Yale SHAW-BOX Operation & Service Manual
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Yale SHAW-BOX Operation & Service Manual

Yale SHAW-BOX Operation & Service Manual

Wire rope hoists
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Follow 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
instructions and 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.
Wire Rope Hoists
Operation & Service Manual
Before installing hoist, fill in the information below.
Refer to the Hoist and Motor data plates.
Model No.
Serial No.
Purchase Date ____________________________________________
Voltage
Rated Load
____________________________________________
____________________________________________
____________________________________________
____________________________________________

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Summary of Contents for Yale SHAW-BOX

  • Page 1 Wire Rope Hoists Operation & Service Manual Before installing hoist, fill in the information below. Refer to the Hoist and Motor data plates. Model No. ____________________________________________ Serial No. ____________________________________________ Purchase Date ____________________________________________ Voltage ____________________________________________ Rated Load ____________________________________________ Follow 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.
  • Page 2 STATES AND IN CANADA As a Yale/Shawbox Hoist and Trolley user you are assured of reliable repair and parts services through a network of Master Parts Depots and Service Centers that are strategically located in the United States and Canada. These facilities have been selected on the basis of their demonstrated ability to handle all parts and repair requirements promptly and efficiently.

  • Page 3: Table Of Contents

    Contents General information ........................................ 6 Information about safety messages ..................................6 1.1.1 Explanation of signal words and symbols ..............6 1.1.2 Safety instructions ......................6 1.1.3 Section safety messages ....................6 1.1.4 Embedded safety messages ..................6 1.1.5 Safety alert symbols ......................7 1.1.6 Additional symbol ......................
  • Page 4 Travel limit switches ......................................40 4.8.1 Monorail trolley ....................... 40 4.8.2 Double rail trolley ......................40 Electrical equipment ......................................41 4.9.1 Supply cables......................... 41 4.9.2 Terminals........................41 4.9.3 Protection of equipment ....................42 4.9.4 Emergency stop ......................42 4.9.5 Runway conductor disconnecting means ..............42 4.9.6 Disconnect switch ......................
  • Page 5 7.14.3 Removing rope guide ....................79 7.14.4 Replacing wire rope ....................... 80 7.14.5 Fitting rope guide ......................81 7.14.6 Checking rope drum for wear ..................82 7.14.7 Inspection and maintenance of rope sheave .............. 83 7.14.8 Checking load hook ....................... 84 7.15 Trolley ............................................

  • Page 6: General Information

    General information General information You have purchased a Yale product. This product was constructed in accordance with the applicable European standards and regulations. Read carefully and observe this manual. Store the manual within easy reach at the place of operation.

  • Page 7: Safety Alert Symbols

    General information 1.1.5 Safety alert symbols Symbol Meaning General hazard Electric shock hazard Falling parts hazard Suspended load hazard Hand injury hazard 1.1.6 Additional symbol Symbol Meaning Important note Spare parts WARNING Safety hazard. Incorrect or defective spare parts may lead to damage, malfunctions or the complete failure of the machine.

  • Page 8: Crane Logbook

    General information Crane logbook A completed crane logbook must be kept for each hoist. The results of the periodic inspections must be entered in the logbook. Transport and storage Transport The product is delivered on a special pallet. This enables it to be loaded and unloaded safely with a fork-lift truck.

  • Page 9: After-Sales Service

    General information After-sales service You have purchased a high-quality product. Our after sales service will give you advice on its correct use. In order to maintain the safety and constant availability of the product, we recommend concluding a maintenance agreement. Seminars: Comprehensive understanding of material handling products is a prerequisite for the correct use of equipment.

  • Page 10: General Safety Notes

    General safety notes General safety notes The products are constructed according to the state of the art and recognised safety rules. However, during use danger to the life and limb of the user or a third party can arise, or adverse effects can affect the product and other property. Use for intended purpose •...

  • Page 11: Residual Hazards

    General safety notes Residual hazards The machine has been subjected to a risk analysis. The design and construction based on this correspond to the state of the art. However, residual hazards remain during operation and maintenance and these could result in serious or even fatal injuries to personnel.

  • Page 12: Working Above Floor Level

    General safety notes Working above floor level Personnel must be protected from falling. Observe the national, state, and local regulations, and company policies when working above the floor level. Sound pressure level The sound pressure level was measured at a distance of 3 ft from the wire rope hoist. The mean sound pressure level is calculated for one operating cycle (50% with maximum permissible load, 50% without load).

  • Page 13: Safety-Conscious Operation

    General safety notes 2.10 Safety-conscious operation YK/SK wire rope hoists are constructed according to the state of the art and equipped with an overload safety device in standard version. In spite of this, dangers may arise from inappropriate use or use for an unintended purpose. 1.

  • Page 14: Introduction

    Introduction Introduction Wire rope hoists are intended for lifting freely movable loads. The modular concept of our series of wire rope hoists permits a multitude of variations on the basis of series components. The design is characterized by the rope drum and hoist motor being arranged in parallel. The hoist drive is a cylindrical rotor motor with a separately activated D.C.

  • Page 15: Incorporation

    Introduction Incorporation Stationary hoist (hoist for incorporation) The hoist is connected to a fixed structure by means of bolt joints permitting it to be attached to a base, wall or ceiling. Mobile hoist The hoists can be mounted on 4 different types of travel carriage. 03.2018...

  • Page 16: Installation

    Installation Installation Stationary hoist Possible mounting positions and fleet angles Feet “at bottom” and “at top” are possible for designs with bottom hook block (rope lead- off vertically downwards). The YK/SK wire rope hoist with 1PS and 1PS twin hook rope lead-off can be installed in various positions (fleet angles see page 20-23, section 4.2 “Fleet angle”) 1.

  • Page 17: Attachment At Bottom

    Installation 4.1.1 Attachment at bottom Type YKA/SKA Type YKB/SKB Screw M16-8.8 Screw M20-8.8 SCHNORR Safety Washer S16 SCHNORR Safety Washer S20 ® ® Nut, M16-8 Nut, M20-8 Type YKC/SKC Type YKE/SKE, YKD/SKD (2PS, 4PS, 2PD) Nut, M24-8 Screw M30-8.8 SCHNORR Safety Washer S24 SCHNORR Safety Washer S24...
  • Page 18 Installation Type YKE/SKE (1PS) Nut, M24-8 SCHNORR Safety Washer S24 ® Screw M24-8.8 Fig. 8 03.2018...

  • Page 19: Attachment At Top

    Installation 4.1.2 Attachment at top Type YKA/SKA Type YKB/SKB Nut, M16-8 Nut, M20-8 SCHNORR Safety Washer S16 SCHNORR Safety Washer S20 ® ® Screw M16-8.8 Screw M20-8.8 Type YKC/SKC Type YKE/SKE (1PS) Nut, M24-8 Screw M24-8.8 SCHNORR Safety Washer S24 SCHNORR Safety Washer S24 ®...

  • Page 20: Fleet Angle

    Installation Fleet angle 4.2.1 Attachment at bottom Wire rope hoist types YKA/SKA, YKB/SKB, YKC/SKC, YKE/SKE 1PS, 1PS twin hook YKC/ YKA/ YKB/ YKE/ α1 4° 5° 8° 8° α2 23° 13° 20° 18° α3 27° 30° 30° 30° α4 74° 73°...

  • Page 21: Attachment At Top

    Installation 4.2.2 Attachment at top Wire rope hoist types YKA/SKA, YKB/SKB, YKC/SKC, YKE/SKE 1PS, 1PS twin hook YKE/ YKA/ YKB/ YKC/ α1 4° 5° 8° α2 23° 13° 20° α3 27° 30° 30° α4 74° 73° 76° α5 16° 17° 14°...

  • Page 22: Attachment At Side

    Installation 4.2.3 Attachment at side Wire rope hoist types YKA/SKA, YKB/SKB, YKC/SKC, YKE/SKE 1PS, 1PS twin hook YKA/ YKB/ YKC/ YKE/ α1 21° 23° 18° α2 12° 13° 20° α3 74° 73° 76° α4 10° 10° 20° α5 21° 23° 18°...

  • Page 23: Fleet Angle

    Installation 4.2.4 Fleet angle 1. Adjust the rope guide to the fleet angle. Wire rope hoist 2. Observe also the radial rope exit angle γ. type γ YKA/SKA 39° YKB/SKB 39° YKC/SKC 39° YKE/SKE 39° Tab. 6 4.2.5 Angle of installation WARNING Rope damage hazard.

  • Page 24: Monorail Trolleys

    Installation Monorail trolleys The trolleys are constructed according to the state of the art and supplied with mounted buffers. 4.3.1 Monorail trolley (KE-S33 - 76) with wire rope hoist types YKA/SKA, YKB/SKB, YKC/SKC, YKD/SKD, YKE/SKE NOTICE Material damage hazard. If the flange width is altered (by customer), it may be necessary to alter the counterweight to prevent the trolley canting.

  • Page 25: Drive Shaft For Travel Drive (Trolleys Ke-S33 - Ke-S65)

    Installation 4.3.2 Drive shaft for travel drive (trolleys KE-S33 - KE-S65) Drive shaft Ø D Position [in] [in] [in] 3.5 - 5.7 15.4 5.7 - 7.7 7.7 - 9.8 19.5 SF17 1.. 9.9 - 12 SF17 2.. 12.1 - 13.8 23.4 13.8 - 15.7 15.8 - 17.7...

  • Page 26: Drive Shaft For Trolley Drive (Trolley Ke-S76)

    Installation 4.3.3 Drive shaft for trolley drive (trolley KE-S76) The drive shaft is suitable for girder flange widths “B” from 4.9 in. to 19.7 in. Fig. 16 Wire rope Wheel Trolley Travel drive Tightening torque hoist type Ø D [in] "...

  • Page 27: Monorail Trolley (Ue-S4)

    Installation 4.3.4 Monorail trolley (UE-S4) with YKB/SKB, YKC/SKC, 1PS wire rope hoists (single fall) Fig. 17 Ø D Trolley Tightening torque [in] INP IPE " [in] UE-S4 B = 3.5…19.7 in B+2.6 0.059 1.12 Tab. 10 for INP beam: -0.079 in. 1.
  • Page 28 Installation Centering connection piece 1. Loosen nuts (5) and shift connection piece (6) on connecting bolt (7) so that dimensions “z1” and “z2” between trolley side cheeks (4) and connection piece (6) are equal on both sides. 2. Tighten nuts (5) with torque spanner to the specified tightening torques (see table above).

  • Page 29: Monorail Trolley (Ue-S776)

    Installation 4.3.5 Monorail trolley (UE-S776) with YKE/SKE, 4PS wire rope hoist (four-fall) Fig. 18 Tightening Ø D Trolley z max torque [in] INP IPE " [in] 7.9 UE-S776 B = 7.3…19.7 in B+3.6 0.059 3.7 Tab. 11 1. Check flange width “B” and clearance c ± 0.079 in. against Tab. 11 and set trolley to beam width if necessary.
  • Page 30 Installation Centering connection piece 1. Loosen nuts (5) and shift connection piece (6) on connecting bolt (7) so that dimensions “z1” and “z2” between trolley side cheeks (4) and connection piece (6) are equal on both sides. 2. Tighten nuts (5) with a torque spanner to the specified tightening torque (see table above).

  • Page 31: Articulated Trolley (Dke-S4 / Dke-S6)

    Installation 4.3.6 Articulated trolley (DKE-S4 / DKE-S6) with YKA/SKA, YKB/SKB, YKC/SKC wire rope hoists Fig. 20 Wire rope Tightening torque hoist type Ø D y Z max Nut (3) Nut (5) [in] Trolley [in] YKA/SKA, 3.9 DKE-S4 3.5 - 11.8 0.059 B+3.1 2.6 5.8 YKB/SKB YKC/SKC 5.5 DKE-S6 4.7 - 11.8 0.059 B+3.3 3 6.3 Tab.
  • Page 32 Installation Installation if end of runway is not accessible 1. Loosen nuts (3) on threaded bolts (1) in the square tube of the trolley side cheeks (4) and unscrew by dimension “x”. 2. Push trolley side cheeks (4) apart in parallel up to the unscrewed nuts (3) until dimension B+y or c+x is reached, and lift trolley onto runway from below.
  • Page 33 Installation Drive shaft for travel drive (DKE-S4 / DKE-S6) Trolleys with one travel drive Fig. 21 Drive shaft D Ø D L4 ±0.079 [in] [in] [in] [in] 3.5 - 5 15.4 5.1 - 8.7 19.5 1.83 4.7 - 11 19.5 11.1 - 11.8 Tab.

  • Page 34: End Stops For Monorail Trolleys

    Installation End stops for monorail trolleys WARNING Falling parts hazard. If there are no end stops, the trolley can travel over the end of the runway. ➢ Mount suitable end stops at the end of the runway before commissioning the hoist. The monorail trolleys are supplied as standard with buffers.

  • Page 35: Double Rail Trolley (Oe-S)

    Installation Double rail trolley (OE-S) The double rail trolleys are supplied with mounted buffers. NOTICE The trolley must run smoothly over the whole runway without jamming or increased friction at the wheel flanges. Increased friction at the flanges due to poor beam quality or incorrect trolley adjustment may lead to increased wear.

  • Page 36: End Stops For Double Rail Trolleys

    Installation End stops for double rail trolleys WARNING Falling parts hazard. If there are no end stops, the trolley can travel over the end of the runway. ➢ Mount suitable end stops at the end of the runway before commissioning the hoist. 4.6.1 Wheel diameter D = 3.9 in.

  • Page 37: Anti-Jump Catch

    Installation Anti-jump catch 4.7.1 Description of system The anti-jump catch acts as an anti-derail device, preventing the trolley jumping off the rail and falling. Trolley types OE-S04, OE-S05 Trolley types OE-S06, OE-S07 Fig. 28 Fig. 29 4.7.2 Procedure WARNING Falling parts hazard. ➢...
  • Page 38 Installation Vertical adjustment Fig. 32 1. Measure dimension “X”. 2. Select positions of hook and eccentric from the table. Trolley type OE-S04 Trolley type OE-S04 Trolley type OE-S05 Hook position Eccentric position Hook Hook Eccentric Eccentric position position [in] [in] 1.65 - 1.77 1.57 - 1.69 1.79 - 1.89...
  • Page 39 Installation Trolley types OE-S06 - OE-S07 Hook position Eccentric position Hook Eccentric position [in] 1.5 - 1.59 1.61 - 1.79 1.81 - 1.99 2.01 - 2.19 2.2 - 2.38 2.4 - 2.58 2.6 - 2.78 Fig. 35 2.8 - 2.97 2.99 - 3.17 3.19 - 3.37 3.39 - 3.56...

  • Page 40: Travel Limit Switches

    Installation Travel limit switches 4.8.1 Monorail trolley The travel limit switches (optional) are mounted on the trolley. 4.8.2 Double rail trolley The travel limit switch assembly is supplied ready-wired but not mounted and must be secured to the towing arm for the power supply. WARNING Falling parts hazard.

  • Page 41: Electrical Equipment

    Installation Electrical equipment DANGER Electric shock hazard ➢ Make sure an electrical qualified person performs the work. ➢ Observe the relevant safety and accident prevention regulations. The electrical equipment of the hoist was designed, manufactured and tested in accordance with standard EN 60204-32. It comprises all electrical equipment of the hoist: Electrical equipment was installed per NFPA 70 or other National, State, and Local regulations.

  • Page 42: Protection Of Equipment

    Installation 4.9.3 Protection of equipment Protective devices include: • Devices for overcurrent protection (fuses, circuit breakers) • Motor protection devices • Overload safety devices • Temperature monitors • Limit switches The protective devices in the electrical equipment installed in the scope of supply must in no case be removed, replaced by different devices or bridged.

  • Page 43: Electromagnetic Compatibility

    Installation 4.9.8 Electromagnetic compatibility Electromagnetic compatibility (EMC) mainly concerns the emission of electromagnetic interference and the immunity of electronic components and systems to this interference. If the following interference suppression measures are correctly installed and applied, the equipment will not cause any electromagnetic interference above the level permissible for the intended operating environment and have sufficient resistance to electromagnetic interference to function without error.

  • Page 44: Overload Safety Device

    Installation 4.9.9 Overload safety device The wire rope hoist is supplied with an overload protection. Description of system The overload safety device is a device which automatically prevents the hoist moving loads exceeding its safe working load during normal operation, taking into account the dynamic effects.

  • Page 45: Connecting To Mains

    Installation Overload safety device by others When an overload safety device and thus the placement of the load sensors to measure the rope forces are designed by others, all requirements relating to rope reeving, fleet angle and angle of installation of the hoist must be observed, see chap. 4.2 The overload safety device must be set during commissioning, see supplementary operating instructions.

  • Page 46: Control And Control Functions

    Installation 4.9.11 Control and control functions Each hoist control is equipped with an electronic control device. This electronic control device functions as a central safety device for the overload safety device and as motor control and monitoring unit. The device functions are adapted to the different hoist and drive types and the particular function modules selected (load limits, pole-changing or frequency-controlled motors, etc.) by parameterising the device.

  • Page 47: Electric Motors And Related Equipment

    Installation 4.9.12 Electric motors and related equipment The hoist motors meet the standards of EN 60034-1 and are specially dimensioned and designed for hoist operating conditions. Hoist motor • 12/2-pole motor with separately controlled D.C. brake for contactor control • The brake is designed as an operating brake •...

  • Page 48: Reeving Rope

    Installation 4.11 Reeving rope The wire rope is wound onto the drum in the factory. If not, see page 80, section 7.14.4 “Replacing wire rope”. The wire rope hoist must be switched on in order to reeve the rope. All work must therefore be carried out with extreme care: for your safety and for smooth functioning of the wire rope hoist! If the bottom hook block is not fitted, proceed as follows:...
  • Page 49 Installation YKA/SKA - YKE/SKE YKC/SKC Tab. 17 YKA/SKA - YKE/SKE YKC/SKC Tab. 18 YKA/SKA - YKE/SKE YKC/SKC Tab. 19 L = left-hand thread R = right-hand thread Fig. 47 03.2018...
  • Page 50 Installation Rope anchorage (YKA/SKA – YKE/SKE) YKA/SKA – YKB/SKB YKC/SKC – YKE/SKE [mm] [in] [mm] [in] Xmax 0.24 0.59 1.97 1.97 3.94 3.94 1. Observe information plate at rope anchorage. 2. Insert end of rope into rope anchorage according to reeving 3.
  • Page 51 Installation Rope anchorage (YKA/SKA - YKC/SKC) Length L YKA/ YKB/ YKC/ Fig. 53 Fig. 54 Fig. 55 Tab. 22 Fig. 56 a±0.12 b±0.12 [in] [in] YKA 8.5 YKB 10.4 11.4 YKC 13.1 14.4 Tab. 25 Fig. 57 Length L YKA/ YKB/ YKC/ A ±0.12 b±0.12...
  • Page 52 Installation Rope anchorage (YKE/SKE) Length L YKE/SKE L2-L5 L2-L5 Fig. 63 L2-L5 L3-L5 Tab. 27 Fig. 64 Length L YKE/SKE L2-L5 L2-L5 L2-L5 Tab. 28 Fig. 65 Length L YKE/SKE L2-L5 L2-L5 L2-L5 L3-L5 Tab. 29 Fig. 66 *1 Gear side 03.2018...

  • Page 53: Commissioning

    Commissioning Commissioning The wire rope hoist has been subjected to a final inspection by the manufacturer in accordance with the EC Machinery Directive. WARNING Safety hazard. ➢ Make sure a qualified person performs commissioning. When the hoist is commissioned and / or after a service call a comprehensive retest must always be performed.

  • Page 54: Operating

    Operating Operating WARNING Safety hazard. Bridging limit switches or operating the hoist with a damaged rope or brake is not permissible. Operating precautions 1. DO read the Operation & Service Manual. 2. DO read the applicable sections of FEM 9.756, Section IX “SERIES LIFTING EQUIPMENT”...
  • Page 55 Operating 35. DO NOT allow the rope or hook to be used as a ground for welding. 36. DO NOT allow the rope or hook to be touched by a live welding electrode. 37. DO NOT remove or obscure the warnings on the hoist. 38.

  • Page 56: Duties Of Crane Operator

    Operating Duties of crane operator Personal protective equipment must be provided by the owner. Requirements for workplace 1. The operator must not stand in the hazard area. 2. The hazard area must be clearly visible. 3. The movement of the load in all directions must be clearly visible. WARNING Safety hazard.

  • Page 57: Using Control Pendant

    Operating Using control pendant WARNING Danger of unintentional movement of hoist If the rocker switch is no longer depressed by the operator, it returns to the 0 position, the hoist motion is automatically stopped (dead man’s control). If the hoist malfunctions, e.g. the actual motion does not correspond to the motion intended in activating the rocker switch, release the rocker switch immediately.

  • Page 58: Operating Hoist With Frequency Inverter

    Operating Operating hoist with frequency inverter • 1st step: slow • 2nd step: accelerate When the 1st step is activated, the hoist is accelerated to slow speed and slow speed is maintained. When the 2nd step of the pushbutton is activated, the hoist is accelerated as long as the 2nd step is activated or until maximum speed is reached.

  • Page 59: Inspection And Maintenance

    Inspection and maintenance Inspection and maintenance This section deals with operational reliability, availability, and maintaining the value of your wire rope hoist. Although this wire rope hoist is practically maintenance-free, the components subject to wear (e.g. wire rope, brake) must be inspected regularly. Inspection and maintenance must be carried out by qualified persons.

  • Page 60: Inspection Intervals

    Inspection and maintenance Inspection intervals W0789 W0791 Fig. 70 Inspection table see page ● ● Function of brakes (1) with regard to braking efficiency and activation ● Emergency hoist limit switch (2), if there is no operational hoist limit switch, operational hoist limit ●...

  • Page 61: Maintenance Intervals

    Inspection and maintenance Maintenance intervals W0792 W0794 W0793 Fig. 71 Maintenance table see page ● Brake (20), measure air gap, replace brake disk if necessary 63, 64, 65 ● Overload safety device (21) ● Grease rope (22) with brush ● Grease rope guide (23) with brush ●...

  • Page 62: Motors

    Inspection and maintenance Motors DANGER Electric shock hazard. Some motor parts are live. Any contact with live parts can cause severe injury or death. Motors have dangerous rotating parts and hot surfaces. Ensure that: • the motor runs correctly (e.g. no variations in speed, no noise emission), •...

  • Page 63: Hoist Motor Brake (Rsm)

    Inspection and maintenance Hoist motor brake (RSM) This inspection and maintenance is of particularly important to ensure safety. If brake maintenance is not performed correctly or the brake does not function correctly, the load may fall! WARNING Falling load hazard. ➢...

  • Page 64: Hoist Motor Brake (Nm) (Pole-Changing)

    Inspection and maintenance Hoist motor brake (NM) (pole-changing) WARNING Falling load hazard. ➢ Carry out work on the hoist brake only when the hoist is unloaded and the bottom hook block has been set down. ➢ Before starting disconnect power and implement a Lockout/Tagout (LOTO) procedure before servicing the equipment.

  • Page 65: Hoist Motor Brake (Nm) (4-Pole)

    Inspection and maintenance Hoist motor brake (NM) (4-pole) WARNING Falling load hazard. ➢ Carry out work on the hoist brake only when the hoist is unloaded and the bottom hook block has been set down. ➢ Before starting disconnect power and implement a Lockout/Tagout (LOTO) procedure before servicing the equipment.
  • Page 66 Inspection and maintenance 18. Replace in reverse order. 19. Ensure that the check hole for measuring the air gap is aligned with the opening in the fan wheel cover. 20. Lock stud screws (6) with locking varnish. 21. Observe tightening torques of fixing screws (8) (see table below). Hoist motor type Hoist brake Smax.

  • Page 67: Hoist Motor Brake (Nm) 4Hs

    Inspection and maintenance Hoist motor brake (NM) 4HS. WARNING Falling load hazard. ➢ Carry out work on the hoist brake only when the hoist is unloaded and the bottom hook block has been set down. ➢ Before starting disconnect power and implement a Lockout/Tagout (LOTO) procedure before servicing the equipment.

  • Page 68: Travel Motor Brake

    Inspection and maintenance 17. Replace in reverse order. 18. Ensure that the check hole for measuring the air gap is aligned with the opening in the fan wheel cover. 19. Lock stud screws (6) with locking varnish. 20. Observe tightening torques of fixing screws (8) (see following table). Hoist motor type Hoist brake Smax.

  • Page 69: Hoist Limit Switch

    Inspection and maintenance Hoist limit switch The hoist limit switch layout installed must be determined on the basis of the sticker in the limit switch (see stickers). More free switching elements, hoist limit switch layouts are possible as an option (see circuit diagram) 7.9.1 Hoist limit switch (standard)

  • Page 70: Hoist Limit Switch

    Inspection and maintenance 7.10 Hoist limit switch 7.10.1 Description of hoist limit switch system • The wire rope hoist is equipped as standard with an emergency hoist limit switch for disconnecting in top and bottom hook position (switching points A↑ and A↓). •...

  • Page 71: Testing Emergency Hoist Limit Switch, Version 2

    Inspection and maintenance The clearances between the switching points for operational and emergency hoist limit switches are set for normal operating conditions, however they can be increased if necessary. 7.10.4 Testing emergency hoist limit switch, version 2 1. Test at slow speed without load. 2.

  • Page 72: Setting Hoist Limit Switch

    Inspection and maintenance 7.10.6 Setting hoist limit switch DANGER Electric shock hazard The cover of the hoist limit switch must be removed to set the contacts. This exposes live contact connections. Make sure an electrical qualified person performs the work. Adjust hoist limit switch at the setscrews (S1) - (S6) depending on version: Turning to the left: switching point is moved “downwards”.
  • Page 73 Inspection and maintenance Formula: b = V × t × 0.023 ft Switching point B↑/B↑↑ (S3/S4) (minimum clearance between B↑ and A↑ 2.4 in.) Hoist speed [fpm] (YKC/SKC-L05-…S262-V) 1. Lift bottom hook block to 0.39 . before the desired cut-off point, if necessary turn setscrew (S3) to the right beforehand.
  • Page 74 Inspection and maintenance Switching point B↓/B↓↓ (S5/S6) (version 2 only) (Minimum clearance between B↓ and A↓ 4.7 in.) 1. Lower bottom hook block to 0.39 in. above desired hook position, if necessary turn setscrew (S5) to the left beforehand. Observe minimum clearance, see Fig. 82. 2.

  • Page 75: Servicing Hoist Limit Switch

    Inspection and maintenance 7.10.7 Servicing hoist limit switch Maintenance work is restricted to checking the cut-off points. No maintenance or inspection is necessary for the hoist limit switch itself. NOTICE Material damage hazard. Any dust deposits that may be visible when the housing is opened must on no account be removed with compressed air as this would force the dust into the contacts and impair the switching function.

  • Page 76: Hook Dimensions C For Ke-S

    Inspection and maintenance 7.11 Hook dimensions C for KE-S.. trolleys The following hook dimensions C apply for the top operational hoist limit switch cut-off point (B↑). WARNING Hook dimension C must not be less than specified in the following. If the calculated flange width is between two values in the table, always set the larger dimension C.

  • Page 77: Overload Safety Device

    Inspection and maintenance 7.12 Overload safety device 7.12.1 Testing overload safety device If an overload is detected, the wire rope hoist is switched off in the upwards direction. Only lowering is then possible. Lifting is not possible until the wire rope hoist has been unloaded.

  • Page 78: Rope Drive

    Inspection and maintenance 7.14 Rope drive 7.14.1 Rope and rope attachment - general information After commissioning a new wire rope hoist, or after replacing the rope, the rope of multi- fall hoists may twist. This can be seen from the bottom hook block turning, particularly when unloaded. WARNING Damaged or twisted rope hazard.

  • Page 79: Replacement Of Wire Rope Due To Broken Wires

    Inspection and maintenance 7.14.2 Replacement of wire rope due to broken wires • Part number of rope see factory certificate. • Number of permissible broken wires see rope certificate. YKA/SKA – 7.14.3 Removing rope guide YKC/SKC First method (preferable!) 1. Unscrew protective plate (1) under the rope drum at points (a). The rope guide can then be rotated freely.

  • Page 80: Replacing Wire Rope

    Inspection and maintenance 7.14.4 Replacing wire rope YK/SK wire rope hoists have a special rope which is the optimum for the most common applications. WARNING Hazard from unsuitable rope The substitute rope must be equivalent to the original in terms of quality, strength and make-up.

  • Page 81: Fitting Rope Guide

    Inspection and maintenance 7.14.5 Fitting rope guide 1. Grease thread and rope guide groove thoroughly. 2. Place the half-ring (1) with the short window section onto the rope drum next to the last rope winding so that the rope exits from the region of the window (x). (a) Special tool 3.

  • Page 82: Checking Rope Drum For Wear

    Inspection and maintenance 7.14.6 Checking rope drum for wear Fig. 94 Type of wire Rope diameter Nominal values Limits for wear rope hoist da min di min t max [in] [in] [in] [in] [in] [in] [in] YKA/SKE 0.22 4.91 4.73 0.087 4.88 4.71...

  • Page 83: Inspection And Maintenance Of Rope Sheave

    Inspection and maintenance 7.14.7 Inspection and maintenance of rope sheave 1. Check rope sheaves for wear. We recommend having them checked by a qualified person. They should also be checked for easy running, indicating that the ball bearings are in good condition. Wear on rope sheave Notes on limits for wear Rope sheave...

  • Page 84: Checking Load Hook

    Inspection and maintenance 7.14.8 Checking load hook RSN, Hook size [in] 0.94 1.14 1.22 1.46 1.57 1.89 2.28 2.64 2.95 3.35 4.17 h min 1.09 1.16 1.39 2.17 2.51 2.81 3.18 3.96 Tab. 41 Fig. 97 RSN, Hook size [in] 1.97 2.36 2.64 2.95...

  • Page 85: Trolley

    Inspection and maintenance 7.15 Trolley Wheels, wheel drive and runway Fig. Nominal value Limit for wear Ø d Ø d1 [in] 3.15 1.08 2.99 1.16 3.94 3.74 1.38 1.75 1.85 5.51 5.24 1.67 1.77 1.75 5.98 1.85 7.87 1.67 7.48 1.77 Tab.

  • Page 86: Remaining Service Life

    Inspection and maintenance 7.16 Remaining service life The operating mode and operating time must be established by the owner, see section 1.3 and recorded in the logbook in order to calculate the remaining service life. After the service life has expired a general overhaul (S.W.P. = Safe Working Period) must be carried out.

  • Page 87: Wearing Parts

    Wearing parts Wearing parts WARNING Safety hazard. ➢ Make sure that replacement and repairs are performed by qualified persons only. Serial number When ordering original spare parts, always indicate the serial number of the hoist. This is affixed to the inside of the bearing support plate. Fig.
  • Page 88 Wearing parts Rope guide Wire rope hoist type Order no. Order no. Order no. YKA/SKA A0343002430 A0343001430 A0343000430 YKB/SKB A0443000430 A0443002430 A0443001430 YKC/SKC A0543001430 A0543002430 A0543000430 YKE/SKE (2PS), L4 - L5 A0643008430 YKE/SKE A0643003430 A0643004430 A0643000430 Tab. 48 Fig. 104 Wire rope (E) See factory certificate or rope certificate for length and number of wire rope.

  • Page 89: Troubleshooting

    Troubleshooting Troubleshooting DANGER Electric shock hazard. ➢ Make sure an electrical qualified person performs the work. ➢ Disconnect power and implement a Lockout/Tagout (LOTO) procedure before servicing the equipment. Trouble Possible cause Remedy Hoist does NOT operate No power to hoist 1.
  • Page 90 Troubleshooting Trouble Possible cause Remedy Loud clicking noise when motor Air gap on brake is too wide 1. Measure air gap on motor. starts 2. Replace brake disk if the maximum air gap is reached. Lifting of rated load NOT Low voltage 1.

  • Page 91: Decommissioning

    Decommissioning Decommissioning 10.1 Dismantling WARNING Falling parts hazard ➢ Secure hoist when dismantling. 1. Dismantle hoist correctly. 2. First remove lubricants. 10.2 Scrap disposal NOTICE Electronic components, electric scrap, lubricants and other auxiliary substances are hazardous waste and may only be disposed of by approved recycling companies. Overload devices must be returned to the manufacturer.

  • Page 92: Technical Data

    Technical data Technical data 11.1 Conditions of use The hoist is designed for use in industry and for the ambient conditions usual in industry in non-hazardous areas. Special measures are necessary for particular applications such as e.g. high degree of chemical pollution, outdoor use, offshore application, etc.

  • Page 93: Hoist

    Technical data 11.2 Hoist The designation of the type of wire rope hoist and the motor installed can be seen from the rating plate/factory certificate. All technical data given refer to the standard version and standard operating conditions. The technical data given in the order acknowledgement or individual documentation apply for optional versions and off-standard applications.

  • Page 94: Pole-Changing Hoist Motors

    Technical data 11.2.2 Pole-changing hoist motors ../…-MF 60Hz 60 Hz Motor Power [c/h] cos phi k Mains fuse CC / J *2 208…230 V 360…400 V 208…230 V 360…400 V [HP] 12/2H33-MF 0.7/4.7 20/50 360/180 8.2/15.3 15.3/89.9 4.7/8.8 8.8/52.1 0.73/0.77 0.9/5.8 20/40 240/120...

  • Page 95: Pole-Changing Hoist Motors 50Hz

    Technical data 11.2.3 Pole-changing hoist motors 50Hz 50 Hz Motor Power [c/h] cos phi k Mains fuse CC / J *2 220…240 V 380…415 V 220…240 V 380…415 V [HP] 12/2H73 4.2/25.5 20/50 360/180 38.4/62.6 76.5/423 22.0/36.0 44.0/243 0.59/0.63 5.1/32.2 20/40 240/120 38.3/83.5...

  • Page 96: Frequency-Controlled Hoist Motors

    Technical data 11.2.5 Frequency-controlled hoist motors ../4H..-MF 100 Hz 100 Hz Hoist motor Power Mains fuse CC / J *1 380…415 V 500…525 V 660…690 V 380…415 V 500…525 V 660…690 V [HP] 4H33-MF 4H42-MF 10.7 4H62-MF 15.5 12.4 10.1 18.0 14.4 10.9...

  • Page 97: Frequency-Controlled Hoist Motors ../4Hs.-Mf 100 Hz

    Technical data 11.2.7 Frequency-controlled hoist motors ../4HS.-MF 100 Hz 100 Hz Hoist motor Power Mains fuse CC / J *1 380…415 V 500…525 V 380…415 V 500…525 V [HP] 4HS3 10.7 4HS5 15.5 12.4 10.1 18.0 14.4 12.1 21.0 16.8 4HS7 16.1 24.0...

  • Page 98: Cable Cross Sections And Lengths Of Supply Cable

    Technical data 11.3 Cable cross sections and lengths of supply cable 11.3.1 Cable cross sections and lengths of supply cable for pole-changing hoist motors …-MF Hoist Stationary Hoist Hoist/crane Hoist Rising mains Crane Crane motor max. 33 ft type Fixed installation in Fixed installation in Festoon cable in free Fixed...

  • Page 99: Tightening Torques

    Technical data 11.4 Tightening torques WARNING Safety hazard. Unsuitable installation material and incorrect tightening torques may lead to damage and accidents. ➢ Use only original spare parts. ➢ Tighten screw connection with a torque spanner to the prescribed tightening torque. Screw grade 10.9 Metric...
  • Page 100 Technical data Other screw connections and applicable tightening torques Screw connection Wire rope type Screw connection Tightening torque Part 1 / Part 2 Metric size Grade Gear casing/panel box YKA/SKA – YKB/SKB Gear casing/support plate YKA/SKA YKB/SKB YKC/SKC Rope drum/gear drive shaft YKC/SKC Rope drum/clamping plate YKA/SKA...

  • Page 101: Lubricants

    Technical data 11.5 Lubricants YKA/SKA, YKB/SKB, YKC/SKC, YKE/SKE, YKA/SKA, YKB/SKB, YKC/SKC, YKD/SKD YKE/SKE F0450a Fig 107 Lubrication point Type of lubricant Factory filling (DIN 51502) Alternative lubricants Quantity Aral Degol BG 460 Plus YKA/SKA: 1.7 qt Castrol Alpha SP 460 YKB/SKB: 2.3 qt Fuchs Renolin CLP 460 Castrol Tribol 1100/460...
  • Page 102 WARRANTY LIMITATION OF WARRANTIES, REMEDIES AND DAMAGES INDEMNIFICATION AND SAFE OPERATION C. IN NO EVENT SHALL SELLER BE LIABLE TO BUYER OR ANY THIRD PARTY WITH RESPECT TO ANY GOOD, WHETHER IN CONTRACT, Buyer shall comply with and require its employees to comply with directions set forth in TORT OR OTHER THEORY OF LAW, FOR LOSS OF PROFITS OR LOSS instructions and manuals furnished by Seller and shall use and require its employees OF USE, OR FOR ANY INCIDENTAL, CONSEQUENTIAL, SPECIAL,...

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