Yale SHAW-BOX Operation & Service Manual
ba-o.2.6.0-us-1.1-y | A11867501 Rev AA
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. 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
ba-o.2.6.0-us-1.1-y | A11867501 Rev AA
YALE/SHAWBOX HOIST PARTS AND SERVICES ARE AVAILABLE IN THE UNITED
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. To quickly obtain the name of the Master Parts Depot or Service Center located nearest you,
call (800) 888-0985, Fax: (716) 689-5644, visit www.cmworks.com
LAS PIEZAS Y REPARACIONES DE LOS POLIPASTOS DE YALE/SHAWBOX
ESTÁN ASEGURADAS EN ESTADOS UNIDOS Y CANADÁ
Como usuario de un polipasto y carro de Yale/Shawbox le aseguramos cualquier reparación o la disponibilidad de
cualquier pieza de repuesto a través de una red de almacenes de piezas de repuesto y centros de servicio situados
estratégicamente en Estados Unidos y Canadá. Estas instalaciones se han seleccionado en base a su capacidad
demostrada en la reparación de equipos y suminstro de piezas de repuesto de forma rápida y eficaz. Para obtener la
dirección del almacén de piezas de repuesto o del centro de servicio más cercano, llame al teléfono (800) 888-0985.
Fax: (716) 689-5644, visite www.cmworks.com (sólo en Estados Unidos y Canadá).
LE SERVICE DE RÉPARATION ET DE PIÈCES POUR PALANS YALE/SHAWBOX
EST DISPONIBLE AUX ÉTATS-UNIS ET AU CANADA
Soyez assurés qu'en temps d'utilisateur de palan et treuil Yale/Shawbox, d'un service de réparation et de pièces fiable
par l'entremise d'un réseau de Centres de service et de Dépôts de pièces maîtresses qui sont stratégiquement situés
aux États-Unis et au Canada. Ces établissements ont été sélectionnés sur une base de leur habileté démontrée à
s'occuper promptement et efficacement des besoins de réparation de pièces. Appelez le (800) 888-0985, Fax: (716)
689-5644, visite www.cmworks.com pour obtenir rapidement le nom du dépôt de pièces maîtresses ou du centre de
service situé le plus près.
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Contents
1 General information ................................................................................................................................................................................................ 6
1.1 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 ............................................................................................................ 7
1.2 Spare parts ................................................................................................................................................................................................................ 7
1.3 Target audience and responsibilities .................................................................................................................................................................. 7
1.4 Crane logbook .......................................................................................................................................................................................................... 8
1.5 Transport and storage ............................................................................................................................................................................................ 8
1.6 Weight ........................................................................................................................................................................................................................ 8
1.7 Installation, commissioning, maintenance and repairs ................................................................................................................................... 8
1.8 After-sales service ................................................................................................................................................................................................... 9
1.9 Periodic inspections ............................................................................................................................................................................................... 9
1.10 Environmental information .................................................................................................................................................................................... 9
1.10.1 Life cycle assessment ..................................................................................................... 9
1.10.2 Energy consumption ....................................................................................................... 9
2 General safety notes ............................................................................................................................................................................................. 10
2.1 Use for intended purpose .................................................................................................................................................................................... 10
2.2 Inappropriate use ................................................................................................................................................................................................... 10
2.3 Residual hazards ................................................................................................................................................................................................... 11
2.4 Organizational safety precautions ..................................................................................................................................................................... 11
2.5 General regulations ............................................................................................................................................................................................... 11
2.6 Recommended PPE .............................................................................................................................................................................................. 11
2.7 Working above floor level .................................................................................................................................................................................... 12
2.8 Sound pressure level ............................................................................................................................................................................................ 12
2.9 Fire safety ................................................................................................................................................................................................................ 12
2.10 Safety-conscious operation ................................................................................................................................................................................ 13
2.11 Attaching load ........................................................................................................................................................................................................ 13
3 Introduction ............................................................................................................................................................................................................ 14
3.1 Incorporation .......................................................................................................................................................................................................... 15
4 Installation ............................................................................................................................................................................................................... 16
4.1 Stationary hoist ...................................................................................................................................................................................................... 16
4.1.1 Attachment at bottom .................................................................................................... 17
4.1.2 Attachment at top .......................................................................................................... 19
4.2 Fleet angle ............................................................................................................................................................................................................... 20
4.2.1 Attachment at bottom .................................................................................................... 20
4.2.2 Attachment at top .......................................................................................................... 21
4.2.3 Attachment at side ......................................................................................................... 22
4.2.4 Fleet angle ..................................................................................................................... 23
4.2.5 Angle of installation ....................................................................................................... 23
4.3 Monorail trolleys .................................................................................................................................................................................................... 24
4.3.1 Monorail trolley (KE-S33 - 76) ...................................................................................... 24
4.3.2 Drive shaft for travel drive (trolleys KE-S33 - KE-S65) ............................................... 25
4.3.3 Drive shaft for trolley drive (trolley KE-S76) ................................................................. 26
4.3.4 Monorail trolley (UE-S4) ................................................................................................ 27
4.3.5 Monorail trolley (UE-S776) ........................................................................................... 29
4.3.6 Articulated trolley (DKE-S4 / DKE-S6) ......................................................................... 31
4.4 End stops for monorail trolleys .......................................................................................................................................................................... 34
4.5 Double rail trolley (OE-S) ...................................................................................................................................................................................... 35
4.6 End stops for double rail trolleys ....................................................................................................................................................................... 36
4.6.1 Wheel diameter D = 3.9 in. ........................................................................................... 36
4.6.2 Wheel diameter D = 4.9 - 7.9 in.................................................................................... 36
4.7 Anti-jump catch ...................................................................................................................................................................................................... 37
4.7.1 Description of system .................................................................................................... 37
4.7.2 Procedure ....................................................................................................................... 37
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4.8 Travel limit switches ............................................................................................................................................................................................. 40
4.8.1 Monorail trolley ............................................................................................................... 40
4.8.2 Double rail trolley ........................................................................................................... 40
4.9 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 .......................................................................................................... 42
4.9.7 Connection fuses ........................................................................................................... 42
4.9.8 Electromagnetic compatibility ....................................................................................... 43
4.9.9 Overload safety device.................................................................................................. 44
4.9.10 Connecting to mains...................................................................................................... 45
4.9.11 Control and control functions ........................................................................................ 46
4.9.12 Electric motors and related equipment ........................................................................ 47
4.10 YK/SK hoists with frequency inverter (VFD) .................................................................................................................................................... 47
4.11 Reeving rope .......................................................................................................................................................................................................... 48
5 Commissioning ...................................................................................................................................................................................................... 53
6 Operating................................................................................................................................................................................................................. 54
6.1 Operating precautions .......................................................................................................................................................................................... 54
6.2 Duties of crane operator....................................................................................................................................................................................... 56
6.3 Using control pendant .......................................................................................................................................................................................... 57
6.4 Operating hoist with frequency inverter ........................................................................................................................................................... 58
6.5 Emergency stop ..................................................................................................................................................................................................... 58
7 Inspection and maintenance ............................................................................................................................................................................... 59
7.1 Inspection intervals ............................................................................................................................................................................................... 60
7.2 Maintenance intervals ........................................................................................................................................................................................... 61
7.3 Motors ...................................................................................................................................................................................................................... 62
7.4 Hoist motor brake (RSM) ...................................................................................................................................................................................... 63
7.4.1 Checking brake .............................................................................................................. 63
7.4.2 Replacing brake disk (brake rotor) ............................................................................... 63
7.5 Hoist motor brake (NM) (pole-changing) ........................................................................................................................................................... 64
7.5.1 Checking brake .............................................................................................................. 64
7.5.2 Replacing brake disk (brake rotor) ............................................................................... 64
7.6 Hoist motor brake (NM) (4-pole) .......................................................................................................................................................................... 65
7.6.1 Checking brake .............................................................................................................. 65
7.6.2 Replacing brake disk (brake rotor ................................................................................ 65
7.7 Hoist motor brake (NM) 4HS. ............................................................................................................................................................................... 67
7.7.1 Checking brake .............................................................................................................. 67
7.7.2 Replacing brake disk (brake rotor) ............................................................................... 67
7.8 Travel motor brake ................................................................................................................................................................................................ 68
7.9 Hoist limit switch ................................................................................................................................................................................................... 69
7.9.1 Hoist limit switch (standard) .......................................................................................... 69
7.10 Hoist limit switch ................................................................................................................................................................................................... 70
7.10.1 Description of hoist limit switch system ........................................................................ 70
7.10.2 Testing emergency hoist limit switch, version 1 .......................................................... 70
7.10.3 Testing operational hoist limit switch, version 1 .......................................................... 70
7.10.4 Testing emergency hoist limit switch, version 2 .......................................................... 71
7.10.5 Testing operational hoist limit switch, version 2 .......................................................... 71
7.10.6 Setting hoist limit switch ................................................................................................ 72
7.10.7 Servicing hoist limit switch ............................................................................................ 75
7.11 Hook dimensions C for KE-S.. trolleys .............................................................................................................................................................. 76
7.12 Overload safety device ......................................................................................................................................................................................... 77
7.12.1 Testing overload safety device ..................................................................................... 77
7.12.2 Maintenance of overload safety device with pressure sensor ................................... 77
7.12.3 Maintenance of overload safety device with shear force sensor ............................... 77
7.13 Crane test ................................................................................................................................................................................................................ 77
7.14 Rope drive ............................................................................................................................................................................................................... 78
7.14.1 Rope and rope attachment - general information ....................................................... 78
7.14.2 Replacement of wire rope due to broken wires ........................................................... 79
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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 ...................................................................................................................................................................................................................... 85
7.16 Remaining service life .......................................................................................................................................................................................... 86
7.16.1 Operating hours counter in SLE load monitor ............................................................. 86
7.16.2 SMC multi-controller (optional) ..................................................................................... 86
7.17 General overhaul ................................................................................................................................................................................................... 86
8 Wearing parts ......................................................................................................................................................................................................... 87
8.1 Serial number ......................................................................................................................................................................................................... 87
8.2 Hoist ......................................................................................................................................................................................................................... 87
9 Troubleshooting .................................................................................................................................................................................................... 89
10 Decommissioning ................................................................................................................................................................................................. 91
10.1 Dismantling ............................................................................................................................................................................................................. 91
10.2 Scrap disposal ....................................................................................................................................................................................................... 91
11 Technical data ........................................................................................................................................................................................................ 92
11.1 Conditions of use .................................................................................................................................................................................................. 92
11.2 Hoist ......................................................................................................................................................................................................................... 93
11.2.1 Pole-changing hoist motors ../…-MF 50Hz ................................................................. 93
11.2.2 Pole-changing hoist motors ../…-MF 60Hz ................................................................. 94
11.2.3 Pole-changing hoist motors 50Hz ................................................................................ 95
11.2.4 Pole-changing hoist motors 60Hz ................................................................................ 95
11.2.5 Frequency-controlled hoist motors ../4H..-MF 100 Hz ................................................ 96
11.2.6 Frequency-controlled hoist motors ../4H..-MF 120 Hz ................................................ 96
11.2.7 Frequency-controlled hoist motors ../4HS.-MF 100 Hz .............................................. 97
11.2.8 Frequency-controlled hoist motors ../4HS.-MF 120 Hz .............................................. 97
11.3 Cable cross sections and lengths of supply cable ......................................................................................................................................... 98
11.3.1 Cable cross sections and lengths of supply cable for pole-changing hoist motors …-
MF ................................................................................................................................... 98
11.3.2 Cable cross sections and lengths of supply cable for pole-changing hoist motors .. 98
11.4 Tightening torques ................................................................................................................................................................................................ 99
11.5 Lubricants ............................................................................................................................................................................................................. 101
11.6 Lubricants for travel drive .................................................................................................................................................................................. 101
11.7 Circuit diagrams .................................................................................................................................................................................................. 101
1 General information
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1 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.
1.1 Information about safety messages
1.1.1 Explanation of signal words and symbols
The following signal words are used in safety messages.
Signal word
Meaning
DANGER
Indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE
Indicates possible material or environmental damage.
1.1.2 Safety instructions
The fundamental hazards and required safety measures are listed in section “General
safety notes”.
1.1.3 Section safety messages
Section safety messages relate to an entire section and are laid out as follows.
SIGNAL WORD
Type and source of hazard
Possible consequences if disregarded
➢ Measures to prevent the hazard
1.1.4 Embedded safety messages
Embedded safety messages are placed directly before or after a required action and are
structured as follows.
SIGNAL WORD Type and source of hazard, possible consequences if disregarded.
➢ Measures to prevent the hazard,
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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
1.2 Spare parts
WARNING
Safety hazard. Incorrect or defective spare parts may lead to damage, malfunctions or
the complete failure of the machine.
➢ Use only original spare parts.
1.3 Target audience and responsibilities
Owner
Whoever uses and employs the product or has it operated by suitable trained personnel
is considered to be the owner (employer/company).
Trained personnel
Trained personnel are persons who have been instructed and trained in the duties with
which they are entrusted and the risks which may arise from incorrect behavior, have
been advised on the necessary protective devices, precautions, applicable regulations,
accident prevention regulations and prevailing conditions and have proven their ability.
Qualified person
A qualified person is a person who by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, training, and experience,
successfully demonstrates the ability to solve/resolve problems relating to the subject
matter, the work, or the project.
Electrical qualified person
An electrical qualified person is defined as:
One who has received training in and has demonstrated skills and knowledge in the
construction and operation of electric equipment and installations and the hazard
involved.
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1.4 Crane logbook
A completed crane logbook must be kept for each hoist. The results of the periodic
inspections must be entered in the logbook.
1.5 Transport and storage
Transport
Fig. 1
The product is delivered on a special pallet. This enables it to be loaded and unloaded
safely with a fork-lift truck.
1. WARNING Falling parts hazard. If the product is to be transported suspended,
attach the product to the sling points provided. The sling points are designed for a
max. diagonal pull ≥ 45°.
2. Do not allow the hoist to drop. Set the product down on the ground correctly.
3. Avoid damage to the product and its components by loading and unloading it
correctly.
Storage
1. Store the product and its accessories in a dry place.
2. Store it in a stable position, secure it against toppling or overturning.
3. Observe environmental protection laws for storage (do not allow oil etc. to leak).
4. Make sure that the ground is firm and does not permit the machine to sink in.
5. Ensure the load is evenly distributed, support the hoist at several points.
6. Do not kink the ropes and avoid contact with the ground.
1.6 Weight
See factory certificate.
1.7 Installation, commissioning, maintenance and repairs
1. Make sure that installation, commissioning, maintenance and repairs are carried out
by qualified persons only.
2. We recommend having installation carried out by qualified personnel engaged by the
manufacturer.
3. Do not carry out any alterations or modifications.
4. Make sure that additional fitments are approved by the manufacturer.
(During welding work, electrode and ground must be in contact with the same
component!)
5. Use only original spare parts for repairs.
6. Make sure that dismantled guards are screwed down again and locked.
If the wire rope hoist is constantly operated out of doors and exposed to the elements
without protection, we recommend fitting a canopy or at least “parking” the hoist under a
roof.
• For detailed information about installation see section “Installation”.
• For detailed information about commissioning see section “Commissioning”.
• For detailed information and about maintenance and repairs see section “Inspection
and maintenance”.
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1.8 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. Competent and practically oriented, we impart the specialist
knowledge required for the correct use, monitoring and care of your system.
Ask for our seminar program.
1.9 Periodic inspections
• Hoists and cranes must be inspected by a qualified person least once a year, more
frequently if so specified by national regulations.
• The results of the inspections must be recorded and filed in the test logbook.
• The remaining service life of the hoist must also be established during this inspection.
• The periodic inspections must be adapted to the hoist’s use. Intensive use or adverse
environmental conditions entail shorter maintenance intervals.
All tests must always be initiated by the owner!
1.10 Environmental information
Environmental aspects have been taken into account when developing and
manufacturing this equipment. Please note the instructions on safe lubrication and waste
disposal to avoid pollution risks during use. Appropriate use and correct maintenance will
improve the environmental performance of this product.
1.10.1 Life cycle assessment
The stages of the product service life are:
• Production of materials,
• components and energy,
• transport to factory,
• manufacture and assembly,
• transport to customer,
• on-site installation,
• operating phase including maintenance and modernization,
• dismantling and recycling of materials at end of service life.
1.10.2 Energy consumption
The energy consumption during the operating phase has the highest impact on the
environment. Electricity is required for starting and running the motors and for lighting,
heating, cooling and other optional electrical components and parts of the hoist.
2 General safety notes
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2 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.
2.1 Use for intended purpose
• Wire rope hoists are intended for lifting freely movable loads. Depending on their
design, they are for stationary or mobile use.
• In the case of wire rope hoists with multiple load-bearing equipment, ensure that the
load is distributed evenly between the falls.
• Any fundamental alterations and modifications to the product, such as e.g. welding on
load-bearing components, structural alterations to load-bearing components,
alteration of drives, alteration of speeds and motor outputs, replacing trolleys, etc.
must be authorized by the manufacturer, otherwise the declaration of
conformity/declaration of incorporation will be invalidated.
• Also any work on or additions to the control must be authorized by the manufacturer.
The manufacturer cannot accept any liability for malfunctioning after unauthorized
work on the control.
• The conditions in the place of use of the hoist must correspond to the operating
conditions for which the hoist was designed (including indoor/outdoor use, ambient
temperature, radiation temperature, wind, dust, splash water, snow, water, etc.
• For hoists which work in combination and have more than one control (tandem
operation), action must be taken to coordinate the controls. This applies also to the
reaction of the protective devices. Controls must be constructed accordingly.
• For hoists intended for automatic operation, the control must be designed
accordingly.
2.2 Inappropriate use
• Use in areas with potentially explosive atmosphere.
• Transporting molten metal.
• Exceeding the maximum working load.
• Transporting persons.
• Pulling/towing or raising/lowering of a guided load.
• Using the hoist in applications in which the working load changes with the position of
the load, as the hoist is not equipped with a load display and additional warning
device when it cuts off at overload.
• Breaking away, pulling or towing of loads.
• Use of rope drive for “guided loads” without being designed for this type of
application.
• Breaking away of tilted loads if the rope drive is designed for the “guided load”
application.
• Pulling loads at an angle, dragging loads or moving vehicles with the load or load
suspension equipment.
• Do not knot load ropes or chains or shorten them with devices such as bolts, screws
or similar.
• Removing the safety latch from suspension and load hooks.
• Manipulating the overload safety device.
• Operation with slack rope (loose windings on the rope drum).
• If the product forms “part of a machine”, the person placing it on the market must
ensure that the product meets the specific regulations of the application.
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2.3 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.
• Risk of crushing
• Hazard due to falling parts (attached to the load or on the load)
• Load toppling due to unsuitable or damaged load-bearing equipment
• Risk of electric shock
Preventative measures:
1. Use LOTO (Lockout/Tagout) procedure in accordance to national, state and local
regulations and company policy.
2. Switch the machine off and ensure it cannot be switched on again before carrying out
maintenance, cleaning and repair work.
3. Switch off the power supply before all work on the electrical system. Check that the
components to be replaced are free of current and voltage.
4. Do not remove any safety devices or override them by manipulating them.
5. When lifting or lowering loads ensure that no-one is in the immediate danger area.
6. It is forbidden for anyone to stand in the danger area.
2.4 Organizational safety precautions
• The owner may only employ insured persons to operate a crane single-handedly
(crane operator), install or perform maintenance on the product if they are capable
both physically and mentally,
• have been instructed in operating and maintaining the crane and have shown him
proof of their competence and
• may be expected to perform the duties assigned them reliably.
• At regular intervals, check that work is being carried out in a safety-conscious
manner.
• Observe the intervals specified for periodic inspections. File the test reports in the
logbook.
2.5 General regulations
• Safety and accident prevention regulations.
• All national, state and local regulations.
2.6 Recommended PPE
Fig. 2
Personal protective equipment to be provided by the owner
• Safety shoes
• Gloves (only if there is no danger of them being drawn into equipment)
• Protective goggles
• Hart hat
• Hearing protection
• Closely fitting clothes (danger of clothing being drawn into equipment)
• When operating the hoist or standing close to the hoist, wire rope or chain there is a
danger of fingers, clothing, jewelry, etc. being drawn into equipment
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2.7 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.
2.8 Sound pressure level
Fig. 3
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).
Instead of stating an emission value based on a workplace, the values from Tab. 1 and
Tab. 2 at measuring distance “h” can be used.
Fig. 4
Wire rope
hoist type
[db (A)] +/-3
h [ft]
3 ft
7 ft
13 ft
26 ft
52 ft
YKA/SKA
76
73
70
67
64
YKB/SKB
76
73
70
67
64
YKC/SKC
78
75
72
69
66
YKE/SKE
78
75
72
69
66
Tab. 1
Wire rope
hoist type
[db (A)] +/-3
h [ft]
3 ft
7 ft
13 ft
26 ft
52 ft
YKA/SKA
76
70
64
58
52
YKB/SKB
76
70
64
58
52
YKC/SKC
78
72
66
60
50
YKE/SKE
78
72
66
60
50
Tab. 2
2.9 Fire safety
WARNING
Safety hazard. Never use a powder extinguisher in the presence of high voltages.
Only fight the fire if this is possible without subjecting yourself to risk. Switch off the crane
if this is possible. Evacuate the area. Advise other persons on potential danger and call
for help.
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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. The owner is responsible for ensuring that work is carried out with safety in mind and
avoiding risks.
2. Read the instructions before starting to work with the product.
3. Standing under a suspended load is forbidden. Danger to life and limb!
4. Observe the “Duties of crane operator”.
5. Before starting work, find out where the emergency stop button is (usually in the
control pendant).
6. Do not put your hand between edges which might crush or cut.
7. Do not grasp the moving rope.
8. Take note of the relevant instructions when attaching loads.
9. Do not stand between load and wall.
10. Start lifting the load carefully.
11. Never attempt to remedy a malfunction while the load is suspended.
12. Never use bent, open or distorted load hooks, or attempt to straighten them.
13. Have a damaged hook safety latch repaired.
14. Never anneal the hook.
15. Never lock the buttons of the control switch in place.
16. Never allow the load to drop into the hoist’s load-bearing equipment.
17. Before lifting loads, ensure that the stated maximum working load is not exceeded.
18. When lifting and setting down loads, ensure that they are in a stable position in order
to avoid accidents due to the load toppling or overturning.
19. Secure the load if the power is cut.
20. Do not kink or crush control cables.
21. Choose a safe place from which to operate the hoist.
22. Joining or mending ropes, chains or belts is not permitted.
23. Never touch metal components that are colder than 32°F or hotter than 131°F without
wearing protective gloves.
24. Do not use the emergency limit switch (ultimate limit switch for highest and lowest
hook position) as an operational limit switch.
25. Report damage and defects to the product (abnormal noises, impaired braking
function, deformations, etc.) to the person responsible immediately. Do not use the
product until the faults have been eliminated.
26. Do not remove information plates from the product. Replace illegible or damaged
plates.
27. Have hoist inspected by the relevant authority before commissioning.
2.11 Attaching load
1. Use only tested and approved slings for attaching the load.
2. The hoist rope must not be wound around the load.
3. The load must always be suspended from the base of the hook. The tip of the hook
must not be subjected to load.
4. Removing the safety latch from suspension and load hooks is not permitted.
5. Only attach hook block when stopped.
6. Hook or hook block turns under load – release the hook block and rope when lifting
the load.
7. Do not reach into the hook block opening at the rope inlet – crushing hazard!
8. Guide the hook block on the load hook bracket - not on the hook base! – crushing
hazard!
3 Introduction
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3 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. brake. Its
design complies with the FEM calculation regulations which are adapted to the
requirements of hoist operation.
The main components of the wire rope hoist are the hoist motor, the gear, the rope drum
and the control box with connection parts.
Our certified quality assurance system to DIN ISO 9001 guarantees consistently high
quality.
14
15
16 17 18
Fig. 5
1 Panel box with connection parts
2 Emergency hoist limit switch, operational hoist limit switch
3 Gear
4 Mounting point for safety brake (YKB/SKB – YKE/SKE)
5 Rope drum
6 Rope guide with rope tensioning spring
7 Clamps for rope attachment
8 Rope drum bearing
9 End cover
10 Motor
11 Brake
12 Fan
13 Fan cover
14 Stationary wire rope hoist, hoist for incorporation
15 Wire rope hoist with “short headroom” monorail trolley
16 Wire rope hoist with “standard headroom” monorail trolley
17 Wire rope hoist with “articulated” monorail trolley
18 Wire rope hoist with double rail trolley
3 Introduction
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3.1 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.
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4 Installation
4.1 Stationary hoist
Fig. 6
Wire rope
hoist type
MT (rope drum torque)
[lbf in]
YKA/SKA
½ × F × 5 in
YKB/SKB
½ × F × 6.6 in
YKC/SKC
½ × F × 8.6 in
YKE/SKE
½ × F × 14 in
Possible mounting positions and fleet angles
Feet “at bottom” and “at top” are possible for designs with bottom hook block (rope leadoff 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. If possible, install the hoist in the preferred installation position ***
(see page 20, section 4.2 1 “Attachment at bottom”)
2. Use the fixing elements specified, see the following figures and tables.
3. Take care that no distortion arises from unevenness (max. 0.5°, max. 0.079 in.)
4. The customer's substructure must take up the torque M
T
from the rope drum. It must
therefore be torsion resistant.
5. If the rope lead-off is not vertical, the shearing forces arising must be taken up by a
shear bar.
6. For tightening torques see page 102, section 11.4 “Tightening torques”.
Standard reevings
1PS
2PS
4PS
1PD
2PD
4PD
Fig. 7
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4.1.1 Attachment at bottom
Type YKA/SKA
pcs
(1)
Screw M16-8.8
6
(2)
SCHNORR® Safety Washer S16
12
(3)
Nut, M16-8
6
Type YKB/SKB
pcs
(1)
Screw M20-8.8
6
(2)
SCHNORR® Safety Washer S20
12
(3)
Nut, M20-8
6
Type YKC/SKC
pcs
(1)
Nut, M24-8
6
(2)
SCHNORR® Safety Washer S24
12
(3)
Screw M24-8.8
6
Type YKE/SKE, YKD/SKD (2PS, 4PS, 2PD)
pcs
(1)
Screw M30-8.8
8
(2)
SCHNORR® Safety Washer S24
16
(3)
Nut, M30-8
8
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Type YKE/SKE (1PS)
pcs
(1)
Nut, M24-8
8
(2)
SCHNORR® Safety Washer S24
16
(3)
Screw M24-8.8
8
Fig. 8
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4.1.2 Attachment at top
Type YKA/SKA
pcs
(1)
Nut, M16-8
8
(2)
SCHNORR® Safety Washer S16
16
(3)
Screw M16-8.8
8 Type YKB/SKB
pcs
(1)
Nut, M20-8
8
(2)
SCHNORR® Safety Washer S20
16
(3)
Screw M20-8.8
8
Type YKC/SKC
pcs
(1)
Nut, M24-8
8
(2)
SCHNORR® Safety Washer S24
16
(3)
Screw M24-8.8
8
Type YKE/SKE (1PS)
pcs
(1)
Screw M24-8.8
8
(2)
SCHNORR® Safety Washer S24
16
(3)
Nut, M24-8
8
Fig. 9
4 Installation
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4.2 Fleet angle
4.2.1 Attachment at bottom
Wire rope hoist types
YKA/SKA, YKB/SKB, YKC/SKC, YKE/SKE
1PS,
1PS twin hook
YKA/
SKA
YKB/
SKB
YKC/
SKC
YKE/
SKE
α1
4°
5°
8°
8°
α2
23°
13°
20°
18°
α3
27°
30°
30°
30°
α4
74°
73°
76°
80°
α5
30°
30°
30°
25°
α6
113°
103°
110°
108°
α7
63°
61°
60°
60°
α8
11°
12°
16°
20°
α9
24°
26°
30°
-
α10
7°
7°
8°
8°
α12
90°
90°
90°
-
Tab. 3
Fig. 10
***
Preferred installation position
1)
Standard
2)
By turning rope guide
4)
By turning rope guide and grease pan.
Type YKE/SKE: Version (G) not possible
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4.2.2 Attachment at top
Wire rope hoist types
YKA/SKA, YKB/SKB, YKC/SKC, YKE/SKE
1PS,
1PS twin hook
YKA/
SKA
YKB/
SKB
YKC/
SKC
YKE/
SKE
α1
4°
5°
8°
on
request
α2
23°
13°
20°
α3
27°
30°
30°
α4
74°
73°
76°
α5
16°
17°
14°
α6
35°
32°
36°
α7
74°
74°
76°
α12
90°
90°
90°
α13
90°
90°
90°
Tab. 4
Fig. 11
1)
Standard
2)
By turning rope guide
4)
By turning rope guide and grease pan.
Type YKE/SKE: Version (H) not possible
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4.2.3 Attachment at side
Wire rope hoist types
YKA/SKA, YKB/SKB, YKC/SKC, YKE/SKE
1PS,
1PS twin hook
YKA/
SKA
YKB/
SKB
YKC/
SKC
YKE/
SKE
α1
21°
23°
18°
on
request
α2
12°
13°
20°
α3
74°
73°
76°
α4
10°
10°
20°
α5
21°
23°
18°
α6
23°
20°
20°
α7
27°
30°
30°
α8
74°
73°
76°
α9
4°
5°
8°
α10
23°
13°
20°
α11
27°
30°
30°
α12
74°
73°
76°
α13 - -
70°
α14 - -
6°
Tab. 5
Fig. 12
2)
By turning rope guide
4)
By turning rope guide and grease pan.
Type YKE/SKE: Version (H) not possible
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4.2.4 Fleet angle
Wire rope hoist
type
γ
YKA/SKA
39°
YKB/SKB
39°
YKC/SKC
39°
YKE/SKE
39°
Tab. 6
1. Adjust the rope guide to the fleet angle.
2. Observe also the radial rope exit angle γ.
4.2.5 Angle of installation
WARNING
Rope damage hazard. The wire rope must not touch the rope guide or structural
elements.
➢ Always install the hoist horizontal.
Fig. 13
1. Install hoists with rope drives with bottom hook blocks always horizontal to their
longitudinal axis.
2. Do not exceed the fleet angle to the direction of the rope drum groove and the rope
sheave of 4°/3° for non-rotation-resistant wire ropes, 2°/1° for rotation-resistant wire
ropes.
However even at these angles a reduction in service life is to be expected.
3. Equip rope sheaves with a suitable guard to prevent the rope jumping out of the
groove, max. clearance of the guard <0.5 × rope diameter.
The rope must not slip off the sheave axle if the sheave breaks.
The rope suspension must be designed to prevent kinking and other additional
stresses.
The rope suspension for non-rotation-resistant wire ropes must be designed so that it
cannot rotate around its longitudinal axis.
The rope spread angle of 45° in top hook position must not be exceeded.
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4.3 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
Fig. 14
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.
Please have it checked by our after-sales service.
1. Check flange width “B” and clearance “c” against Tab. 7 and set trolley to beam
width if necessary.
Installation if end of runway is freely accessible
1. Slide trolley onto end of runway and check play “f/2”.
Installation if end of runway is not accessible
1. Unscrew nuts (2) on threaded bolts (1) and slide trolley side cheek (3) outwards by
approx. “x” in. or until dimension B+y is reached (Tab. 7).
2. Push hoist side of trolley onto lower flange of runway beam and secure against
slipping.
3. Push trolley side cheek (3) towards the runway beam on support bolt (4).
4. Adjust dimension “c” with nuts (2), tighten nuts (2).
5. Check track gage “c” and play f/2.
6. Tighten nuts (2) with torque spanner to the specified tightening torque (see table
below).
Hoist
Wheel
Ø D
Trolley
c
f/2 x y
z max
Tightening
torque
[in]
INP
IPE
IPB
"
[in]
[lbf ft]
YKA/SKA
3.1
KE-S33
B = 3.5…19.7 in
B+2.6 1)
0.059
2.8
5.4
1.04
155
YKB/SKB
3.9
KE-S44
B+2.6 1)
0.059
3.1
5.8
1.12
155
YKC/SKC
5.5
KE-S65
B = 4.7…19.7 in
B+2.6 1)
0.059
3.7
6.4
1.54
155
YKD/SKD
7.9
KE-S76
B = 4.9…19.7 in
B+3.6 1)
0.059
3.7
7.4
1.89
155
YKE/SKE
Tab. 7
1)
for INP beam: -0.079 in.
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4.3.2 Drive shaft for travel drive (trolleys KE-S33 - KE-S65)
Drive shaft
Ø D B L
Position
[in]
[in]
[in]
3.1
3.9
SF17 1..
SF17 2..
3.5 - 5.7
15.4
X3
-
5.7 - 7.7
-
X4
7.7 - 9.8
19.5
X3 - 9.9 - 12
-
X4
12.1 - 13.8
23.4
X3 - 13.8 - 15.7
-
X4
15.8 - 17.7
27.4
X3
-
17.8 - 19.7
-
X4
5.5
SF17 2..
4.7 - 7.9
19.9
X3
-
7.9 - 12.2
-
X4
12.2 - 15.7
27.4
X3
-
15.8 - 19.7
-
X4
7.9
SF17 2..
4.9 - 8.7
20.1
see next page
8.7 - 15.7
29.1
15.8 - 19.7
30.7
Tab. 8
Fig. 15
Ø D
L3 ±0.079
L4 ±0.079
[in]
[in]
[in]
3.1
3.8
1.83
3.9
5.5
4.91
1.83
Tab. 9
1. Fit drive shaft in mounting position X3 or X4 depending on flange width (B) of runway
beam and length (L) of drive shaft (D).
2. Fit circlips (S).
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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
hoist type
Wheel
Ø D
Trolley
Travel drive
L d f/2
Tightening torque
[in]
INP
IPE
IPB " [in]
[in] [lbf ft]
YKD/SKD
YKE/SKE
7.9
KE-S76
SF17 2..
B = 4.9 - 8.7 in
20
B+3.6 1)
0.059
155
B = 8.7 - 15.7 in
29
B = 15.8 - 19.7 in
31
1)
for INP beam: -0.079 in.
1. Insert drive shaft (5) into the two drive pinions (6) from the counterweight side, then
assemble spacer tube (7) and adjusting ring (8).
2. Adjust drive shaft (5) so that on the hoist side the shaft end projects by between
min. 0 in. and max. 4.72 in. beyond the drive pinion (6) and on the counterweight
side the shaft end projects by between min. 1.9 in. and max. 6.3 in. beyond the
trolley side cheek (10).
3. Lock adjusting ring (8) with adjusting screw so that on spacer tube (7) lying against
drive pinion (6) there is a play of approx. 0.079 - 0.157 in. to adjusting ring (8).
4. After fitting travel drive, check drive shaft (5) for ease of movement.
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4.3.4 Monorail trolley (UE-S4)
with YKB/SKB, YKC/SKC, 1PS wire rope hoists (single fall)
Fig. 17
Ø D
Trolley
c
f/2 x y
z
max
Tightening
torque
[in]
INP
IPE
IPB
"
[in]
[lbf ft]
3.9
UE-S4
B = 3.5…19.7 in
B+2.6 1)
0.059 3 5.6
1.12
155
Tab. 10
1)
for INP beam: -0.079 in.
1. Check flange width “B” and clearance c ±0.079 in. against Tab. 10 and set trolley to
beam width if necessary. Ensure that the connection piece (square tube) (6) is in the
center (of dimension “c”) between the trolley side cheeks (z1 = z2).
2. After unscrewing nuts (3) together with nuts (2), adjust clearance c ±0.079 in. and
tighten nuts (3).
3. Tighten nuts with torque spanner to the specified tightening torques (see table
above).
4. Clearance “c” results in a flange play of f/2 +0.039 in. on each side. If necessary,
correct flange play by means of clearance “c”.
Installation if end of runway is freely accessible
1. Slide trolley onto end of runway and check play f/2.
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.
3. Slide trolley onto the bottom flange of the runway beam on the axle keep plate side
(8) and secure against shifting.
4. Push trolley side cheeks (4) back to nuts (2), retighten nuts (3).
5. Check track gage c ±0.079 in. and play of guide rollers f/2.
6. Tighten nuts with torque spanner to the specified tightening torques (see table
above).
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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).
Connecting bolt and drive shaft
Drive shaft
Ø D B L
Position
[in]
[in]
[in]
3.1
3.9
SF17 1..
SF17 2..
3.5 - 5.7
15.4
X3
-
5.7 - 7.7
-
X4
7.7 - 9.8
19.5
X3
-
9.9 - 12
-
X4
12.1 - 13.8
23.4
X3
-
13.8 - 15.7
-
X4
15.8 - 17.7
27.4
X3 - 17.8 - 19.7
-
X4
5.5
SF17 2..
4.7 - 7.9
19.9
X3 - 7.9 - 12.2
-
X4
12.2 - 15.7
27.4
X3
-
15.8 - 19.7
-
X4
7.9
SF17 2..
4.9 - 8.7
20.1
see next page
8.7 - 15.7
29.1
15.8 - 19.7
30.7
1. Use connecting bolt and drive shaft suitable for beam range “B”.
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4.3.5 Monorail trolley (UE-S776)
with YKE/SKE, 4PS wire rope hoist (four-fall)
Fig. 18
Ø D
Trolley
c
f/2 x y
z max
Tightening
torque
[in] INP
IPE
IPB
"
[in]
[lbf ft]
7.9
UE-S776
B = 7.3…19.7 in
B+3.6
0.059
3.7
7.4
1.9
155
Tab. 11
1. Check flange width “B” and clearance c ± 0.079 in. against Tab. 11 and set trolley to
beam width if necessary. Ensure that the connection piece (square tube) (6) is in the
center (of dimension “c”) between the trolley side cheeks (z1 = z2).
2. After unscrewing nuts (3) together with nuts (2), adjust clearance c ± 0.079 in. and
tighten nuts (3).
3. Do not distort plate (10). Tighten nuts (5) lightly and then unscrew by a quarter turn.
Lock nuts (9) against nuts (5) with a torque spanner (see table above).
4. Tighten nuts (3) with a torque spanner to the specified tightening torque (see table
above).
5. Clearance “c” results in a flange play of f/2 +0.039 in. on each side. If necessary,
correct flange play by means of clearance “c”.
Installation if end of runway is freely accessible
1. Slide trolley onto end of runway and check play f/2.
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.
3. Slide trolley onto the bottom flange of the runway beam on the axle keep plate side
(8) and secure against shifting.
4. Push trolley side cheeks (4) back to nuts (2), retighten nuts (3).
5. Check track gage c ± 0.079 in. and play of guide rollers f/2.
6. Tighten nuts (3) with a torque spanner to the specified tightening torque (see table
above).
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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).
Connecting bolt and drive shaft
3. Use connecting bolt and drive shaft suitable for beam range “B” (for dimensions, see
Fig. 19).
Drive shaft for trolley drive (trolley UE-S776)
Fig. 19
B L L1
L2
f/2
[in]
[in]
[in]
[in]
[in]
7.3 - 8.7
20.1
3.3
5.1 - 3.7
0.059
8.7 - 14.2
24.4
3.3
6.8 - 1.3
14.2 - 17.7
29.1
5.3
3.9 - 0.35
17.8 - 19.7
29.1
3.3
2.3 - 0.35
Tab. 12
The drive shaft is suitable for girder flange widths “B” from 7.3 in. to 19.7 in. (see Tab.
12 for length “L”).
1. Insert drive shaft (1) into the two drive pinions (6) from the counterweight side, then
assemble spacer tube (3) and adjusting ring (4).
2. Adjust drive shaft (1) to dimension “L1”, dimension “L2” must lie between the values
given in the table.
3. Lock adjusting ring (4) with adjusting screw.
4. After fitting travel drive, check drive shaft (1) for ease of movement. The axial play
must be approx. 2 – 4 mm (0.08 – 1.57 in.)
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