5-4
Published 3/26/2018, Control # 596-05
HOIST AND COUNTERWEIGHT GRT8100 SERVICE MANUAL
REMOVING/INSTALLING THE HOIST
Refer to Figure 5-4, on page 5-5.
Removing
1. Remove cable from hoist drum.
2. Tag and disconnect hoist hydraulic lines from motor and
brake. Cap or plug all lines and openings.
3. Remove lower hose from sight glass. Collect oil as it
drains.
4. Remove gearbox sight glass hoses and fittings from
gearbox.
5. Tag and disconnect hoist control valve electrical wires.
6. Remove hydraulic motor (6).
7. Remove the hydraulic motor adapter plate and O-ring.
8. Remove standoff fitting from right side of hoist assembly.
9. Tag and disconnect hoist rotation indicator sensor
electrical wires.
10. Remove hoist rotation indicator sensor (5).
11. Remove two shafts (7).
12. Remove hoist roller (11).
13. Using an adequate lifting device, slightly lift hoist
assembly.
NOTE: Hoist assembly weighs approximately 412 kg
(908 lb).
14. Remove bearing support (8) capscrews (6 long, 3 short).
Install three long capscrews into the three short
capscrew holes. Used capscrews as jack screws to pull
the bearing support (8) off the drum shaft (1).
15. Remove the hoist mounting capscrews and washers,
then remove the hoist assembly.
Installing
1. Ensure the hoist and superstructure mounting surfaces
are clean and free from debris and the hoist has not
been damaged during handling.
2. With the hoist supported by a suitable lifting device,
position the hoist inside the superstructure.
NOTE: Hoist assembly weighs approximately 412 kg
(908 lb).
3. Secure the hoist assembly to the superstructure using
the capscrews and washers. Torque the capscrews -
refer to Fasteners and Torque Values, page 1-15 for
proper torque value.
4. Install the bearing support assembly (8) to the drum
shaft with grease fittings at the 11-o’clock position. Align
and install the six long capscrews into the threaded
turntable holes. Install the three short capscrews into the
blind holes. Torque capscrews following specification
under Fasteners and Torque Values, page 1-15
5. Install the hoist roller (11).
6. Install the two shafts (7)
7. Install the hoist rotation indicator sensor (5).
8. Connect the hoist rotation indicator sensor electrical
connectors as tagged during removal.
9. Install the standoff fitting. Torque standoff fitting to
35 Nm (26 ft-lb).
10. Lubricate O-ring, then install O-ring and hydraulic motor
adapter plate. Apply medium strength thread locker to
the capscrews and torque to 42 Nm (31 ft-lb).
11. Install new O-ring (22). Lube O-ring, then install
hydraulic motor.
12. Connect the hoist control valve electrical connectors as
tagged during removal.
13. Reattach gearbox sight glass hoses and fittings.
14. Reattach lower hose to bottom of sight glass.
15. Connect the hydraulic lines to the motor and brake as
tagged during removal.
16. Ensure the bearing is full of grease.
17. Ensure gear box is filled with oil to the proper level.
Refer to section titled Hoist, page 9-26.
18. Install cable onto hoist assembly. Refer to Installing
Cable On Hoist, page 5-3.
19. Adjust the minimum wrap switch, refer to Adjusting
Minimum Wrap Switch, page 5-9.
Functional Check
1. Attach a test weight to the hook. Raise and lower the
load several times.
2. Check for smooth operation of the hoist motor and brake
system.
3. Ensure hydraulic connections are secure and free from
leaks.
Hoist Fluid Level Check
Refer to the sub-section titled Hoist, page 9-26 of the
Lubrication section for information on properly checking the
hoist oil level.
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