shaw box wire rope hoist free sample

The Yale YK and Shaw-Box SK are designed with safety in mind, incorporating standard safety features such as a block-operated limit switch, adjustable geared limit switch, motor temperature control and overload protection.

Yale Hoists is one of the most popular brands in the material handling industry! In addition to Yale’s line of market leading Global King wire rope hoists, manual hoists and lever tools are also available. The Shaw-Box line products feature capacities from a 1/2 ton wire rope hoist to a 100 ton capacity trolley/hoist. Whatever your need, Yale and Shaw-Box Hoists have the right options to get the job done!

With locations in Wisconsin and Michigan, All-Lift Systems is a proud distributor, stocks Yale and Shaw-Box replacement parts, and is a certified repair center for Yale and Shaw-Box Hoists. Looking for a Yale or Shaw-Box product not on our website?  Please contact us.

RATED LOADS THRU 15 METRIC TONNEFollow all instructions and warnings for inspecting, maintaining and operating this hoist.The use of any hoist presents some risk of personal injury or property damage. That risk is greatly increased if proper instructionsand warnings are not followed. Before using this hoist, each operator should become thoroughly familiar with all warnings,instructions and recommendations in this manual. Retain this manual for future reference and use.Forward this manual to operator. Failure to operate equipment as directed in manual may cause injury.

B, C & D-FRAME MODELS (MONORAIL)September 2014 P/N: 11353399 REV. AA FOREWORDThis manual contains important information to help you install, operate, The contents of this manual are of necessity, general in nature and maymaintain and service your new YALE electric hoist. We recommend that cover features not incorporated on your hoist; or, you may have orderedyou study its contents thoroughly before putting the hoist into use. We features not covered by this manual. Therefore, the user must exercisealso recommend that you read Section IX - Series Lifting Equipment of care in applying instructions given in this manual. If specific informationthe European Federation of Materials Handling and Storage Equipment not in this manual is required, contact the factory.(FEM) and the applicable performance and safety standards referencedtherein. Then, through proper installation, application of correct THE INFORMATION CONTAINED IN THIS MANUAL IS FOR INFOR-operating procedures, and by practicing the recommended maintenance MATIONAL PURPOSES ONLY AND YALE DOES NOT WARRANT ORprocedures, you can expect maximum lifting service from the hoist. OTHERWISE GUARANTEE (IMPLIEDLY OR EXPRESSLY) ANYTHING OTHER THAN THE COMPONENTS THAT YALE MANUFACTURESIt will likely be a long time before parts information found in the Parts AND ASSUMES NO LEGAL RESPONSIBILITY (INCLUDING, BUTList is needed. Therefore, after the hoist is installed and you have NOT LIMITED TO CONSEQUENTIAL DAMAGES) FOR INFORMATIONcompletely familiarized yourself with operation and preventative CONTAINED IN THIS MANUAL.maintenance procedures, we suggest that this book be carefullyfiled for future reference.When ordering replacement parts from this book, it will be necessarythat you include with your order: the Hoist Serial Number and ModelNumber that are found on the nameplate attached to the hoist as shownin Figure 4-1. For your convenience, a space has been provided on thefront cover of this Manual for entering this information. We recommendthat you fill it out immediately so it is readily at hand when needed. NOTICE: Information contained in this book is subject to change without notice.

INDEX SECTION I GENERAL DESCRIPTION Page Paragraph 1-1 General .................................................................................................................................................................................................... 3 Paragraph 1-2 Basic Construction .................................................................................................................................................................................. 3 Paragraph 1-3 Selection & Application Guide ................................................................................................................................................................ 3 SECTION II INSTALLATION Paragraph 2-1 General .................................................................................................................................................................................................... 4 Paragraph 2-2 Installing Hoist ......................................................................................................................................................................................... 4 Paragraph 2-3 Connecting Hoist to Electrical Service .................................................................................................................................................... 5 Paragraph 2-4 Pre-Operational Checks .......................................................................................................................................................................... 5 SECTION III OPERATION Paragraph 3-1 General .................................................................................................................................................................................................... 6 Paragraph 3-2 Push Button Operation ........................................................................................................................................................................... 6 Paragraph 3-3 Operating Precautions ............................................................................................................................................................................ 6 SECTION IV LUBRICATION Paragraph 4-1 General .................................................................................................................................................................................................... 7 Paragraph 4-2 Changing Gear Case Oil ......................................................................................................................................................................... 7 Paragraph 4-3 Lubrication of Hoist Cable ...................................................................................................................................................................... 8 Paragraph 4-4 Lubrication of Limit Switch ..................................................................................................................................................................... 8 Paragraph 4-5 Lubrication of Geared Trolley Wheels and Pinions.................................................................................................................................. 8 Paragraph 4-6 Lubrication of Rope Guide ...................................................................................................................................................................... 8 Paragraph 4-7 Lubricant Specifications ......................................................................................................................................................................... 9 SECTION V INSPECTION AND PREVENTIVE MAINTENANCE Paragraph 5-1 General .................................................................................................................................................................................................. 10 Paragraph 5-2 Inspection Lower Block......................................................................................................................................................................... 13 Paragraph 5-3 Inspection Upper Block......................................................................................................................................................................... 13 Paragraph 5-4 Inspection Electrical Controls................................................................................................................................................................ 13 Paragraph 5-5 Inspection of Rope Guide ..................................................................................................................................................................... 13 Paragraph 5-6 Rope Inspection, Replacement & Maintenance .................................................................................................................................... 14 Paragraph 5-7 Rope Reeving......................................................................................................................................................................................... 15 Paragraph 5-8 Inspection of Rope Drum & Shaft.......................................................................................................................................................... 17 Paragraph 5-9 Inspection of Hoist Gearing................................................................................................................................................................... 17 Paragraph 5-10 Inspection of Motor Brake & Actuating Mechanism ........................................................................................................................... 18 Paragraph 5-11 Inspection of Traverse Drive ................................................................................................................................................................ 21 Paragraph 5-12 Testing Block Operated Limit Switch .................................................................................................................................................. 22 Paragraph 5-13 Testing Over-Capacity Limit Switch .................................................................................................................................................... 22 Paragraph 5-14 Testing Hoist ....................................................................................................................................................................................... 22 SECTION Vl TROUBLESHOOTING ............................................................................................................................................................................... 22 SECTION Vll ADJUSTMENTS Paragraph 7-1 Motor Brake Adjustment ....................................................................................................................................................................... 24 Paragraph 7-2 Block Operated Limit Switch Adjustment ............................................................................................................................................. 24 Paragraph 7-3 Geared Rotary Limit Switch Adjustment ............................................................................................................................................... 24 Paragraph 7-4 Over-Capacity Limit Switch Adjustment ............................................................................................................................................... 25 Paragraph 7-5 Shortening of Push Button Station ....................................................................................................................................................... 25 SECTION VIII WIRING DIAGRAMS .......................................................................................................................................................................... 25-27 SECTION IX PARTS LIST Paragraph 9-1 General .................................................................................................................................................................................................. 28 Paragraph 9-2 List of Parts Illustrations ........................................................................................................................................................................ 28

2 Part No. 11353399SECTION I - GENERAL DESCRIPTION Class of Operating Time Class of Operating Time indicates the average period per day during1-1. GENERAL. which the mechanism is in operation, which is anytime the equipment is in motion. The Class of Operating Time is determined by calculation ofYALE "Global King" electric hoists are wire rope and drum type hoists the average daily operating time (average daily use):that are manufactured with an integral trolley. These hoists are all lowheadroom models with the rope drum and upper block or dead end Where:supported on opposite sides of the beam, by the trolley frame. There t = Average Daily Operating Time (hr/day)are three basic frame sizes, each with two standard lifts. The "B" Framehandles capacities up to 5 tonne, the "C" Frame handles up to 10 tonne H = Average Hoist Height (ft)and the "D" Frame handles up to 15 tonne. The "B" Frame has anintegral trolley with three different flange width ranges available: 4 5/8" N = Number of Cycles Per Hour (cycles/hr)through 8", 8-1/8" through 14" and 14-1/8" through 20" with a maximum T = Daily Working Time (hr/day)flange thickness of 1-5/8". The "C" Frame integral trolley has a flangewidth range of 6" through 20", with the same range breaks and flange V = Hoisting Speed (ft/min)thickness allowance as the "B" Frame above. The "D" Frame integraltrolley has a flange width range of 8" through 14" and 14-1/8" through 2xHxNxT20" with a maximum flange thickness of 1-3/4". The hoist motor is2-speed with a 4:1 ratio between high and low speeds, as standard. t=The motor driven trolley has two available speeds with 1, 2 speed, V x 60or variable frequency control. Load SpectrumThe 2 part reeved hoist has the same three basic frame sizes as stated Load Spectrum indicates the extent of which the mechanism is subjectedabove. Each frame size has one basic 80" standard lift. The B" frame to maximum stresses (full capacity lifts) or whether it is subject to smallerhandles capacities up to 2-1/2 tonne, the C" frame handles capacities loads only. Use the charts below to estimate your load spectrum. Forup to 5 tonne and the D" frame handles capacities up to 7-1/2 tonne. an exact means of calculating your load spectrum, refer to FEM 9.511 "Classification of Mechanisms".The trolley adjustment range for the 2 part reeved hoist is as follows.The B" frame flange width range is 4-5/8" through 6", 6-1/8" through12" and 12-1/8" through 18". Maximum flange thickness is 1-5/8".The C" frame flange width range is 4-5/8" through 6", 6-1/8" through12", 12-1/8" through 18" and 18-1/8" through 24". Maximum flangethickness is 1-5/8".The D" frame flange width range is 4-5/8" through 6", 6-1/8" through12" and 12-1/8" through 18". Maximum flange thickness is 1-3/4".Throughout this manual, you will see references to the S2" and S4"frame size hoists. If you are unsure about which frame type you have,count the number of rope falls that are supporting the lower block orsee section 5-7 rope reeving.

1-2. BASIC CONSTRUCTIONYALE "Global King" hoists consist of a rugged steel frame, madefrom structural tubing, which houses a lifting drum and serves as thesuspension means for the rated hoist load. An aluminum gearcase,attached to one end of the drum frame, houses a triple-reduction,helical gear train. Applying power to the gearcase is a 2-speed, AChoisting motor with a 4:1 speed ratio coupled with a 200% torque DCbrake. High strength wire rope and a covered lower sheave block actas the load carrying means. Standard equipment includes a rope guide,a rotary-geared limit switch to limit hook travel in both up and downdirections and an overload capacity limit switch. An optional blockoperated limit switch can be used to limit the upward travel of the lowerblock. An integral trolley, consisting of a 2-speed AC motor and a sealedworm reducer, applies torque to the trolley wheels through a cross-shaftand pinion arrangement, which provides traverse motion to the hoist. Asingle NEMA 4/12 control enclosure houses both the hoist and trolleyelectrical system controls. A push button control station (purchasedseparately) for operating the hoist is suspended on a wire strain cableattached to the hoist.

1-3. SELECTION & APPLICATION GUIDE. Once the average daily operating time, "t", is calculated for a specificHoist Duty Classification application, the Class of Operating Time can be identified. UsingYour YALE Global King" hoist was designed to meet a specific duty the Class of Operating Time along with the Load Spectrum, one canclassification as described by the FEM Rules for the Design of Serial determine the duty classification requirement of the application. DefiningLifting Equipment". The methodology used to determine the duty class the proposed equipment usage in this manner is critical to selecting therequirements of your specific application is shown below. correct hoist for the application.

YALE Global King" hoists are defined as mechanisms" by the FEM and Classification of Mechanismsare classified as such by the following factors: Class of Operating Timeand Load Spectrum. Your application must be definable by these two Class of Operating Timefactors in order to determine duty classification. Load T2 T3 T4 T5 T6 Spectrum Average Daily Operating Time (hr/day) 1 12 24 48 L1 1Dm 1Cm 1Bm 1Am 2m L2 1Cm 1Bm 1Am 2m 3m L3 1Bm 1Am 2m 3m 4m L4 1Am 2m 3m 4m 5m

3 Part No. 11353399Example: 2-2. INSTALLING HOISTAn application requires that a hoist be used to repeatedly lift and movesmall to medium size loads, but occasionally will be required to lift heavyloads equal to 5 metric tonne. This hoist will be operated daily for asingle 8-hour shift and will be required to perform 15 lifting cycles perhour. The average height, which the load is lifted, is 18ft at a desiredspeed of 20ft/min.The average daily operating time can be calculated from the above TRAVERSE SET SCREWS

The description of the example application implies that the load spectrumis likely an L1 or L2. Choosing an L2 load spectrum factor and using thecalculated average daily operating time, one can determine from the"Classification of Mechanisms" table above, the duty classification forthis application is 2m for a 5 metric ton rated hoist.For a more thorough explanation of the determination of mechanism Figure 2-1. Trolley Wheel Spacing ("B" & "C" Frame Shown)classification, refer to FEM 9.511 "Classification of Mechanisms".Your YALE "Global King" hoist was designed to meet the duty OPEN-END BEAM:classifications as described above. The standard 5t, 10t and 15t If the trolley can be installed directly from the end of the supportingcapacity models are rated at 2m duty classification, while the 7.5t beam, adjust the spacing between the trolley wheel flanges to becapacity model is rated at 3m duty classification. 3/16"-1/4" greater than the exact width of the beam flange (See Figure 2-1). Before adjusting the width of the trolley frame, make sure to loosen2 part reeved models @ 2-1/2, 5, and 7-1/2 tonne capacity are rated the pinion set screws nearest the traverse drive on the keyed cross shaftat 2m duty classification, while the 3-3/4 tonne model is rated at 3m and those on the traverse reducer. Do not lose the keys for the pinionduty classification. and reducer during adjustment. Also, the electrical conduit/cable must not be constrained when attempting to adjust the trolley sides, in or out.SECTION II - INSTALLATION The trolley width is adjusted by loosening the jam nuts on the traverse drive side of the threaded rods at each end of the hoist. If necessary, lubricate the frame alignment bars with penetrating oil before attempting2-1. GENERAL. to adjust trolley width. The trolley side may then be pushed or driven intoYALE "Global King" electric hoists are lubricated and tested before position by turning the adjusting nuts on the threaded rods. Adjust nutsbeing shipped from the factory. To place a hoist in service, install on each side of the hoist simultaneously, to avoid binding. After adjustingonto beam by adjusting appropriately for the flange width, connect the trolley to the proper width, tighten all adjusting nuts and setscrews,to electrical service and perform pre-operation tests and checks. and re-secure the electrical conduit/cable. Verify that the geared wheels mesh properly with the traverse drive pinions. Using proper equipment, carefully lift the hoist and install on the end of the beam. Lubricate the wheel gear and pinion (WG, Section IV, Paragraph 4-5). When hoists are adjusted or repaired in the field, all set screws must return to the original settings from the manufacturer. This is done by following the below instructions: Only qualified personnel with proper supervision shall install the hoist on the monorail and perform the final 1)Apply Loctite 242 to the threads and install the setscrews back pre-operation inspection. into the proper location 2)Tighten setscrews for the traverse pinion gear down onto the key and shaft to 70 in-lbs before beginning the use of the hoist

Working in or near exposed energized electrical NOTICE equipment presents the danger of electric shock. Loosen all electrical cable or conduit attached to the frame TO AVOID INJURY: and alignment bars before adjusting trolley width. Ensure that the electrical cable is not stretched, pinched, twisted or DISCONNECT POWER AND IMPLEMENT LOCKOUT/ otherwise damaged when adjusting trolley width. TAGOUT PROCEDURE BEFORE REMOVING COVER OR SERVICING THIS EQUIPMENT. CLOSE-END BEAM: For trolleys which are to be mounted along the span of a beam not having open ends, the trolley must be adjusted in the same manner as described above to a width that allows clearance between the axle ends and the beam flange. Using proper lifting equipment, the trolley and hoist must then be lifted to the beam where it is to be installed. Once in position, adjust the spacing between the trolley wheel flanges to be 3/16"-1/4"" greater than the exact width of the beam flange (See Figure 2-1). After tightening all adjusting bolts, set screws, and all electrical conduit/cable clamps, carefully set the trolley on the beam. Lubricate the wheel gear and pinion (WG, Section IV, Paragraph 4-5).

4 Part No. 113533992-3. CONNECTING HOIST TO ELECTRICAL SERVICEElectrical service to the hoist may be power cable or a guarded systemhaving sliding shoe or wheel type collectors. On three phase hoists, it is possible to have "ReverseFollow ANSI/NFPA 70, state, and local electrical codes including Phasing" causing the block to lower when the "UP" buttonthe grounding provisions thereof when providing electrical serviceto the hoist. is depressed. When this condition exists, the automatic limit switch is inoperative and hoist operation will beMake electrical connections using the appropriate wiring diagrams dangerous.furnished with the hoist. Only qualified journeyman electricians shallmake any electrical connections, including connections to collectorsor power cord. e)Check Lower Block and Hoisting Cable. Depress "DN" push button and run lower block to its lowest position. No less than two wraps shall remain on the drum with the loaded hook in its lowest position. Also check to see that the lower block and rope do not twist excessively. If it does twist to the extent that two ropes rub Be certain that electrical power supply is OFF and locked against each other, disengage the swaged rope end from the frame in the open position before attempting any electrical anchor and twist the rope four or five turns in a direction opposite to that which the block turns. Reconnect rope to the frame anchor, connections to the hoist. This equipment must be holding firmly to eliminate rope twisting back to its original position. effectively grounded according to the National Electric Operate hoist up and down a few times. If lower block still rotates Code ANSI/NFPA 70, or other applicable codes. excessively, repeat process until twisting is corrected. f)Lubricate Hoisting Cable. For longer cable life, it is recommended that the cable be lubricated at time of installation by applying a heavy coating of lubricant CL (Para. 4-7) as outlined in SECTION IV, Paragraph 4-3. Power supply to hoist and trolley must be the same voltage, g)Check Limit Switch Operation. frequency, and phase that are specified on the hoist and trolley (1) A geared rotary type upper and lower limit switch is provided as nameplate. standard equipment on YALE "Global King" hoists. This switch is adjustable and although preset by the factory, it should be adjusted at time of installation to the desired high and low limits2-4. PRE-OPERATIONAL CHECKS of lower block travel. Refer to SECTION VII, Paragraph 7-3. a)Check Oil Level. (Figure 2-1) The gearcase has been filled with (2) A block operated upper limit switch can be furnished as optional oil to the proper level. However, this should be rechecked before equipment on YALE "Global King" hoists. This limit stop is operating the hoist. factory set to stop the lower block at the safest high position, guarding against over travel and possible damage to hoist.Check oil level by removing the Oil Level Plug indicated in Figure Minimal adjustments can be made. When equipped with this 2-1. When properly filled, oil should be level with the bottom of the option, the hoist should be tested by jogging the lower block tapped hole. Fill to this level with oil as specified in Paragraph 4-2.e. against the limit switch actuator arm to assure the switch is b)Check all connections for tightness of bolts, inclusion of lock functioning properly. When the lower block lifts the actuator, washers or other type fasteners to ensure correct components "the hoist will automatically stop. If the lower block coasts have been used. This check must be made for all connections: through the limit switch when lifting, a reversing switch will mechanical, structural and electrical, including both field and automatically close and reverse direction of motion to lowering. factory-made connections. h)An overcapacity limit switch is provided as standard equipment on c)Check to ensure that all shipping supports, tie-downs, brackets YALE "Global King" hoists. This switch is adjustable and although or other items used only for shipping or storage purposes are preset by the factory, it should be adjusted at the time of installation removed from the equipment. to the desired setting. Refer to SECTION VII, Paragraph 7-4. d)Check Push Button Operation and Phasing. To properly check i)When first using the hoist and trolley, operate with lighter loads the phase of the hoist, follow these steps: through full travel before applying maximum load.(1) With "POWER OFF", operate all the push buttons and determine that they do not bind or stick in any position.

(2) Connect hoist to power source.(3) Operate "UP" button briefly to determine direction of hook travel.(4) If hook raises when "UP" button is depressed, phasing is correct.(5) If hook lowers when "UP" button is depressed, hoist is "Reverse Phased." TURN AND LOCK POWER OFF and check the pushbutton wiring. If the pushbutton was wired properly, correct the problem by interchanging any two leads at power source connection. Do not change internal wiring of hoist.

5 Part No. 11353399 3-3. OPERATING PRECAUTIONS. Safe operation of an overhead hoist is the operator"s responsibility. Listed below are some basic rules that can make an operator aware Damage to the hoist, a dropped load, and injury may result of dangerous practices to avoid and precautions to take for his own if limit switches fail due to improper use. safety and the safety of others. Observance of these rules, in addition to frequent examinations and periodic inspection of the equipment, TO AVOID INJURY: may save injury to personnel and damage to equipment. UNDER NORMAL OPERATING CONDITIONS, STOP HOIST TRAVEL BEFORE ENGAGING LIMIT SWITCHES. LIMIT SWITCHES ARE SAFETY DEVICES AND SHOULD NOT BE USED AS NORMAL OPERATING CONTROL. Equipment covered herein is not designed or suitable as a power source for lifting or lowering persons.

a)DO read applicable sections of FEM Section IX, Series Lifting Equipment and the Operation, Service and Parts Manual. Some hoists may be shipped with the electrical controls b)DO be familiar with hoist operating controls, procedures, loose (disconnected) and will not have the upper and and warnings. lower limit switches connected. DO NOT OPERATE HOIST c)DO make sure hook travel is in the same direction as shown on UNTIL LIMIT SWITCHES ARE PROPERLY CONNECTED the controls. If opposite direction occurs, see Pre-Operation AND ADJUSTED. Failure to do so may allow hoist to be Checks, Section II, Paragraph 2-4.b. operated beyond proper travel limits, which can cause load to drop, resulting in damage to equipment or injury. d)DO make sure hoist limit switches function properly. e)DO maintain firm footing when operating hoist. f)DO make sure that the load slings or other approved attachmentsSECTION III - OPERATION are properly sized and seated in the hook saddle.

3-1. GENERAL. g)DO make sure that the hook latch is closed and not supporting the load.Operation of YALE "Global King" hoists is controlled by a convenientpendant push button station. With it, the hoist can be controlled to give h)DO make sure that load is free to move and will clear all obstructions.fast lifting and lowering; or controlled to lift or lower the load in smallincrements, providing accurate positioning capability. The push button i)DO take up slack carefully, check load balance, lift a few inchesstation has a built-in interlock to prevent depressing opposing buttons and check load"s holding action before continuing.simultaneously. j)DO avoid swinging of load or load hook.When first using the hoist, break in by operating under lighter loads to k)DO make sure that all persons stay clear of the suspended load.full travel before applying maximum load. l)DO warn personnel of an approaching load.3-2. PUSH BUTTON OPERATION m)DO protect wire rope from weld splatter or other a.)For the hoist motion depress push button marked "UP" damaging contaminants. to raise load. n)DO promptly report any malfunction, unusual performance, b.)For the hoist motion depress push button marked "DN" or damage of the hoist. to lower load. o)DO inspect hoist regularly, replace damaged or worn parts, c.)For the trolley traverse motion: and keep appropriate records of maintenance.

With two speed control depress buttons marked "<<" , ">>" p)DO use the hoist manufacturer"s recommended parts when or "N", "S" to activate the trolley traverse motion repairing a hoist.

With one speed control depress buttons marked "<" , ">" q)DO use hook latches. or "N", "S" to activate the trolley traverse motion. r)DO apply lubricant to the wire rope as recommended. d.)On two-speed hoist or trolley motions, partial depression of a s)DO NOT lift more than rated load. button operates hoist or trolley at slow speed; depressing button completely operates hoist or trolley at full speed. t)DO NOT use the hoist load-limiting device to measure the load. u)DO NOT use damaged hoist or hoist that is not working properly. v)DO NOT use the hoist with twisted, kinked, damaged, or worn wire rope. w)DO NOT lift a load unless wire rope is properly seated in its groove(s). Excessive "jogging" will cause premature burning of contact x)DO NOT use wire rope as a sling or wrap rope around the load. tips, motor overheating and premature brake wear.

6 Part No. 11353399 y)DO NOT lift a load if any binding prevents equal loading on vv)DO NOT use hoist in location that will not allow operator movement all supporting ropes. to be free of the load. z)DO NOT apply the load to the tip of the hook. ww)DO, when starting to lift, move the load a few inches at which time the hoist should be checked for proper load holding action. aa)DO NOT operate unless load is centered under hoist. The operation shall be continued only after the operator is assuredbb)DO NOT allow your attention to be diverted from operating that the hoist is operating properly and that the load is supported the hoist. in the center of the base bowl/saddle of the hook.

dd)DO NOT use limit switches as routine operating stops unless yy)DO use common sense and best judgment whenever operating recommended. They are emergency devices only. a hoist.

ee)DO NOT use hoist to lift, support, or transport people. zz)DO NOT remove drop lugs. Removal will create an unsafe operating condition. ff)DO NOT lift loads over people. aaa) DO NOT lift guided loads.gg)DO NOT leave a suspended load unattended unless specific precautions have been taken. SECTION IV - LUBRICATION hh)DO NOT allow sharp contact between two hoists or between hoist and obstructions. 4-1. GENERAL. ii)DO NOT allow the rope or hook to be used as a ground for welding. The lubrication services outlined in Paragraphs 4-3 thru 4-6 should be jj)DO NOT allow the rope or hook to be touched by a live performed before initial operation of the hoist. The lubrication services welding electrode. outlined in Paragraphs 4-2 thru 4-6 should be performed at regular intervals at least every six (6) months, coinciding with spring and fall kk)DO NOT remove or obscure the warnings on the hoist. seasons is recommended. The reason for this is that on hoists installed outside or in unheated areas a "cold test" oil is required in such (below ll)DO NOT adjust or repair a hoist unless qualified to perform hoist freezing) climates making seasonal changes necessary. maintenance.mm)DO NOT attempt to lengthen the wire rope or repair damaged 4-2. CHANGING GEARCASE OIL wire rope. nn)DO NOT allow personnel not physically fit or properly qualified, to operate hoist.oo)DO NOT operate hoists unless hook moves in the same direction as indicated on the push button. If opposite direction occurs, see pre-operation checks, Section II Paragraph 2-4.b.pp)DO NOT operate hoist unless limit switches are operating properly.qq)DO avoid operating hoist when hook is not centered under hoist. Avoid side pulls and swinging of load or load hook when traveling hoist. rr)DO operate hoist within recommended duty cycle and DO NOT "jog" unnecessarily. ss)DO conduct regular visual inspections for signs of damage and wear. tt)DO NOT operate hoist with hooks that have opened up. See Section V, Paragraph 5-2.f. uu)DO provide supporting structure that has an appropriate design factor based on the load rating and dead weight of the hoist. If in doubt of the supporting structure"s strength, consult a structural engineer.

Figure 4-1. View of Hoist Showing Location of Name Plates and Oil Plugs ("B" & "C" Frame Shown)

DO NOT operate hoist with the hoisting rope out of the drum a)Add 5% solution of Mobilsol A (or equivalent) to the oil and run grooves. Such operation may result in damage to the rope for a short time. This will clean components and hold particles in guide and rope and could result in the rope breaking. This suspension for draining. may result in dropping the load that can cause damage to b)Remove oil drain plug from bottom of gearcase and drain oil out. equipment and injury to operator or other personnel. Hoist Dispose of oil in accordance with local environmental codes. rope will remain in the drum grooves during operation under normal operating conditions, however, slack or kinked rope, excessive side pulls, swinging or jerking of load, or similar abuse, may cause damage to the rope guide causing the rope to leave the grooves. Avoid skin contact with Mobilsol A. In case of skin contact: dry wipe the skin, cleanse the area with a waterless hand cleaner and follow by washing thoroughly with soap and water.

7 Part No. 11353399 c)Reinstall drain plug. 4-3. LUBRICATION OF HOISTING CABLE. d)Remove oil level plug from front of gearcase cover. Hoists are shipped from the factory without an exterior coating of grease on hoisting cable. It is recommended that the cable be thoroughly coated at installation and kept well lubricated with CL (Paragraph 4-7).

4-6. LUBRICATION OF ROPE GUIDE a)Maintenance. The rope guide is made of a molded self-lubricated reinforced nylon material. It is lubricated prior to installation at the factory and requires only periodic inspection. (1) Periodically re-grease with MPG (Paragraph 4-7) by applying grease to the leading edge of the guide and rope drum. (2) Every 6 months, the rope guide should be removed per Section V, Paragraph 5-5, cleaned and inspected. When reassembled, the rope guide should be thoroughly greased with MPG (Paragraph 4-7) and the hoist run up and down to lubricate bothFigure 4-2. Gearcase Width Illustration the drum and the wire rope.

e)Refill through filler hole to proper level (bottom of oil level plug hole) using GCOH (Paragraph 4-7). The amount of oil required depends on the overall size of the gearcase; three sizes are used for "Global King" hoists. To determine size and amount of oil to add, measure the width of hoist gearcase (see Figure 4-2). The "B" Frame measures 9-3/4" wide and requires approximately 5 quarts of oil. The "C" Frame measures 12-1/2" and requires approximately 11 quarts of oil. The "D" Frame measures 17" and requires approximately 12 quarts of oil.

Wheel Gear and Pinion Mobil Oil Corp. ---------------------------------------- Molitac 375 NC ---------------------------------------- Grease Texaco Inc. -------------------------------------------- Crater H -------------------------------------------- CL No Specification Amoco Oil Co. ------------------------------------------ Amovis 5-X ------------------------------------------ Cable Lubricant Mobil Oil Corp. ---------------------------------------- Mobilarma 798 ---------------------------------------- Wire Rope Lubricant Sun Oil Corp. -------------------------------- Sunoco Wire Robe Lubricant -------------------------------- Texaco Inc. Crater A Texclad 2 GO AGMA Lubricant No. 1 No. 2 Viscosity @ 100 F 193-235 SUS 284-347 SUS Viscosity Index 60 Min. 60 Min. General Oil Pour Point -20F (-29C) 10F (-12C) Amoco Oil Co. Rykon Oil 46 American Industrial Oil 68 General Oiling to PreventRusting an Provide Limited Mobil Oil Corp. --------------------------------------Mobil DTE Oil Heavy--------------------------------------Lubrication for Points Not Considered Normal Wear Shell Oil Co. Rotella 10W Rotella 10W-30 Points Sun Oil Co. Sunvis 932 Sunvis 968 Texaco Oil Inc. Rando Oil 46 Rando Oil 68 MPG NLGI Grease No.1 No. 2 6ASTM Worked 310-340 265-295 Penetration Dropping Point 360F (182C) 360F (182C) Multipurpose Grease Base Lithium Lithium Amoco Oil Co. Amolith Grease 1 EP Amolith Grease No. 2 EP Grease Lubricated Wear Mobil Oil Corp. Mobilith AW1 Mobilith AW 2 Points Provided Shell Oil Co. ------------------------------------------Retinax LC----------------------------------------------- Sun Oil Co. Presitge 741 EP Sunoco Multipurpose 2 Texaco Oil Inc. Multifak EP 1 Multifak EP 2 No. 7 or 7C No. 8 or 8C GCOT AGMA Lubricant (Compounded) Compounded ISO Viscosity Grade 460 680 Refer to YALE Hoist Field Service Amoco Oil Corp. Worm Gear Oil Cylinder #680 Department for Gear Case Oil Gearcase Mobil SHC 634 Mobil SHC 643 Operating Mobil Oil Corp. Sythetic, Extra Hecla Synthetic, Mobil 600W Temperatures above Super Traverse Gear Case 125 F Shell Oil Co. Valvata J460 Valvata J680 Texaco Oil Inc. Meropa 460 Meropa 680

9 Part No. 11353399SECTION V - INSPECTION AND The user should revise the inspection interval, add additional units or provide a similar form to suit particular conditions that may exist.PREVENTIVE MAINTENANCE However, written, dated and signed inspection reports should be maintained particularly on critical items such as hoist hooks, hoisting5-1. GENERAL. rope, sheaves, drums and brakes. Periodic review of old inspection reports can point out service life of hoist components, forecastingAll YALE "Global King" hoists are inspected and tested at the factory. need for adjustment, repair or replacement of these components.Regular in-service inspection and preventative maintenance programsnot only help reduce overall maintenance costs but may also prevent As a matter of expedience, appointed maintenance personnelservice shutdowns by forewarning of problems that could cause these inspecting hoist can also take care of minor adjustments, repairs andshutdowns. Regular inspections, periodic minor adjustments, regular cleaning, where required. Note column on Inspection Schedule andcleaning and lubrication and replacement of worn parts can help Maintenance Report form headed Corrective Action and Notes. Whenpreserve good performance and operation of your hoist. corrective action is made during inspection, note condition of part or unit as inspected in appropriate Condition column with a checkMany factors influence the inspection and preventative maintenance mark (). Note "during inspection" corrective action taken and date inprogram required for your hoist. Frequency and severity of service and space provided. In this manner, items requiring further attention willmaterial handled, local environmental conditions and various applicable be checked () without showing corrective action. This will advise thecodes are some of the factors that the user must consider to adjust person responsible for hoist operation and safety, or whoever reviewsinspection and maintenance program outlined in this section to meet his the inspection reports, that deficiencies exist. The designated person willspecific conditions. check all deficiencies as listed and re-examine or otherwise determine whether they constitute a safety hazard.The inspection and maintenance intervals outlined in this section areconsidered a minimum. Recommended in the schedule are minimuminspection and maintenance intervals based on average daily use in anormal environment. Your YALE "Global King" hoist was designed tomeet a specific duty classification as described by the FEM "Rules forthe Design of Serial Lifting Equipment" and is to be used in accordance Deficiencies may be hazardous to personnel andwith the duty rating identified on the equipment nameplate. For more equipment. Do not operate a hoist having deficienciesdetails regarding hoist duty cycles and average daily use, please unless a designated qualified person has determined thatreference FEM Section IX, Series Lifting Equipment or the Hoist DutyClassification page in this manual. these deficiencies DO NOT constitute a safety hazard.

Environmental conditions in which the hoist operates are also important Written, dated and signed inspection reports for many items areconsiderations for the user, when adjusting hoist inspection and mandatory under OSHA regulations, and many state safety codes.maintenance programs to local conditions. Frequency of inspectionand maintenance must be increased if hoist is subjected to severe It is strongly recommended that the Inspection Schedule andatmospheric environmental conditions, such as corrosive vapors, Maintenance Report, shown herein, be completed by a qualifiedextreme heat or cold, cement or dust and other airborne contaminants. person designated with the responsibility for hoist operation andThe user should carefully consider all environmental conditions and safety or an inspector appointed by this person.adjust frequency and degree of maintenance for his local conditions.Consult the factory"s Field Service Department for advice regarding Inspection records can point out the service life of hoist componentsunusual environmental conditions. and help forecast the need for adjustments, repairs, and ordering of replacement parts. File and review these reports after each inspection.Various codes also regulate inspection and maintenance programs.Attention must be given to applicable federal standards, OSHA All YALE "Global King" hoists are equipped with a Pulse monitor,regulations, national standards, state and local codes which may include which is wired into the control circuit in the control enclosure. Thismandatory rules relating to hoist inspection and maintenance. The user equipment consists of a circuit board, a serial communications port,should become familiar with all applicable codes for his area and be and onboard memory, which will retain data even when the hoistguided accordingly. is removed from power. The Pulse monitor takes the "pulse" of the equipment by recording the most recent hoist activities including allListed on the Recommended Inspection and Maintenance Schedule normal operation events, motor starts, over-capacity lifts and thermalare inspection frequencies and requirements. Perform these inspections overload events. In addition, the monitor records the total cumulativeregularly as scheduled and additional inspections as may be required for operating time and motor starts for the life of the equipment. Each Pulseactivity, service, and environment of your hoist. The hoist operator must be monitor is programmed with the equipment serial number at the factory.responsible for determining the operating conditions and severity of service. Data may be downloaded from