F 25,000 SUS (contains diluent)

Wheel Gear andPinion Grease

Mobil ® Oil Corp. ---------------------------------------- Mobiltac ® 375 NC --------------------------------------

Texaco ® Inc. --------------------------------------------- Crater H ® -------------------------------------------

CL No Specification

Cable Lubricant

Wire RopeLubricant

Amoco ® Oil Co. ------------------------------------------- Amovis ® 5-X -----------------------------------------

Mobil ® Oil Corp. ----------------------------------------- Mobilarma ® 798 ---------------------------------------

Sun ® Oil Co. -------------------------------- Sunoco ® Wire Rope Lubricant ------------------------------

Texaco ® Inc. Crater A Texclad ® 2

GO AGMA Lubricant No. 1 No. 2

General Oil

General Oiling toPrevent Rusting andProvide LimitedLubrication for PointsNot ConsideredNormal Wear Points

Viscosity @ 100° F 193 - 235 SUS 284 - 347 SUS

Viscosity Index 60 Min. 60 Min.

Pour Point -20°F (-29°C) 10°F (-12°C)

Amoco ® Oil Co. Rykon ® Oil 46 American Industrial Oil ® 68

Mobil ® Oil Corp. ------------------------------------- Mobil ® DTE Oil Heavy -----------------------------------

Shell ® Oil Co. Rotella ® 10W Rotella ® 10W-30

Sun ® Oil Co. Sunvis ® 932 Sunvis ® 968

Texaco ® Inc. Rando ® Oil 46 Rando ® Oil 68

MPG NLGI Grease No. 1 No. 2

Multipurpose Grease

Grease LubricatedWear Points Providedwith Fittings and Gridor Gear Type Flexible

Couplings

6ASTM WorkedPenetration

310 - 340 265 - 295

Dropping Point 360°F (182°C) 360°F (182°C)

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. --------------------------------------------- Retinax LC -------------------------------------------

Sun ® Oil Co. Prestige ® 741 EP Sunoco ® Multipurpose 2 EP

Texaco ® Inc. Multifak ® EP 1 Multifak ® EP 2

GCOT AGMA LubricantNo. 7 or 7C

(Compounded)No. 8 or 8C

(Compounded)Refer to YALE Hoist

Field ServiceDepartment for

GearcaseOperating

Temperatures above125° F

Gear Case Oil

Traverse Gear Case

ISO Viscosity Grade 460 680

Amoco ® Oil Corp. Worm Gear Oil Cylinder Oil #680

Mobil ® Oil Corp.Mobil ® SHC 634Synthetic,Mobil ® 600W

Mobil ® SHC 634Synthetic,Extra HeclaSuper

Shell ® Oil Co. Valvata ® J460 Valvata ® J680

Texaco ® Inc. Meropa ® 460 Meropa ® 680

4.7. LUBRICANT SPECIFICATIONS

Page 10

SECTION V - INSPECTION ANDPREVENTIVE MAINTENANCE

5-1. GENERAL. All YALE "Global King" hoists are inspectedand tested at the factory. Regular in-service inspection andpreventative maintenance programs not only help reduce overallmaintenance costs but may also prevent service shutdowns byforewarning of problems that could cause these shutdowns.Regular inspections, periodic minor adjustments, regularcleaning and lubrication and replacement of worn parts canhelp preserve good performance and operation of your hoist.

Many factors influence the inspection and preventativemaintenance program required for your hoist. Frequency andseverity of service and material handled, local environmentalconditions and various applicable codes are some of the factorsthat the user must consider to adjust inspection andmaintenance program outlined in this section to meet hisspecific conditions.

The inspection and maintenance intervals outlined in thissection are considered a minimum. Recommended in theschedule are minimum inspection and maintenance intervalsbased on average daily use in a normal environment. YourYALE "Global King" hoist was designed to meet a specific dutyclassification as described by the FEM "Rules for the Designof Serial Lifting Equipment" and is to be used in accordancewith the duty rating identified on the equipment nameplate.For more details regarding hoist duty cycles and average dailyuse, please reference FEM Section IX, Series Lifting Equipmentor the Hoist Duty Classification page in this manual.

Environmental conditions in which the hoist operates are alsoimportant considerations for the user, when adjusting hoistinspection and maintenance programs to local conditions.Frequency of inspection and maintenance must be increasedif hoist is subjected to severe atmospheric environmentalconditions, such as corrosive vapors, extreme heat or cold,cement or dust and other airborne contaminants. The usershould carefully consider all environmental conditions and adjustfrequency and degree of maintenance for his local conditions.Consult the factory's Field Service Department for adviceregarding unusual environmental conditions.

Various codes also regulate inspection and maintenanceprograms. Attention must be given to applicable federalstandards, OSHA regulations, national standards, state andlocal codes which may include mandatory rules relating tohoist inspection and maintenance. The user should becomefamiliar with all applicable codes for his area and be guidedaccordingly.

Listed on the Recommended Inspection and MaintenanceSchedule are inspection frequencies and requirements. Performthese inspections regularly as scheduled and additionalinspections as may be required for activity, service, andenvironment of your hoist. The hoist operator must beresponsible for determining the operating conditions and severityof service.

Inspection Schedule and Maintenance Report Form.

Shown on page 12 of this manual is a recommended InspectionSchedule and Maintenance Report form that lists variouscomponents of the hoist. The form also includes trolleycomponents, runway components, and miscellaneous items.This form is suggested as a guide for written inspection reports.Inspections are recommended each month and should beperformed thoroughly enough to inform the hoist user ofdeficiencies for any item listed. This form does not supersede

the Inspection and Maintenance Schedule listed on page 11 ofthis manual but may be used to record scheduled inspectionand maintenance services required.

The user should revise the inspection interval, add additionalunits or provide a similar form to suit particular conditions thatmay exist. However, written, dated and signed inspection reportsshould be maintained particularly on critical items such ashoist hooks, hoisting rope, sheaves, drums and brakes. Periodicreview of old inspection reports can point out service life ofhoist components, forecasting need for adjustment, repair orreplacement of these components.

As a matter of expedience, appointed maintenance personnelinspecting hoist can also take care of minor adjustments, repairsand cleaning, where required. Note column on InspectionSchedule and Maintenance Report form headed CorrectiveAction and Notes. When corrective action is made duringinspection, note condition of part or unit as inspected inappropriate Condition column with a check mark (�). Note"during inspection" corrective action taken and date in spaceprovided. In this manner, items requiring further attention willbe checked (�) without showing corrective action. This willadvise the person responsible for hoist operation and safety,or whoever reviews the inspection reports, that deficienciesexist. The designated person will check all deficiencies as listedand re-examine or otherwise determine whether they constitutea safety hazard.

Written, dated and signed inspection reports for many itemsare mandatory under OSHA regulations, and many state safetycodes.

It is strongly recommended that the Inspection Schedule andMaintenance Report, shown herein, be completed by a qualifiedperson designated with the responsibility for hoist operationand safety or an inspector appointed by this person.

Inspection records can point out the service life of hoistcomponents and help forecast the need for adjustments, repairs,and ordering of replacement parts. File and review these reportsafter each inspection.

All YALE "Global King" hoists are equipped with a Pulse™

monitor, which is wired into the control circuit in the controlenclosure. This equipment consists of a circuit board, a serialcommunications port, and onboard memory, which will retaindata even when the hoist is removed from power. The Pulsemonitor takes the "pulse" of the equipment by recording themost recent hoist activities including all normal operation events,motor starts, overcapacity lifts and thermal overload events. Inaddition, the monitor records the total cumulative operatingtime and motor starts for the life of the equipment. Each Pulsemonitor is programmed with the equipment serial number atthe factory.

Deficiencies may be hazardous to personnel andequipment. Do not operate a hoist having deficienciesunless a designated qualified person has determinedthat these deficiencies DO NOT constitute a safetyhazard.

WARNING

Page 11

Notes

Data may be downloaded from the monitor, via the serialcommunications link, by a certified technician. Pulse monitordata may be used to determine equipment usage and to verifythat the application does not exceed the hoist duty rating asidentified on the equipment nameplate. The data can also be

helpful in establishing and scheduling preventative maintenanceas well as an aid in troubleshooting the equipment. Foradditional information refer to the Pulse monitor manual (P/N11817503) sent with this manual.

Hours of "On" time

* Complete inspection, disassembly and maintenance required. It is recommended that your YALE repair Station be contacted for this service.

LoadSpectrum

Hoist Duty

2m 3m

L1 12500 25000

L2 6300 12500

L3 3200 6300

L4 1600 3200

RECOMMENDED INSPECTION AND MAINTENANCE SCHEDULE

TIME INTERVAL INSPECTION OR MAINTENANCE

Daily or start of eachshift (visual)

* 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 spoolingon drum. Inspect hooks, upper and lower blocks, and all load bearing components for damage.

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 - add oil as

required per Paragraph 4-2.e.

6 Months

******

LOWER BLOCK -Inspect per Paragraph 5-2.UPPER BLOCK -Inspect per Paragraph 5-3.ROPE GUIDE-Inspect per Paragraph 5-5.OVER-CAPACITY LIMIT SWITCH-Inspect per Paragraph 5-13.BLOCK OPERATED LIMIT SWITCH (if equipped)-Inspect per Paragraph 5-12.Lubricate hoist cable per Paragraph 4-3. Lubricate upper and lower hook block, Lubricate outboardbearing cartridge at grease fitting, Add a light film of MPG grease to the bevel gear in the screwtype limit switch per Paragraph 4-7.

Annually* Complete inspection. Motor brake and actuating mechanisms inspected and adjusted per

Paragraph 5-10. Inspect hooks with crack detecting procedures per Paragraph 5-2.

Page 12

DATE

Motor

Motor Brake

Mechanical Load Brake

Overload Clutch

Couplings

Gears, Shafts & Bearings

Upper Block

Lower Block

Hook & Throat Opening X Record Hook Throat Opening

Hoist Rope

Rope Drum

Rope Guide

Guards

Limit Switches

Pushbutton

Wiring

Motor

Brake (when so equipped)

Couplings

Gears, Shafts & Bearings

Frame

Wheels

Bumpers

Guards

Conductors

Collectors

Hoist

Trolley

Monorail Joints

Monorail

Main Conductors

Main Collectors

General Condition

Load Attachment Chains

Rope Slings & Connections

Change Gearcase Lub.

Grounding Faults

* See text for DAILY & WEEKLY REQUIREMENTS. SIGNED & DATED REPORT REQUIRED – OSHA.INSPECTION INTERVAL. X MAGNETIC PARTICLE OR EQUIVALENT EXAMINATION REQUIRED.

INSPECTION SCHEDULE AND MAINTENANCE REPORTHOIST SERIAL NO. (MFGRS) _______________________ CUSTOMER CRANE IDENTITY NO. _______________________RATED LOAD _________________ LOCATION IN PLANT __________________________________TYPE ________________________ THIS INSPECTION IS MONTHLY � ANNUAL �

VOLTAGE _____________________ SEMI-ANNUAL �

INSPECTED BY: ________________ DATE _____________

*Recom- CONDITIONCOMPONENT, UNIT OR PART mended (Check column best indicating condition when CORRECTIVE ACTION

and location Inspection part or unit is inspected. Use note column to NOTESInterval the right if condition is not listed below.)

COMPONENT,UNIT OR

PART

(Indicate corrective action taken during inspection and note date. For correctiveaction to be done after inspection, a designated person must determine thatthe existing deficiency does not constitute a safety hazard before allowingunit to operate. When corrective action is completed, describe and note datein this column.)

Typical Inspection Schedule and Maintenance Report form.User must adjust inspection interval and components to suit his individual conditions and usage. 12375gwr

MO

NTH

LY

SE

MI-A

NN

UA

L

AN

NU

AL

GO

OD

AD

JUS

TME

NT

RE

QU

IRE

D

RE

PAIR

RE

QU

IRE

D(L

oose

Par

ts o

rW

ires

)

RE

PLA

CE

ME

NT

RE

QU

IRE

D(W

orn

or D

amag

ed)

LUB

RIC

ATIO

NR

EQ

UIR

ED

(Low

Oil

or G

reas

e,R

ust o

r C

orro

sion

)

CLE

AN

ING

OR

PAIN

TIN

GR

EQ

UIR

ED

HO

IST

LOC

ATI

ON

TRO

LLEY

RU

NW

AYS

RE

SIS

TOR

SM

ISC

.C

ON

TRO

LST

ATI

ON

OR

PUSH

BU

TTO

N

Page 13

5-2. INSPECTION OF LOWER BLOCKRefer to the Section IX, Figure 9-4.Lower Block Assembly.

a) Check lubrication of all parts. Also lubricate the shank ofthe hook that passes through the crosshead. If the thrustbearing is removed, apply MPG grease (Section IV,Paragraph 4-7).

b) Check each sheave to insure rope groove is smooth andfree from burrs, or other surface defects.

c) Check each sheave for freedom of rotation; replacebearings if defective.

d) Make certain that the spring pin holding the hook nut tothe 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 operatingcondition.

f) Check throat opening of the hook. (Refer to Figure 5-2.) Itis recommended that upon receipt of the hoist, ameasurement be made and recorded of the hook throatopening. OSHA regulations require that the hook bereplaced if the throat opening exceeds 15 percent of theoriginal opening, or if the hook is twisted more than 10degrees from the unbent plane. We suggest that a gageblock properly identified to the hoist, similar to the oneshown in Figure 5-2, be made for each hook for use inthese measurements.

Figure 5-2. Gage Block

g) Hooks showing signs of cracks must be replaced. Hooksshould be inspected at least once per year using dyepenetrants, magnetic particle, or other suitable non-destructive test methods.

h) Check wear of the hook, especially at the saddle andreplace if worn more than 10% of original dimensions.

Be certain that main power switch is locked in openposition (OFF) before opening hinged control enclosurecover mounted to the counterweight.

WARNING

a) Open hinged control panel enclosure cover mounted tothe counterweight and inspect wiring and terminals.Terminals should be securely crimped to wires andinsulation sound. Terminal screws should be tight.

b) Check condition of contactor assembly, transformer, andupper limit switches.

5-5. INSPECTION OF ROPE GUIDE

a) General. The rope guide is intended to help prevent therope from "back-winding" and to hold the rope in the propergroove. Side pulling and excessive load swing will severelydamage the rope guide and must be avoided.

5-3. INSPECTION OF UPPER BLOCKRefer to the Section IX, Figure 9-5.Upper Block Assembly.

a) Check upper block sheaves for wear, damage and freedomof rotation. If sheaves do not rotate freely, disassembleblock and inspect bearings. Replace worn or damagedbearings, washers, pins, or sheaves.

b) Make certain that all sheaves, bearing and hanger pinsare free of foreign material. Bearings without grease fittingsare lubricated for the life of the bearing and require nofurther lubrication.

c) Make certain that the rope retention bolts are not bent,loose or otherwise distorted; bolts must have closeclearance to sheave flange to keep rope in sheave grooves.

5-4. INSPECTION OF ELECTRICAL CONTROLS

Arrangement of electrical control equipment varies with thetype of control, physical space and the optional control featuresordered with the hoist.

Note the location in the electrical enclosure of the control circuitfuse, transformer, limit stop switches and the hoist contactors.Trolley contactors and optional hoist and trolley fuses are alsolocated in this enclosure.

Use wiring diagrams furnished with hoist to determine electricalcomponents on your hoist; then determine component locationand identity on your hoist.

Side pulling and excessive load swing will severelydamage the rope and rope guide. Failure of thesecomponents may result in injury.

WARNING

Do not operate a hoist having unusual vibrations,sounds, or with anything visibly or otherwise wrong.Danger may be present that the hoist operator cannotsee. Determine and correct the cause of unusualconditions and make certain hoist can be operatedsafely.

WARNING

Page 14

Figure 5-3 Rope Guide Assembly

b) Disassembly of "A" Frame Rope Guide. Refer to Fig. 5-3.For further assistance in locating components, refer tothe parts list in Section IX.

(1) Remove socket head cap screws and lock washers(Items 6 and 7). Remove drum frame rod (Item 8).

(2) Remove shoulder bolts (Item 3) and compressionsprings (Item 4). The two halves of the rope guidebody (Item 1) can now be pulled off the drumseparately. When reassembling be sure that the halfwith the rope slot is on the top half of the drum.

Once shoulder bolts are removed, the halves willseparate and, if not properly supported, the halvescould fall.

WARNING

(3) Carefully unhook the rope tensioning spring (Item 5),which is under tension.

The rope tensioning spring is under considerabletension; use caution when unhooking to avoid injury.

WARNING

(4) Remove the split plastic shroud (Item 2) from the drum.When reassembling the rope guide, be sure the plasticshroud (Item 2) fits snugly in the rope guide bodygroove.

(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), afterassembling.

5-6. ROPE INSPECTION, MAINTENANCE ANDREPLACEMENT

a) Inspection. Wire rope on your hoist is one of the mostimportant components requiring frequent inspection andmaintenance. All wire ropes will eventually deteriorate toa point where they are not safe and will requirereplacement. Wire rope should be thoroughly inspectedat regular monthly intervals by an authorized person anda determination made when further use of the rope wouldconstitute a safety hazard. Each inspection should includea written dated and signed report of rope condition.Reports should be filed and reviewed each month andany rope deterioration carefully noted. Inspectionsrevealing, but not limited to the following conditions, shouldcause inspector to question remaining strength of ropeand consider replacement. Inspections should take placeat the most active sections of the rope, which may beidentifiable through visual inspection of rope color. Ropeswill wear more quickly in areas that are more frequently incontact with the running sheaves and drum.

(1) Replace wire rope if the number of visible brokenwires exceeds 13 over a length of 6 times the nominaldiameter (6d) or exceeds 26 wires over a length of30d.

(2) Replace wire rope, if a complete strand has broken.

(3) Replace wire rope, if rope exhibits swelling, bruises,permanent bends, kinks, crushing, bird-caging orespecially heavy wear.

(4) Replace wire rope, if rope has suffered heat damagefrom any cause.

Figure 5-4. Correct Method of Measuring Rope

12169

Wire Rope improperly handled or abused can create aSAFETY HAZARD. Read and comply with inspection,maintenance and replacement information givenherein.

WARNING

Page 15

'580

%/2&.

/2:(5

'($'�(1'

������������

�������

(5) Rope corrosion and/or rust formation, internal orexternal.

(6) Effects from improper lubrication.

(7) Rope being idle for one month or more due toshutdown or inactivity.

Special attention should be exercised when inspecting ropenormally hidden during inspecting procedures.

Please refer to FEM Section IX, Series Lifting Equipment,namely Section 9.661, "Dimensions and Design of RopeReeving Components" and ISO 4309, "Wire Ropes - Care,Maintenance, Installation, Examination and Discard", forillustrations and definitions when following the above guidelinesfor rope inspection.

b) Maintenance. Keep rope well lubricated to help reduceinternal friction and prevent corrosion. Lubricant, asdescribed in Paragraph 4-3, should be applied as a partof the regular maintenance program. Special attention isrequired to lubricate sections of rope over equalizingsheaves and other hidden areas.

Avoid dragging ropes in dirt or around sharp objects that willscrape, nick, crush, or induce sharp bends in the rope.

Use only factory-approved rope with swaged wire ropesocket.

WARNING

c) Replacement. When recommended by an authorizedinspector, the rope should be replaced. Replacement ropeassemblies are shipped from the factory carefully coiledto prevent damage by kinking. Care must be taken toavoid twisting or kinking when uncoiling and handlingduring reeving.

Before replacing rope, check condition of grooves insheaves and drums to determine if they are excessivelyworn.

When first using hoist after rope replacement, break inrope by operating under lighter loads to full travel beforeapplying maximum load.

5-7. ROPE REEVING

a) General. Place reel on stand with shaft through the centerof reel so rope can be pulled straight out with reel rotating.

It is imperative that rope reel or coil rotates as ropeunwinds. If coil or reel does not rotate the wire will betwisted as it is uncoiled and kinking will result. A kinkedrope is unsafe and must be removed from service.

WARNING

b) Before removing the old rope, refer to reeving diagram,Figure 5-5. To assist with re-reeving your hoist, refer tothe reeving diagram and corresponding paragraph thatdescribes the reeving procedure.

Figure 5-5a. Reeving Diagram - 4 Part Single Reeved.(Note: Arrow on Drum Indicates Direction

of Drum when Lowering.)

Figure 5-5b. Reeving Diagram2 Part Single Reeved

c) Removing old rope. Please refer to Section IX to assist inlocating components referred to in the followingparagraphs.

(1) Lower the lower block to a scaffold 6 to 7 feet belowhoist to relieve tension on wire rope. (Lower blockmay be lowered to the floor if desired; however, tohandle less weight and for ease of reeving, adequatescaffold below the hoist is recommended.)

Be certain all personnel are clear of hoist ascomponents, hardware, and wire rope are removedfrom hoist.

CAUTION

(2) Remove the cap screws and hex nuts that retain thelower block sheave covers. Remove covers.

(3) Remove retaining rings from lower block sheave pin.

(4) Slide out lower block sheave(s) and remove wire rope.

(5) Remove two (2) rope retention bolts and nuts fromthe upper block yoke, as needed.

Page 16

Winding rope on rope drums with power can behazardous. Keep hands safe distance from drum; weargloves and use extreme care when winding rope.

WARNING

d) Installing new rope.

(1) Thread rope to drum from trolley frame side thensecure with rope clamps as follows:

(a) Make sure that the rope clamp is orientated suchthat the clamp grooves capture and fully seat therope in the drum grooves. The clamps are designedfor use specifically with the 6.4mm wire rope thatwas supplied with your "A" Frame hoist.

(b) With the rope lying in the bottom of the drumgroove, begin by tightening the rope clamp at thetail end of the rope. Torque the "A" Frame clampsto 12-15 ft.-lbs. (16-20 N-m).

(c) Applying tension to the rope and keeping itproperly seated in the drum groove, install theremaining two clamps to the specified torqueabove.

(2) With all personnel clear of hoist - TURN ON POWER.

(3) Operate hoist "UP" guiding six (6) wraps of new ropeinto drum grooves with gloved hand.

(4) Reinstall rope guide over rope in rope drum groovesas shown in Figure 5-3a. & 5-3b. and outlined inSection V, Paragraph 5-5. Continue lubricating as ropeis spooled onto the drum until about 24'-0" remainunwound.

(5) With outer lower block covers removed, thread thewire rope through the sheaves of the upper and lowerblock as shown in Figures 5-5a and 5-5b.

(6) Attach swaged rope end to the dead end anchor pinand fasten with the retainer rings provided with thehoist.

(7) Replace the lower block sheave covers.

The hoist must be removed from service and placedon the ground for any maintenance that requiresremoval of the output shaft assembly or drum.

WARNING

Figure 5-6. Drum Frame & Geared Limit Switch

(6) Remove one retaining ring on upper block to allowremoval of upper block sheave pin.

(7) Securely grasp the upper block sheave beforecarefully sliding the sheave pin out. Note that twospacers will Also be released as the pin is removed.

(8) Remove wire rope from sheave.

(9) Remove retaining ring(s) and washer from dead endanchor pin. Securely grasp the swaged wire ropebefore removing the anchor pin.

(10) Remove rope guide per Section V, Paragraph 5-5.

(11) Make certain all personnel are clear of hoist andoperate hoist "DN" to completely unwind all wirerope from drum. Stop hoist so all (3) rope clamps areaccessible. Remove rope clamps and wire rope fromdrum.

(8) Lubricate cable per Paragraph 4-3.

e) Checking for and removal of rope twisting.

(1) To remove rope twist in "A" Frame single reeved hoists:

(a) Observe direction block tends to rotate.

(b) Lower the block to a low position and TURN OFF(lock out) POWER.

(c) Remove swaged fitting from anchor pin and rotaterope several turns in a direction tending to correctblock rotation.

(d) TURN ON POWER; raise and lower the blockseveral times to feed the correcting twist in therope through the reeving.

5-8. INSPECTION OF ROPE DRUM AND SHAFT

a) To remove the rope drum, remove the rope guide andhoisting cable, as outlined in Section V, Paragraphs 5-5.and 5-7.c., respectively.

b) Remove the geared limit switch or disconnect the wiresso that the electrical cable will not inhibit removal of thedrum. (see Figure 5-6).

c) Remove the hoist from the beam, place it on the groundand provide adequate means to support the drum beforeremoving the frame rod cap screws and rods at theoutboard end drum frame (see Figure 5-6).

e) The hardware attaching the drum frame to the hoist andtrolley frame may then be removed.

f) Keeping the drum level, remove the drum from the splinedoutput shaft at the gear case end.

Page 17

Figure 5-7. Hoist Gear Case Assembly

5-9. INSPECTION OF HOIST GEARING

a) General. The hoist gear case is a triple-reduction, splashlubricated, vertically split, cast aluminum case and cover.A helical gear train provides smooth and quiet hoistingoperation. The gear shafts are supported with ball androller bearings housed in the back of the case and in thecover. The input pinion is integrated onto the motor shaft.An oil seal housed in the gear case at the motor inputseals the motor shaft as it passes into the gear case.Since the entire motor shaft is submerged in oil, anytimethe motor is removed, the oil must be drained from thegear case. All pinions are integral with their shafts whilethe gears are keyed and pressed onto their shafts, withexception of the integral output shaft. The output shaftpasses through an oil seal in the back of the gear caseand drives the drum by means of a crowned spline. Oneend of the rope drum is supported on this output shaft.

b) Inspection and Disassembly.

Gearcase. (See Figure 5-7.)

(1) Lower hook block to the floor and relieve all load fromropes.

(2) Make sure power to hoist is off and locked out.

Before disassembly, prevent rope drum from freespinning by wedging drum in place with a block ofwood, and resting lower block on work surface so allweight is off rope drum. Rope may also be removedfrom hoist drum.

WARNING

(4) On the "A" Frame hoist, the bolts supporting thegearcase are installed through tabs on the outside ofthe housing and do not pass through the gearcasecover. These bolts are not to be removed, unless theentire gearcase assembly is being removed from thehoist.

(5) Provide adequate means to support the gearcasecover. Remove the smaller socket head cap screwsand lockwashers holding the cover to the gearcase.Carefully draw the cover directly away from thegearcase, as damage to this surface will prevent thegasket from sealing properly. If needed, lightly tap onthe top and bottom cover tabs to release. As the coveris removed, ensure that all gear and shaft assembliesremain in the case and are fully supported by thegearcase bearings.

If output shaft assembly is pulled out of the gear casewith the cover, it will disengage from the drum allowingthe drum to drop. Be certain all shaft assemblies stayin the case.

WARNING

(6) If it is necessary to remove the output shaftassembly from the gear case, the rope drum mustfirst be removed from the hoist. See Section V,Paragraph 5-8.

The hoist must be removed from service and repairedon the ground for any maintenance that requiresremoval of the output shaft assembly or drum.

WARNING

Only once the output shaft is free of the rope drum,can the output shaft assembly be safely removed fromthe gearcase. Provide an adequate means to supportthis shaft and gear assembly before removing, as it isheavy. The "A" Frame gear assembly weighs 14 lbs.

(7) The pinion shaft and gear assemblies may be removedas necessary.

(8) Inspect all gears, pinions, bearings, and the outputshaft spline for wear, pitting, or mechanical damage.Replace the gearcase assembly, as necessary.Thoroughly clean the output shaft external spline teethbefore reassembly.

(9) Assembly is opposite of removal. Use a new gasket.Do not attempt to assemble the cover to the gearcase without a gasket, as the spacing betweenbearings will be reduced. Severe damage to the hoistwill 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 beforereinstalling rope drum.

(10) Test hoist per Section V, Paragraph 5-14 to ensureproper lubrication.

g) Inspect the gearcase output shaft and drum splines forwear.

h) Before re-assembling, by reversing above instructions,make sure to apply a liberal amount of SG (Paragraph4-7) spline grease to both the output shaft and drumsplines. Torque "A" Frame drum mounting bolts to 60-80ft.-lbs. (81-108 N-m).

(3) Drain the oil from the gear case per Section IV,Paragraph 4-2.

Page 18

(9) Install the motor to the gear case. The motor shaftmust be in line with the seal bore and perpendicularto the mounting surface before attempting to insertthe shaft through the seal. The motor shaft must remainhorizontal and not rock up and down or side-to-sidewhile installing the motor or seal damage will occur. Itmay be necessary to rotate the rope drum slightly toalign the gear teeth to mesh with the teeth on themotor shaft. Ensure that the motor seats properly intothe rabbet fit machined in the gear case. Fasten themotor to the gear case.

(10) Reconnect the conduit and power leads to the motor.See Section VIII and refer to the specific wiringdiagrams shipped with your hoist.

(11) Refill gear case with lubricant per Section IV,Paragraph 4-2.

(12) Test hoist to ensure proper operation per Section V,Paragraph 5-14.

Failure to use a factory replacement seal will causepremature seal failure due to specific lip materialrequirements that must be met.

NOTICE

Figure 5-8. Motor Brake

Hoist Motor.

(1) Lower hook block to the floor and relieve all load fromropes.

(2) Make sure power to hoist is off and locked out.

(3) Drain the oil from the gear case per Section IV,Paragraph 4-2.

(4) Disconnect the wiring and conduit from the motorjunction box.

(5) Provide a means to support the hoist motor. The "A"Frame S4 hoist motor weighs approximately 70 lbs.and the S2 hoist motor weighs approximately 50 lbs.The motor must be adequately supported and heldhorizontally while removing and installing, to avoidinput seal damage.

(6) Once the motor is properly supported, remove thehardware fastening it to the gear case. Carefullywithdraw the motor horizontally straight out from thegear case. Do not tip or move the motor from side toside.

(7) Replace the motor shaft seal using an appropriateseal driver. It is recommended that a new seal beinstalled each time the motor is removed from thecase.

IMPORTANT!

(8) Before reinstalling the motor, pack the gear teeth withMPG grease (Paragraph 4-7) and wrap the gear teethwith a number of layers of Teflon tape to protect theseal lip from being damaged by the gear teeth. Coatthe seal lip and the motor shaft with MPG grease.

5-10. INSPECTION OF MOTOR BRAKE AND ACTUATINGMECHANISM

a) General Operation. The hoist brake is an electro-magnetically released, spring set non-adjustable brake.Torque is generated by compressing a friction disk betweenthe stationary motor end bell and the spring loaded brakearmature. The friction disk is fixed to and rotates with themotor shaft. When the magnet coil is energized, thearmature plate is pulled across the air gap. The frictiondisk is carried by a splined hub that permits axialmovement when the brake is released. This axialmovement releases both sides of the friction disk fromtheir mating stationary surfaces and allows the frictiondisk to rotate freely when the brake is energized. Whenpower is removed from the magnetic coil, the compressionsprings push the armature against the friction disk andthe other side of the friction disk against the motor endbell generating the torque necessary to stop the hoistmachinery and hold the load.

It will be necessary to compensate for the friction diskwear when a greater amount of hook movement (drift) isnoticed when stopping. There is no torque adjustment ofthe brake. Friction disk wear can only be compensated forby resetting air gap.

b) Friction Disk Inspection and Air Gap Adjustment.

(1) Lower hook block to the floor and relieve all load fromropes.

(2) Make sure power to the hoist is off and locked out.

Check to be certain main power switch is locked inopen position (OFF), before removing fan shroud.

WARNING

(3) Remove the four (4) bolts attaching the fan shroud tothe motor and remove the fan shroud. See Figure 5-8.

(4) Carefully roll the large O-ring from the groove overthe air gap back toward the magnet body. Do notexcessively stretch this O-ring.

Page 19

(7) To reset the air gap, begin by releasing the (3)mounting bolts 1/2 turn. Turn the hollow spacer boltsinto the magnet body approximately 1/4 turn. Retightenall three mounting screws. Measure the air gap at aminimum of three places around the circumference.Threading the hollow spacer bolts into the magnetbody will decrease the air gap, while backing thesespacer bolts out of the magnet body will increase theair gap. Repeat this step, as necessary, until therequired air gap is achieved. The air gap must be thesame all the way around the brake. Once the air gapis correct, torque the mounting bolts to the value shownin Table 5-1.

(8) Replace the large O-ring over the air gap andreassemble the fan shroud to the motor.

(9) Test hoist per Section V, Paragraph 5-14 to ensureproper brake operation.

c) Brake Disassembly.

(1) Lower hook block to the floor and relieve all load fromropes.

(2) Make sure power to the hoist is off and locked out.

(3) Remove the four (4) bolts attaching the fan shroud tothe motor and remove the fan shroud. See Figure 5-8.

(4) Remove the snap ring behind the plastic fan. Carefullyremove the fan and key from the motor shaft. Removethe snap ring in front of where the fan was mounted.

(5) Disconnect the two wires from the terminal block onthe magnetic body.

Figure 5-9. Traverse Drive Arrangement

Table 5-1. Motor Brake Data

Hoist "A" S2 "A" S4

Mounting Bolt Torque 7.5 ft-lbs. 7.5 ft-lbs.(10 Nm) (10 Nm)

Nominal Air Gap 0.012 in. 0.016 in.(0.3 mm) (0.4 mm)

Maximum Air Gap 0.024 in. 0.028 in.(0.6 mm) (0.7 mm)

Minimum Brake Disk 0.335 in. 0.374 in.Thickness (8.5 mm) (9.5 mm)

(5) Measure the air gap using feeler gages. If the air gapexceeds the maximum value shown in Table 5-1, theair gap must be reset.

(6) To measure the thickness of the friction disk, it isnecessary to remove the brake body from the motorend bell. Remove the three (3) brake mounting boltsand draw the brake body away from the friction disk.Carefully set the brake body down on the motor shaftdirectly in front of the fan. Draw the friction disk awayfrom the end bell and measure the thickness acrossthe friction surfaces. If the friction disk thickness isless than the minimum shown in Table 1, it must bereplaced. See Section IX, Figure 9-8. If the frictiondisk thickness is within the allowable, reassemble thebrake body to the motor end bell and torque themounting bolts to the value shown in Table 5-1.Whenever the friction disk is replaced, it is necessaryto reset the air gap.

(6) Remove the three mounting bolts that attach the brakebody to the motor end bell and remove the brakebody from the motor. Remove the friction disk fromthe motor shaft.

(7) Clean and inspect all components and workingsurfaces. Replace all damaged or worn componentsas necessary. Measure friction disk thickness andreplace if less than the minimum thickness shown inTable 5-1.

d) Brake Re-assembly.

(1) Install the friction disk on the splined hub. The frictiondisk must slide on the splined hub and seat againstthe end bell of the motor.

(2) Install the brake body to the motor end bell using thethree (3) mounting bolts. The air gap must be reset asdescribed in Section V, Paragraph 5-10.b. Torque themounting bolts to the values shown in Table 5-1. Installthe large O-ring in the groove over the air gap. Ensurethis O-ring is not pinched in the air gap.

(3) Connect the brake leads to the terminal block on thebrake body.

(4) Install the forward fan mounting retaining ring andinstall the fan. Install the rear retaining ring. Install thefan shroud and bolts.

(5) Test hoist per Section V, Paragraph 5-14.

a) General. The traverse drive consists of four single flangewheels, two on each side of the beam, carried directly bythe hoist frame. These wheels rotate on sealed ballbearings supported by fixed pins. Pinions drive twoopposing wheels with gear teeth cut into the flange. Bothpinions are mounted on a keyed drive shaft supported bysealed ball bearings at each hoist side. The pinions areheld in place by means of locking setscrews. The driveshaft is driven by a single geared trolley wheel, which isin turn driven by a pinion mounted to a single reductionworm gear reducer.

b) Ensure that the hoist is properly fitted to the beam. Thehoist must be centered on the beam with clearancebetween the sides of the bottom of the beam flange andthe inside faces of the wheel flanges. Proper clearancemust exist along the entire length of beam that the hoistcan traverse. An amount of 3/32 to 1/8 inch clearance per

5-11. INSPECTION OF HOIST TRAVERSE DRIVE

Page 20

d) Examine the drive pinions, cross shaft, and cross shaftbearings. Check pinions for gear tooth wear and properalignment with wheel gear. A spacer washer between thecross shaft bearings and the pinion aligns the gear mesh.Setscrews hold the pinions and spacer washers tightagainst the bearings. Verify that the setscrews are tighton the cross shaft. If it is necessary to adjust or reset thepinions, verify that the cross shaft surface is free ofmechanical damage and oil before tightening thesetscrews. Drive pinions must be replaced as sets andshould be replaced along with the drive wheels. The crossshaft bearings are sealed for life and should be replacedat any sign of mechanical wear or lubricant leakage.

e) Inspect the traverse gearbox and motor. Look for signs ofrough operation, mechanical damage or lubricant leaks.Inspect the reducer and driving pinion for wear. Verifythat all hardware that mounts the reducer to the trolleyframe and the motor to the gear reducer are all presentand tight. Replace and tighten as necessary. The factoryrecommends complete replacement of the traversegearbox. However, gearbox service may be available fromyour local authorized YALE repair center.

5-12. TESTING BLOCK OPERATED LIMIT SWITCH

a) General. The optional block operated limit switch is asecondary upper limit switch actuated when the lowerblock contacts the actuator rod. The rotary-geared limitswitch (screw type limit switch) is the primary upper limitswitch and must be temporarily bypassed to allow theblock operated limit switch to be tested.

b) Procedure. Remove load from the hook. To disconnect thegeared limit switch, refer to Figure 7-2. Remove the limitswitch cover then loosen the two (2) screws holding thelocking plate in place. Allow the locking plate to slidedown and disengage from the adjustment discs. Do notrotate the adjustment discs.

The block operated limit switch may now be tested byslowly and carefully raising the hook until the limit switchrod contacts the lower block. If the hook does not stopwhen the limit switch rod is lifted, immediately release thepushbutton before damage to your hoist occurs. If theblock operated switch functions properly, proceed bytesting in the same manner with rated load on the hook.Once it has been determined that the block operated limitswitch is functioning properly, the geared limit switch mustbe reconnected and tested.

Position the lower block three inches (3") below the pointwhere the block operated limit switch is activated. Thegeared limit switch shall be reconnected by sliding thelocking plate back into position ensuring slots onadjustment discs are fully engaged and tightening lockingplate screws to 4 in-lbs. (See Figure 7-2). The geared limitswitch must then be tested.

Test the geared limit switch by raising the lower block until itstops. Ensure that the geared limit switch stopped the hoistbefore the block operated limit switch was activated. If this isnot the case, see Section VII, Paragraph 7-3 for adjustingthe geared limit switch. Replace geared limit switch coverwhen testing and adjusting is complete.

Check limit switch operation carefully, without load,before placing hoist in service. If misadjusted, SEVEREDAMAGE AND/OR A DROPPED LOAD COULD RESULT.Allow 3" for hook drift in both directions. Never allowless than two (2) complete wraps of rope on drum withhook in lowest position.

WARNING

5-13. TESTING OVER-CAPACITY LIMIT SWITCH

The over-capacity limit switch is provided as standardequipment on YALE "Global King" hoists. This switchis integral to the wire rope dead end assembly and is factorypreset to prevent over-capacity lifts. This device is preset atthe time of hoist inspection to prevent the lifting of loadsweighing 125-150% of rated capacity.

To test the function of the over-capacity limit switch, apply125% of the rated capacity to load hook. If hoist is capableof lifting the load, then actual switch setting may be higher

side is recommended for a total of 3/16 to 1/4 inch widerthan the beam flange. If too little or too much clearance isdetermined, 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, Paragraph4-7) on the wheel gear and pinion mesh. Check wheelbearings for any signs of wear, including rough rotationand signs of lubricant leakage. Replace all damaged ormissing items. Wheels must always be changed inopposing pairs and drive wheels should be changed whenthe drive pinions are replaced.

Ensure that the cross shaft is properly positioned andlocked into place by means of the setscrews. Failure todo so may allow the drive shaft to contact the hoistgearcase.

NOTICE

Damage to the hoist may occur if the block operatedlimit switch fails during testing.

Damage can be avoided by immediately releasing thepushbutton once the lower block has traveled throughthe limit switch weight.

CAUTION

Page 21

than necessary and needs to be adjusted. If hoist cannotlift load, then the switch setting is correct. Refer toSECTION VII, Paragraph 7-4 for information regarding theadjustment of the limit switch setting

5-14. TESTING HOIST

a) General. Testing shall be performed in accordance withFEM Section IX, Series Lifting Equipment, namely Section9.811 "Specification for rope and chain hoists", and thismanual. Before placing hoist in service, hoist should betested to insure safe operation, when hoist has beendisassembled and reassembled. To test, suspend hoistfrom an overhead supporting member of sufficient strengthto support the weight of the hoist and the rated load.Connect hoist to power supply as shown on hoistnameplate and perform the checks listed in b) and c)below.

b) Check hoist as outlined in PRE-OPERATION CHECKS,SECTION II, Paragraph 2-4.

c) Check hoist with rated load.

(1) Attach rated load to lower hook.

(2) Depress "UP" push button and raise load. When pushbutton is released, hoist should stop immediately andhold load at that level.

SECTION Vl - TROUBLESHOOTING

Trouble Probable Cause Remedy

a. Check switches, circuit breakers or fuses andconnections in power supply lines. Check powercollectors.

b. Check voltage required on motor data plate againstpower supply.

c. Shut off and lock out power supply; removeelectrical cover on hoist and check wiringconnections. Also check connections in push buttonstation and limit switches.

d. See that necessary jumper wires are properlyinstalled. Verify that the contactor armatures arefree to move. If binding occurs, replace contactor.Check for burned out contactor coils.

e. Check transformer fuse. If blown, check forgrounding and/or shorts in the push button station.Check the transformer coil for signs of overheating.Replace transformer if burned out. Verify thetransformer secondary is the same voltage as thecoils to which it is connected.

f. Replace motor. Check input power supply. Checkhoist motor connections.

g. Check phase protection device (PPD), if amberLED is steady; interchange any two power supplyline leads per Section II, Paragraph 2-4.b.

6-1. Hoist Will Not Operate a. No power to hoist

b. Wrong voltage

c. Loose or broken wireconnections in hoist electricalsystem

d. Contactor assembly notfunctioning

e. No control voltage

f. Motor burned out

g. Reverse phasing on three-phase hoists

(3) Depress "DN" push button, lower load a shortdistance and release button. Hoist should stopimmediately and hold load at that level.

NOTE:

If load drifts downward slowly in step 2 or 3 above, motorbrake requires adjustment - see Motor Brake Adjustment -SECTION VII, Paragraph 7-1.

SECTION VI - TROUBLESHOOTING

6-1. GENERAL. This section contains possible causes andsolutions to common hoist problems. Please attempt to remedyyour hoist problems by following these steps, before contactingthe factory.

Whenever servicing electrical components, be sure to shut offand lock out power following proper lockout/tagout procedures.

Working in or near exposed energized electricalequipment presents the danger of electric shock.

TO AVOID INJURY:

DISCONNECT POWER AND IMPLEMENT LOCKOUT/TAGOUT PROCEDURE BEFORE REMOVING COVER ORSERVICING THIS EQUIPMENT.

WARNING

Page 22

SECTION Vl - TROUBLESHOOTING

Trouble Probable Cause Remedy

a. Check PPD, if green LED is steady; interchangeany two sets (each winding) of motor power leads.

b. Check wiring connections with appropriate wiringdiagram.

a. Check for loose connections. See that necessaryjumper wires are properly installed on contactor.

b. See that necessary jumper wires are properlyinstalled. Verify that the contactor armatures arefree to move. If binding occurs, replace contactor.Check for burned out contactor coils.

c. Check push button contacts and wires.

a. Reduce loading to rated load of hoist, as shown onnameplate.

b. Check for loose connections. See that necessaryjumper wires are properly installed on contactor.

c. See that necessary jumper wires are properlyinstalled. Verify that the contactor armatures arefree to move. If binding occurs, replace contactor.Check for burned out contactor coils.

d. Check push button contacts and wires.

a. See that power supply current is the same voltageIisted on motor data plate. Check hoist motorconnections. Check size of power supply lines.

a. Reduce loading to rated load as shown onnameplate.

b. Reduce frequency of lifts or amount of jogging.

c. Check current rating on motor data plate againstpower supply. Check hoist and inspect for defective,worn or damaged parts.

d. Disassemble hoist and inspect for defective, wornor damaged parts.

e. Adjust brake per Section VII, Paragraph 7-1.

a. Reduce loading to rated load, as shown onnameplate.

b. With No Load, check hoist for drift. If drifting isexcessive, inspect motor brake (Section V,paragraph 5-10) and adjust as outlined in SectionVII, paragraph 7-1.

a. Check collectors for free movement of spring arm,weak spring or electrical connections.

b. Check all wiring for loose connections.

6-2. Hook Moves in WrongDirection

6-3. Hook Will Raise ButNot Lower

6-4. Hook Will Lower ButNot Raise

6-5. Hoist Will Not Lift RatedLoad

6-6. Hoist Motor Overheats

6-7. Load Drifts ExcessivelyWhen Hoist Is Stopped

6-8. Hoist OperatesIntermittently

a. Reverse phasing on three-phase hoists

b. Hoist wired incorrectly

a. Lower electrical circuit open

b. Contactor assembly notfunctioning

c. Down, push button inoperative

a. Excessive load

b. Hoist electrical circuit open

c. Contactor assembly notfunctioning

d. Up, down button inoperative

a. Low voltage

a. Excessive load

b. Excessive duty-cycle

c. Wrong voltage or frequency

d. Defective motor or wornbearings in hoist frame

e. Brake not adjusted properly

a. Excessive load

b. Motor brake not holding

a. Collectors make poor contact

b. Loose connections

Page 23

SECTION VII - ADJUSTMENTS

7-1. MOTOR BRAKE ADJUSTMENT. These brakes aredesigned so that adjustment is seldom required. If, after aperiod of service, the load hook "drifts" downward more thanusual for your hoist before coming to a stop, the motor brakemay require adjustment to compensate for brake disc wear.

Check to be certain main power switch is locked inopen position (OFF) before removing brake cover.

WARNING

Refer to Figure 5-9 and proceed as outlined in Section V,Paragraph 5-10.

7-2. BLOCK OPERATED LIMIT SWITCH ADJUSTMENT. Theblock operated limit stop, furnished as optional equipment, isminimally adjustable and designed to stop the lower block atthe safest high point of travel to eliminate any possibility ofdouble-blocking. When the safest high point is reached, thelimit switch automatically stops hook travel. If the block switchis not tripping after contact with the lower block body, loosenthe limit switch hub retaining screw and rotate the hub and roddownward to ensure earlier contact. Retighten and test, repeatas needed until switch functions properly.

7-3. GEARED ROTARY LIMIT SWITCH ADJUSTMENT. Thegeared rotary type limit switch is standard equipment and islocated on the drum end opposite the gearcase end.

This limit switch has a rotary screw driven by a gear reductionthat is coupled to the end of the drum shaft. Adjustment discsoperate the contacts of separate switches, one for the hoistingcircuit and one for the lowering circuit. The switch assemblymust be wired in accordance with the appropriate wiringdiagram, which is shipped with the hoist. Instructions foradjusting limit switch are inside cover and are repeated below(see Figure 7-2).

Figure 7-2. Screw-Type Limit Switch Adjustment(Wires Not Shown for Clarity.)

Be certain that electrical power supply is OFF andlocked in the open position before removing limitswitch cover.

WARNING

b) Loosen locking plate screws. Slide locking plate away fromadjustment disc.

c) Turn proper adjustment disc (right for up, left for down)toward switch to reduce hook travel or away from switchto increase hook travel.

d) Slide locking plate back into position ensuring slots onadjustment discs are fully engaged, tighten locking platescrews to 4 in-lbs.

e) Replace cover.

f) Carefully check limit switch operation without load beforeplacing hoist in service. If misadjusted, repeat steps above.Allow 3" for hook drift in both directions. Never allow lessthan two (2) complete wraps of rope on drum with hook inlowest position.

Check limit switch operation carefully, without load,before placing hoist in service. If misadjusted, SEVEREDAMAGE AND/OR A DROPPED LOAD COULD RESULT.Allow 3" for hook drift in both directions. Never allowless than two (2) complete wraps of rope on drumwith hook in lowest position.

WARNING

Provide a light film of MPG grease (Paragraph 4-7) on gear ofboth limit switches.

7-4. OVER-CAPACITY LIMIT SWITCH ADJUSTMENT. Theover-capacity limit switch is standard equipment and isintegrated into the wire rope dead end assembly (see Figure7-3). The device is designed to prevent overloading of theequipment, but is not intended to be used as a load-measuringdevice.

The limit switch is factory preset to prevent the lifting of loadsweighing 125-150% of rated capacity. At times, it may benecessary to adjust the limit switch setting.

Figure 7-3. Over-Capacity Limit Switch

a) Remove four screws and lift off switch cover.

LockingPlate

SwitchSwitch AdjustmentDiscs

12758B

Page 24

To adjust the limit switch setting, simply loosen the locking nut(see Figure 7-3) and then either loosen or tighten the adjustmentbolt into the overload base to achieve the desired setting.Loosening the adjustment bolt will increase the load requiredto trip the limit switch plunger while tightening will reduce thissetting. Only very small adjustment is required. Adjusting thelimit switch setting to increase the capacity limit beyond 125%is not permitted.

Be certain that electrical power supply is OFF andlocked in the open position before attemptingshortening of push button cable.

WARNING

a) Loosen screws at cable connectors and clamps at top ofcable.

b) Adjust steel support cable to proper length and tightenscrews.

Notes

7-5. SHORTENING OF PUSHBUTTON CABLE

c) Loosen upper cable grip and pull excess cable intoconnection box at hoist.

d) Tighten cable grip and cut off excess cable.

e) Strip cable sheath and connect wires with the same typeof terminals previously furnished (care must be taken tomatch previous wire color coding with wire markers inaccordance with the wiring diagram furnished with thehoist).

SECTION VIII - WIRING DIAGRAMS

8-1. GENERAL. Comprehensive wiring diagrams for YALEelectric hoists have been omitted from this book because ofthe many possible variations. This is due to different currentsand types of electrical components used in their construction.Figures 8-1 and 8-2 are examples of typical two-speed hoistand trolley wiring diagrams respectively. However, please consultthe exact wiring diagrams for your hoist. A print of the correctwiring diagram for each hoist is furnished as a separate insertand shipped with the hoist. We suggest you carefully file thewiring diagram with this book for future reference.

Page 25

Figure 8-1. Elementary Wiring Diagram for a Two-Speed Hoist and Trolley with Standard Features

Page 26

Figure 8-2. Component Diagram for a Two-Speed Hoist and Trolley with Standard Features

Page 27

SECTION IX - PARTS LIST

9-1. GENERAL. The parts lists and illustrations in this sectionof the manual cover parts for models of YALE "Global King"Electric hoists. A typical hoist is shown as the basis for theexploded parts illustrations; therefore, certain variations mayoccur from the information given. For this reason, always givethe Hoist Serial Number, Catalog Number, Motor Horsepower,Voltage, Phase, Frequency and Capacity of Hoist when orderingparts.

Throughout this manual, you will see references to the "S2"and "S4" Frame hoists. If you are unsure about which frameyou have, count the number of rope falls that are supportingthe lower block and/or see Section IV, Paragraph 4-2 for asimple gearcase measurement to determine the configurationof your hoist. Your gearcase should have a similar shape tothat shown and will measure 10 in width and requiresapproximately 3 quarts of oil.

Certain parts of your hoist will, in time, require replacementunder normal wear conditions. It is suggested that these partsbe purchased for your hoist as spares for future use. Theseparts are listed at the end of this manual.

WHEN ORDERING PARTS OR INFORMATION ON THISEQUIPMENT, ALWAYS INCLUDE MODEL AND SERIALNUMBER ON ORDER.

Using "Commercial" or other manufacturer's parts torepair Global King Hoists may cause load loss.

TO AVOID INJURY:

Use only YALE Hoist supplied parts. Parts may lookalike but YALE Hoist parts are made of specific materialsor processed to achieve specific properties.

WARNING

The numbers assigned to parts of our various assemblies inour Parts List are the part numbers used in manufacturing.Some of these itemized parts are not for individual sale, butmust be grouped with other related replacement items.

LIST OF PART ILLUSTRATIONS

TITLE FIGURE No. PAGE No.

Hoist Drum, Drum Frame, Gearcase, Motor, Rope Guide, and Limit Switch 9-1 28

Hoist Gearing 9-2 32

Motor Driven Trolley Frame and Drive 9-3 34

Lower Block Assembly 9-4 38

Upper Block Assembly 9-5 40

Wire Rope Dead End Assembly with Limit Switch 9-6 41

Rope Guide Assembly 9-7 43

Hoist Motor Brake – Standard Service 9-8 44

Hoist Motor Brake – Outdoor Service 9-9 46

Notes

Page 28

Figure 9-1. Hoist Drum, Drum Frame, Gearcase, Motor, Rope Guide and Screw Type Limit Switch

Ref. Part Qty.No. Number Description Req’d

1 - 5 HP Hoist Motor, 2-Speed with Brake and Fan (See Figure 9-8 for Parts) 133295001 208 Volt, 3-Phase, 60 Hertz33295002 230 Volt, 3-Phase, 60 Hertz33295003 460 Volt, 3-Phase, 60 Hertz33295004 575 Volt, 3-Phase, 60 Hertz

2 N/A Hex Head Cap Screw, M10 23 N/A Flat Washer, M10 24 N/A Locknut, M10 (Not Shown) 45 44943501 Hoist Gearcase (See Figure 9-2 for Parts) 16 N/A Socket Head Cap Screw, M10 27 N/A Flat Washer, M10 28 N/A Locknut, M10 (Not Shown) 49 43981305 Geared Limit Switch 1

10 11593901 Drum Shaft Insert for Geared Limit Switch 111 N/A Hex Head Cap Screw (Long), M10 212 N/A Hex Head Cap Screw (Short), M10 213 N/A Lock Washer, M10 414 N/A Limit Switch Bracket 115 N/A Heavy Duty External Retaining Ring 116 N/A Flanged Cartridge Ball Bearing 117 - Rope Drum 1

44943901 Rope Drum, 20' Lift Model44943902 Rope Drum, 40' Lift Model

18 23397701 Rope Clamp 3

"A" Frame S4 Reeved: Hoist Components for Figure 9-1.

(continued on next page)

Page 29

Ref. Part Qty.No. Number Description Req’d

19 N/A Socket Head Cap Screw, M6 320 N/A Lock Washer, M6 321 44943801C Rope Guide (See Figure 9-7 for Parts) 122 - Frame Rod 2

23385903 Frame Rod, 20' Lift Model23385904 Frame Rod, 40' Lift Model

23 N/A Socket Head Cap Screw, M10 424 N/A Hi-Collar Lock Washer, M10 425 N/A Drum Frame Bracket 226 - Trolley Frame Side Plate (Drum) 1

N/A Frame Side Plate, 20' Lift ModelN/A Frame Side Plate, 40' Lift Model

27 N/A Stiffener Bar 228 N/A Dead End Support Bar 129 N/A Hex Head Cap Screw, M12 (Long) 430 N/A Flat Washer, M12 131 N/A Hex Head Cap Screw, M12 (Short) 232 N/A Locknut, M12 633 N/A Dead End Support Weldment 134 N/A Hex Head Cap Screw, M8 635 N/A Locknut, M8 636 N/A Hex Head Cap Screw, M8 437 N/A Lock Washer, M8 438 44944702 YALE Brand Label for Gearcase (Not Shown) 1

"A" Frame S4 Reeved: Hoist Components for Figure 9-1. (continued)

Notes

Page 30

Ref. Part Qty.No. Number Description Req’d

1 - 3 HP Hoist Motor, 2-Speed with Brake and Fan (See Figure 9-8 for Parts) 133295501 208 Volt, 3-Phase, 60 Hertz33295502 230 Volt, 3-Phase, 60 Hertz33295503 460 Volt, 3-Phase, 60 Hertz33295504 575 Volt, 3-Phase, 60 Hertz

2 N/A Hex Head Cap Screw, M10 23 N/A Flat Washer, M10 24 N/A Locknut, M10 (Not Shown) 45 44943502 Hoist Gearcase (See Figure 9-2 for Parts) 16 N/A Socket Head Cap Screw, M10 27 N/A Flat Washer, M10 28 N/A Locknut, M10 (Not Shown) 49 43981305 Geared Limit Switch 1

10 11593901 Drum Shaft Insert for Geared Limit Switch 111 N/A Hex Head Cap Screw (Long), M10 212 N/A Hex Head Cap Screw (Short), M10 213 N/A Lock Washer, M10 414 N/A Limit Switch Bracket 115 N/A Heavy Duty External Retaining Ring 116 N/A Flanged Cartridge Ball Bearing 117 44943901 Rope Drum, 40' Lift Model 118 23397701 Rope Clamp 319 N/A Socket Head Cap Screw, M6 320 N/A Lock Washer, M6 3

"A" Frame S2 Reeved: Hoist Components for Figure 9-1.

Figure 9-1. Hoist Drum, Drum Frame, Gearcase, Motor, Rope Guide and Screw Type Limit Switch

(continued on next page)

Page 31

Ref. Part Qty.No. Number Description Req’d

21 44943801C Rope Guide (See Figure 9-7 for Parts) 122 23385903 Frame Rod, 40' Lift Model 223 N/A Socket Head Cap Screw, M10 424 N/A Hi-Collar Lock Washer, M10 425 N/A Drum Frame Bracket 226 N/A Trolley Frame Side Plate (Drum), 40' Lift Model 127 N/A Stiffener Bar 228 N/A N/A -29 N/A Hex Head Cap Screw, M12 630 N/A Flat Washer, M12 131 N/A N/A -32 N/A Locknut, M12 633 N/A N/A -34 N/A N/A -35 N/A N/A -36 N/A N/A -37 N/A N/A -38 44944702 YALE Brand label for Gearcase (Not Shown) 1

"A" Frame S2 Reeved: Hoist Components for Figure 9-1. (continued)

Notes

Page 32

Figure 9-2. Hoist Gearing

Ref. Part Qty.No. Number Description Req’d

44943501C Complete 3200kg Hoist Gearcase Ass'y. - 75.14:1 Ratio 144943590 Gearcase Gasket/Seal Kit (Incl. Ref. Nos. 3, 24, 25)44943591 Gearcase Gasket/Bearings Kit (Incl. Ref. Nos. 3, 10, 15, 16, 20, 21, 23, 24, 25)

1 N/A Gearcase 12 N/A Cover 13 N/A Gasket 14 - Vent Plug 15 - Drain/Fill Level Plug 26 N/A Socket Head Shoulder Screw, M6 27 N/A Hi-Collar Lockwasher, M8 28 N/A Socket Head Cap Screw, M6 79 N/A Hi-Collar Lockwasher, M6 7

10 N/A Ball Bearing 111 N/A External Retaining Ring 112 N/A Intermediate Gear 113 N/A Drum Pinion Shaft 114 N/A Key 115 N/A Ball Bearing 116 N/A Ball Bearing 117 N/A Intermediate Pinion Shaft 118 N/A Key 119 N/A Motor Gear 120 N/A Ball Bearing 121 N/A Ball Bearing 122 N/A Output Shaft 123 N/A Roller Bearing 124 N/A Output Shaft Oil Seal 125 N/A Motor Shaft Oil Seal 126 N/A Torque Pin 227 N/A Threaded Stud, M10 4

"A" Frame S4 Reeved: Hoist Gearing for Figure 9-2.

Page 33

Figure 9-2. Hoist Gearing

Ref. Part Qty.No. Number Description Req’d

44943502C Complete 1600kg Hoist Gearcase Ass'y. - 126.3:1 Ratio 144943590 Gearcase Gasket/Seal Kit (Incl. Ref. Nos. 3, 24, 25)44943591 Gearcase Gasket/Bearings Kit (Incl. Ref. Nos. 3, 10, 15, 16, 20, 21, 23, 24, 25)

1 N/A Gearcase 12 N/A Cover 13 N/A Gasket 14 - Vent Plug 15 - Drain/Fill Level Plug 26 N/A Socket Head Shoulder Screw, M6 27 N/A Hi-Collar Lockwasher, M8 28 N/A Socket Head Cap Screw, M6 79 N/A Hi-Collar Lockwasher, M6 7

10 N/A Ball Bearing 111 N/A External Retaining Ring 112 N/A Intermediate Gear 113 N/A Drum Pinion Shaft 114 N/A Key 115 N/A Ball Bearing 116 N/A Ball Bearing 117 N/A Intermediate Pinion Shaft 118 N/A Key 119 N/A Motor Gear 120 N/A Ball Bearing 121 N/A Ball Bearing 122 N/A Output Shaft 123 N/A Roller Bearing 124 N/A Output Shaft Oil Seal 125 N/A Motor Shaft Oil Seal 126 N/A Torque Pin 227 N/A Threaded Stud, M10 4

"A" Frame S2 Reeved: Hoist Gearing for Figure 9-2

Page 34

Figure 9-3. Motor Driven Trolley Frame and Drive

Ref. Part Qty.No. Number Description Req’d

33295921 Geared Wheel Assembly Pair (Incl. Ref. Nos. 9, 11, 12, 13, 14, 15)33295922 Plain Wheel Assembly Pair (Incl. Ref. Nos. 9, 10, 12, 13, 14, 15)

1 - Trolley Frame Side Plate (Drum) 1N/A Frame Side Plate, 20' Lift ModelN/A Frame Side Plate, 40' Lift Model

2 - Counterweight Plate 1N/A Counterweight, 20' Lift ModelN/A Counterweight, 40' Lift Model

3 - Hoist/Trolley Controls (Specify HP, Voltage, Frequency, No. of Speeds, Options) 14 - Alignment Bar 2

23400201 Alignment Bar, 4" Thru 8-1/2" Trolley Beam Flange Width23400202 Alignment Bar, 8-5/8" Thru 14" Trolley Beam Flange Width

5 N/A Hex Head Cap Screw, M12 226 N/A Lockwasher, M12 127 - Threaded Rod, M12 2

N/A Threaded Rod, 4" Thru 8-1/2" Trolley Beam Flange WidthN/A Threaded Rod, 8-5/8" Thru 14" Trolley Beam Flange Width

8 N/A Plain Hex Nut, M12 12

"A" Frame S4 Reeved: Trolley Frame and Drive Components for Figure 9-3.

(continued on next page)

Page 35

Ref. Part Qty.No. Number Description Req’d

9 N/A Wheel Axle 410 N/A Plain Trolley Wheel 211 N/A Geared Trolley Wheel 212 N/A Ball Bearing 813 N/A Internal Retaining Ring 414 N/A External Retaining Ring 415 N/A External Retaining Ring 416 N/A Ball Bearing w/Retaining Ring 217 N/A Flat Washer 218 N/A Traverse Pinion 219 N/A Key 220 N/A Set Screw, M6 621 - Traverse Cross Shaft 1

N/A Cross Shaft, 4" Thru 8-1/2" Trolley Beam Flange WidthN/A Cross Shaft, 8-5/8" Thru 14" Trolley Beam Flange Width

22 N/A Drop Lug/Bumper Stop 423 11680704 Bumper (Optional) 424 N/A Locknut, M12 2625 N/A External Retaining Ring 126 N/A Output Pinion 127 N/A Hex Head Cap Screw, M8 428 N/A Locknut, M8 429 - Traverse Reducer 1

43907725 Traverse Reducer, 50 FPM43907715 Traverse Reducer, 80 FPM

30 N/A Traverse Motor (Specify HP, Voltage, Frequency, No. of Speeds, Options) 131 N/A Hex Head Cap Screw, 3/8 432 N/A Lock Washer, 3/8 433 N/A Gusset Bracket 334 N/A Gusset Shoe 235 N/A Gusset Stiffener 236 N/A Angle Bracket 337 N/A Hex Head Cap Screw (Long), M12 638 N/A Hex Head Cap Screw (Short), M12 339 N/A Traverse Stiffener Plate 140 N/A Hex Head Cap Screw, M12 341 N/A Hex Head Cap Screw, 3/8 442 N/A Plain Hex Nut, 3/8 443 N/A Locknut, 3/8 4

"A" Frame S4 Reeved: Trolley Frame and Drive Components for Figure 9-3. (continued)

Notes

Page 36

Ref. Part Qty.No. Number Description Req’d

33295921 Geared Wheel Assembly Pair (Incl. Ref. Nos. 9, 11, 12, 13, 14, 15)33295922 Plain Wheel Assembly Pair (Incl. Ref. Nos. 9, 10, 12, 13, 14, 15)

1 N/A Trolley Frame Side Plate (Drum), 40' Lift Model 12 N/A Counterweight Plate, 40' Lift Model 13 - Hoist/Trolley Controls (Specify HP, Voltage, Frequency, No. of Speeds, Options) 14 - Alignment Bar 2

23400201 Alignment Bar, 4" Thru 8-1/2" Trolley Beam Flange Width23400202 Alignment Bar, 8-5/8" Thru 14" Trolley Beam Flange Width

5 N/A Hex Head Cap Screw, M12 226 N/A Lockwasher, M12 127 - Threaded Rod, M12 2

N/A Threaded Rod, 4" Thru 8-1/2" Trolley Beam Flange WidthN/A Threaded Rod, 8-5/8" Thru 14" Trolley Beam Flange Width

8 N/A Plain Hex Nut, M12 129 N/A Wheel Axle 4

10 N/A Plain Trolley Wheel 211 N/A Geared Trolley Wheel 212 N/A Ball Bearing 813 N/A Internal Retaining Ring 4

"A" Frame S2 Reeved: Trolley Frame and Drive Components for Figure 9-3.

(continued on next page)

Figure 9-3. Motor Driven Trolley Frame and Drive

Page 37

Ref. Part Qty.No. Number Description Req’d

14 N/A External Retaining Ring 415 N/A External Retaining Ring 416 N/A Ball Bearing w/Retaining Ring 217 N/A Flat Washer 218 N/A Traverse Pinion 219 N/A Key 220 N/A Set Screw, M6 621 - Traverse Cross Shaft 1

N/A Cross Shaft, 4" Thru 8-1/2" Trolley Beam Flange WidthN/A Cross Shaft, 8-5/8" Thru 14" Trolley Beam Flange Width

22 N/A Drop Lug/Bumper Stop 423 11680704 Bumper (Optional) 424 N/A Locknut, M12 2625 N/A External Retaining Ring 126 N/A Output Pinion 127 N/A Hex Head Cap Screw, M8 428 N/A Locknut, M8 429 - Traverse Reducer 1

43907725 Traverse Reducer, 50 FPM43907715 Traverse Reducer, 80 FPM

30 N/A Traverse Motor (Specify HP, Voltage, Frequency, No. of Speeds, Options) 131 N/A Hex Head Cap Screw, 3/8 432 N/A Lock Washer, 3/8 433 N/A Gusset Bracket 334 N/A Gusset Shoe 235 N/A Gusset Stiffener 236 N/A Angle Bracket 337 N/A Hex Head Cap Screw (Long), M12 638 N/A Hex Head Cap Screw (Short), M12 339 N/A Traverse Stiffener Plate 140 N/A Hex Head Cap Screw, M12 341 N/A Hex Head Cap Screw, 3/8 442 N/A Plain Hex Nut, 3/8 443 N/A Locknut, 3/8 4

"A" Frame S2 Reeved: Trolley Frame and Drive Components for Figure 9-3. (continued)

Notes

Page 38

Figure 9-4a. Lower Block Assembly(S4 Reeved)

Ref. Part Qty.No. Number Description Req’d

44943601C Lower Block Assembly (Excludes Ref. Nos. 17 & 18) 133296201 Sheave Assembly (Incl. Ref. Nos. 12, 13, 14)4X1307 Hook Latch Kit (Not shown)

23398091 Hook Assembly (Incl. Ref. Nos. 2, 3, 4)1 N/A Trunnion Crosshead 12 N/A Hook & Nut Assembly 13 N/A Thrust Bearing 14 N/A Roll Pin 15 N/A Sheave Pin 16 N/A Spacer Tube 27 N/A Lower Block Strap 28 33296501 Inner Sheave Cover 29 N/A Flat Washer, M8 4

10 N/A Socket Head Cap Screw, M8 211 N/A Locknut, M8 212 N/A Rope Sheave 213 N/A Ball Bearing 414 N/A Internal Retaining Ring 215 N/A External Retaining Ring 216 33296511 Outer Sheave Cover 217 23382880 3200 kg Capacity Label 218 23382802 YALE Brand Label 219 N/A Socket Head Cap Screw, M6 620 N/A Locknut, M6 6

"A" Frame S4 Reeved: Lower Block Components for Figure 9-4a.

Page 39

Figure 9-4b. Lower Block Assembly(S2 Reeved)

Ref. Part Qty.No. Number Description Req’d

44944101C Lower Block Assembly (Excludes Ref. Nos. 14 & 15) 133296201 Sheave Assembly (Incl. Ref. Nos. 7, 8, 9)4X1304 Hook Latch Kit (Not Shown)

23398691 Hook Assembly (Incl. Ref. Nos. 2, 3, 4)1 N/A Crosshead Weldment 12 N/A Hook & Nut Assembly 13 N/A Thrust Bearing 14 N/A Roll Pin 15 N/A Sheave Pin 16 N/A External Retaining Ring 27 N/A Rope Sheave 18 N/A Internal Retaining Ring 19 N/A Ball Bearing 2

10 N/A Spacer Washer 211 33296701 Outer Sheave Cover 212 N/A Socket Head Cap Screw, M8 413 N/A Flat Washer, M8 414 23382802 YALE Brand Label 215 23382881 1600 kg Capacity Label 216 N/A Socket Head Cap Screw, M6 317 N/A Locknut, M6 3

"A" Frame S2 Reeved: Lower Block for Figure 9-4b.

Page 40

Figure 9-5. Upper Block Assembly(S4 Reeved)

Ref. Part Qty.No. Number Description Req’d

44944001 "A" Frame Hoist Upper Block Assembly 133296201 Sheave Assembly (Incl. Ref. Nos. 10, 11, 12)

1 N/A Upper Block Yoke 12 N/A Yoke Pin 14 N/A External Retaining Ring 25 N/A Locknut, M6 26 N/A Hex Head Bolt, M6 27 N/A Sheave Pin 18 N/A External Retaining Ring 29 N/A Spacer Washer 2

10 N/A Internal Retaining Ring 111 N/A Sealed Ball Bearing 212 N/A Rope Sheave 1

"A" Frame: Upper Block Components for Figure 9-5.

Page 41

Figure 9-6. Wire Rope Dead End Assembly

Ref. Part Qty.No. Number Description Req’d

44944201C “A” Frame S4 Reeved Rope and Dead end Assembly (Excl. Ref. No. 20) 11 N/A Dead End Yoke 12 N/A Yoke Pin 13 N/A Yoke Sleeve 14 N/A External Retaining Ring 25 N/A Overload Beam Plate 26 N/A Overload Spring Retainer 17 N/A Detent 18 N/A Belleville Spring Washer 49 N/A Socket Head Cap Screw, M6 2

10 N/A Locknut, M6 211 N/A Spacer 212 N/A Dead End Pin 213 N/A Washer 414 N/A External Retaining Ring 415 N/A Overload Spring Base 116 N/A Socket Head Cap Screw, M6 117 N/A Hex Nut, M6 118 N/A Hex Head Cap Screw, M6 219 N/A Locknut, M6 220 - Wire Rope and Swaged End Assembly 1

23397901 Rope Assembly, 20' Lift Model, 6.4mm23397902 Rope Assembly, 40' Lift Model, 6.4mm

21 N/A Limit Switch 122 N/A Limit Switch Bracket 123 N/A Socket Head Cap Screw, M5 324 N/A Lockwasher, M5 325 33290505C "A" Frame Block Operated Limit Switch - Optional Equipment (not shown) 1

"A" Frame S4 Reeved: Dead End for Figure 9-6.

Page 42

Ref. Part Qty.No. Number Description Req’d

44944202C "A" Frame S2 Reeved Rope and Dead end Assembly (Excl. Ref. No. 20) 11 N/A Dead End Yoke 12 N/A Yoke Pin 13 N/A Yoke Spacer 14 N/A External Retaining Ring 25 N/A Overload Beam Plate 26 N/A Overload Spring Retainer 17 N/A Detent 18 N/A Belleville Spring Washer 49 N/A Socket Head Cap Screw, M6 2

10 N/A Locknut, M6 211 N/A Spacer 212 N/A Dead End Pin 213 N/A Washer 414 N/A External Retaining Ring 415 N/A Overload Spring Base 116 N/A Socket Head Cap Screw, M6 117 N/A Hex Nut, M6 118 N/A Hex Head Cap Screw, M6 219 N/A Locknut, M6 220 - Wire Rope and Swaged End Assembly 1

23397903 Rope Assembly, 40' Lift Model, 6.4mm21 N/A Limit Switch 122 N/A Limit Switch Bracket 123 N/A Socket Head Cap Screw, M5 324 N/A Lockwasher, M5 325 33290505C "A" Frame Block Operated Limit Switch - Optional Equipment (not shown) 1

"A" Frame S2 Reeved: Dead End for Figure 9-6.

Figure 9-6. Wire Rope Dead End Assembly

Page 43

Figure 9-7. Rope Guide Assembly

Ref. Part Qty.No. Number Description Req’d

44943801C "A" Frame Rope Guide Assembly 11 N/A Rope Guide Body 12 N/A Plastic Shroud 13 N/A Socket Head Shoulder Bolt, M6 Thread 24 N/A Compression Spring 25 N/A Extension Spring 1

"A" Frame: Rope Guide Components for Figure 9-7.

Page 44

Figure 9-8. Standard Hoist Motor Brake

Ref. Part Qty.No. Number Description Req’d

33295049 Complete Brake Assembly (Includes Ref. Nos. 1,11,16,17 & P/N 33313853) 1

1 33313850 Brake Friction Disc 1

2 Fan 13 33295051 External Retaining Rings (Fan Hub) -4 BRAKE External Retaining Ring (Fan) 15 FAN Fan Hub -6 KIT Key (Fan Hub) -7 Key (Fan) 1

8 33313852 External Retaining Ring (Brake Hub) 19 BRAKE Spacer (Brake Hub) 1

10 HUB Key (Brake Hub) 111 KIT Brake Hub 1

12 33313853 Hollow Core Bolts 313 HARD- O-Ring 114 WARE Bolts (Brake Mounting) 315 KIT Compression Springs 5*

16 N/A Magnet Body - Order Complete Brake 1

17 N/A Armature Plate - Order Complete Brake 1

18 33295055 Fan Shroud 119 SHROUD KIT Bolts (Fan Shroud) 4

"A" S4 Frame: Hoist Brake Components for Figure 9-8.

* Kit comes with (7) springs, but only (5) are utilized in this assembly.

Page 45

Figure 9-8. Standard Hoist Motor Brake

Ref. Part Qty.No. Number Description Req’d

33295549 Complete Brake Assembly (Includes Ref. Nos. 1,11,16,17 & P/N 33295553) 1

1 33295550 Brake Friction Disc 1

2 Fan 13 33295551 External Retaining Rings (Fan Hub) -4 BRAKE External Retaining Ring (Fan) 15 FAN Fan Hub -6 KIT Key (Fan Hub) -7 Key (Fan) 1

8 33295552 External Retaining Ring (Brake Hub) 19 BRAKE Spacer (Brake Hub) 1

10 HUB Key (Brake Hub) 111 KIT Brake Hub 1

12 33295553 Hollow Core Bolts 313 HARD- O-Ring 114 WARE Bolts (Brake Mounting) 315 KIT Compression Springs 7

16 N/A Magnet Body - Order Complete Brake 1

17 N/A Armature Plate - Order Complete Brake 1

18 33295555 Fan Shroud 119 SHROUD KIT Bolts (Fan Shroud) 4

"A" S2 Frame: Hoist Brake Components for Figure 9-8.

Page 46

Figure 9-9. Outdoor Service Hoist Motor Brake

Ref. Part Qty.No. Number Description Req’d

33297049 Complete Brake Assembly (Includes Ref. Nos. 1,11,16,17, 18 & P/N 33294053) 1

1 33313850 Brake Friction Disc 1

2 Fan 13 33295051 External Retaining Rings (Fan Hub) -4 BRAKE External Retaining Ring (Fan) 15 FAN Fan Hub -6 KIT Key (Fan Hub) -7 Key (Fan) 1

8 33294052 External Retaining Ring (Brake Hub) 19 BRAKE Spacer (Brake Hub) 1

10 HUB Key (Brake Hub) 111 KIT Stainless Steel Brake Hub 1

12 33294053 Hollow Core Bolts 313 HARD- O-Ring 114 WARE Bolts (Brake Mounting) 315 KIT Compression Springs 5*

16 N/A Magnet Body - Order Complete Brake 1

17 N/A Stainless Steel Armature Plate - Order Complete Brake 1

18 N/A Stainless Steel Friction Disc - Order Complete Brake 1

19 11803105 Spacer Washers 4

20 33295055 Fan Shroud 121 SHROUD KIT Bolts (Fan Shroud) 4

"A" S4 Frame: Hoist Brake Components for Figure 9-9.

* Kit comes with (7) springs, but only (5) are utilized in this assembly.

Figure 9-9. Outdoor Service Hoist Motor Brake

Ref. Part Qty.No. Number Description Req’d

33297149 Complete Brake Assembly (Includes Ref. Nos. 1,11,16,17, 18 & P/N 33297153) 1

1 33295550 Brake Friction Disc 1

2 Fan 13 33295551 External Retaining Rings (Fan Hub) -4 BRAKE External Retaining Ring (Fan) 15 FAN Fan Hub -6 KIT Key (Fan Hub) -7 Key (Fan) 1

8 33297152 External Retaining Ring (Brake Hub) 19 BRAKE Spacer (Brake Hub) -

10 HUB Key (Brake Hub) 111 KIT Stainless Steel Brake Hub 1

12 33297153 Hollow Core Bolts 313 HARD- O-Ring 114 WARE Bolts (Brake Mounting) 315 KIT Compression Springs 7

16 N/A Magnet Body - Order Complete Brake 1

17 N/A Stainless Steel Armature Plate - Order Complete Brake 1

18 N/A Stainless Steel Friction Disc - Order Complete Brake 1

19 11803107 Spacer Washers 4

20 33295555 Fan Shroud 121 SHROUD KIT Bolts (Fan Shroud) 4

"A" S2 Frame: Hoist Brake Components for Figure 9-9.

A. Seller warrants that its products and parts, when shipped, and itswork (including installation, construction and start-up), whenperformed, will meet applicable specifications, will be of good qualityand will be free from defects in material and workmanship. All claimsfor defective products or parts under this warranty must be made inwriting immediately upon discovery and in any event, within one (1)year from shipment of the applicable item unless Seller specificallyassumes installation, construction or start-up responsibility. All claimsfor defective products or parts when Seller specifically assumesinstallation, construction or start-up responsibility and all claims fordefective work must be made in writing immediately upon discoveryand in any event, within one (1) year from completion of the applicablework by Seller, provided; however, all claims for defective productsand parts made in writing no later than eighteen (18) months aftershipment. Defective items must be held for Seller’s inspection andreturned to the original f.o.b. point upon request. THE ‘FOREGOINGIS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIESWHATSOEVER, EXPRESS, IMPLIED AND STATUTORY,INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIESOF MERCHANTABILITY AND FITNESS.

WARRANTYWARRANTY AND LIMITATION OF REMEDY AND LIABILITY

B. Upon Buyer’s submission of a claim as provided above and itssubstantiation, Seller shall at its option either (i) repair or replace itsproduct, part or work at either the original f.o.b. point of delivery or atSeller’s authorized service station nearest Buyer or (ii) refund anequitable portion of the purchase price.

C. This warranty is contingent upon Buyer’s proper maintenance andcare of Seller’s products, and does not extend to normal wear andtear. Seller reserves the right to void warranty in event of Buyer’suse of inappropriate materials in the course of repair or maintenance,or if Seller’s products have been dismantled prior to submission toSeller for warranty inspection.

D. The foregoing is Seller’s only obligation and Buyer’s exclusiveremedy for breach of warranty and is Buyer’s exclusive remedyhereunder by way of breach of contract, tort, strict liability or otherwise.In no event shall Buyer be entitled to or Seller liable for incidental orconsequential damages. Any action for breach of this agreementmust be commenced within one (1) year after the cause of actionhas accrued.

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 DiscOne Brake Control ModuleOne Brake Hardware KitOne Set of ContactorsOne TransformerOne 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:

Yale�Lift-Tech414 West Broadway AvenueP.O. Box 769Muskegon, MI 49443-0769

Phone: 800 742-9269Fax: 800 742-9270