Yale HOISTS SHAW-BOX YKA, Operation & Service Manual

Page 1: ...low all instructions and warnings for inspecting maintaining and operating this product The use of any hoist presents some risk of personal injury or property damage That risk is greatly increased if...

Page 2: ...repuesto y centros de servicio situados estrat gicamente en Estados Unidos y Canad Estas instalaciones se han seleccionado en base a su capacidad demostrada en la reparaci n de equipos y suminstro de...

Page 3: ...tions 13 2 5 General regulations 13 2 6 Recommended PPE 13 2 7 Working above floor level 14 2 8 Sound pressure level 14 2 9 Fire safety 14 2 10 Safety conscious operation 15 2 11 Attaching load 15 3 I...

Page 4: ...ys KE S 58 4 12 5 Mounting hook operated hoist limit switch with switch rod on trolleys UE S77 67 4 12 6 Mounting hook operated hoist limit switch with switch rod on trolleys OE S 68 4 13 Reeving rope...

Page 5: ...test 132 7 19 Rope drive 133 7 19 1 Rope and rope attachment general information 133 7 19 2 Replacement of wire rope due to broken wires 134 7 19 3 Removing the rope guide 136 7 19 4 Installing the r...

Page 6: ...2 ys A11867501 Rev AE 11 3 2 Cable cross sections and lengths of supply cable for pole changing hoist motors H 162 11 4 Tightening torques 163 11 5 Lubricants 165 11 6 Lubricants for travel drive 165...

Page 7: ...tuation 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 mat...

Page 8: ...sons 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 precau...

Page 9: ...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 Ins...

Page 10: ...e 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 En...

Page 11: ...g 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 incorporat...

Page 12: ...re that the product meets the specific regulations of the application Application of external torques due to forces that are exercised from outside the system e g with gripper operation or through til...

Page 13: ...hat 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 pre...

Page 14: ...g an emission value based on a workplace the values from Tab 1 and Tab 2 at measuring distance h can be used Fig 4 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...

Page 15: ...ed 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...

Page 16: ...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...

Page 17: ...E 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...

Page 18: ...th straps so that they cannot fall 4 1 Stationary hoist Fig 6 Type MT rope drum torque lbf in YKA SKA MT 0 5 F 5 in YKB SKB MT 0 5 F 6 6 in YKC SKC MT 0 5 F 8 6 in YKE SKE MT 0 5 F 14 in Possible moun...

Page 19: ...1 6 Screw M16 8 8 2 12 SCHNORR Safety Washer S16 3 6 Nut M16 8 D 0 83 in 1 6 Screw M20 8 8 2 12 SCHNORR Safety Washer S20 3 6 Nut M20 8 YKC SKC YKD SKD YKE SKE 2PS 4PS 2PD D 0 98 in 1 6 Screw M24 8 8...

Page 20: ...4 Installation 20 07 2020 ba o 2 6 0 us 3 2 ys A11867501 Rev AE YKE SKE 1PS D 1 02 in 1 8 Screw M24 8 8 2 16 SCHNORR Safety Washer S24 3 8 Nut M24 8...

Page 21: ...8 Screw M16 8 8 2 16 SCHNORR Safety Washer S16 3 8 Nut M16 8 D 0 83 in 1 7 8 Screw M20 8 8 2 14 16 SCHNORR Safety Washer S20 3 7 8 Nut M20 8 YKC SKC YKE SKE 1PS D 0 98 in 1 7 8 Screw M24 8 8 2 14 16...

Page 22: ...E SKE 1PS 1PS twin hook YKA SKA YKB SKB YKC SKC YKE SKE 1 4 5 8 8 2 23 13 20 18 3 27 30 30 30 4 74 73 76 80 5 30 30 30 25 6 113 103 110 108 7 63 61 60 60 8 11 12 16 20 9 24 26 30 10 7 7 8 8 12 90 90 9...

Page 23: ...KA SKA YKB SKB YKC SKC YKE SKE 1PS 1PS twin hook YKA SKA YKB SKB YKC SKC YKE SKE 1 4 5 8 on request 2 23 13 20 3 27 30 30 4 74 73 76 5 16 17 14 6 35 32 36 7 74 74 76 12 90 90 90 13 90 90 90 Tab 4 Fig...

Page 24: ...12 13 20 3 74 73 76 4 10 10 20 5 21 23 18 6 23 20 20 7 27 30 30 8 74 73 76 9 4 5 8 10 23 13 20 11 27 30 30 12 74 73 76 13 70 14 6 Tab 5 Fig 10 2 By turning rope guide 4 By turning rope guide and grea...

Page 25: ...her 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 positio...

Page 26: ...he nuts 2 on the threaded bolts 5 and unscrew by dimension x Slide the trolley side cheek 3 apart parallel to the unscrewed nut 2 until the dimension B y is reached Mount the trolley on the wire rope...

Page 27: ...7501 Rev AE 4 3 2 Underslung trolley UE S4 Fig 13 WARNING If the setting is established with the incorrect nuts marked in the figure on the threaded rod end with an X there is a risk of the load toppl...

Page 28: ...ension c with the nut 1 Tighten the nut 2 to the prescribed tightening torque 159 lbf ft Adjustment work connection part Loosen the nuts 5 and slide the connection part 6 on the connecting pin 7 such...

Page 29: ...e section 7 5 Tighten the nuts 3 to the prescribed tightening torque 159 lbf ft Check the track clearance f 2 with a feeler gauge and adjust if necessary see Preparatory work The dimension f 2 must be...

Page 30: ...orque 159 lbf ft Adjustment work connection part Loosen the nuts 5 and 9 then slide the connection part 6 on the connecting pin 7 such that the dimensions e1 and e2 are equal on the left and right bet...

Page 31: ...sm see section 7 5 Tighten the nuts 3 to the prescribed tightening torque 159 lbf ft Check the track clearance f 2 with a feeler gauge and adjust if necessary see Preparatory work The dimension f 2 mu...

Page 32: ...the nut 1 Tighten the nut 2 to the prescribed tightening torque 159 lbf ft Adjustment work lifting beam Loosen the nuts 6 and slide the lifting beam 7 on the connecting pin 2 such that the dimensions...

Page 33: ...5 back against the nuts 2 When doing so thread in the drive through mechanism see section 7 5 Screw the nuts 2 back and tighten to the prescribed tightening torque 159 lbf ft Check the track clearanc...

Page 34: ...34 5 28 C 56 2 2 D 15 0 59 E 70 2 76 F 63 2 48 G 33 1 3 H flange width see table below flange width see table below J 7 35 0 28 1 38 K 25 40 0 98 1 57 L 70 2 76 M 40 1 57 N 94 3 7 P 134 5 28 Q 15 0 59...

Page 35: ...the requirements of ISO 12488 1 2 Make sure that the rail joints are even on both running and guide surfaces Grind down if necessary Check track gage D a b min in in in 3 9 0 1 0 2 1 2 4 9 0 1 0 2 1 2...

Page 36: ...o 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 Pos mm in A 90 3 54 B 200 7...

Page 37: ...2 Procedure WARNING Falling parts hazard Cordon off and secure danger area during installation and dismantling work The anti jump catch is supplied pre mounted on the trolley and must be adapted to t...

Page 38: ...sition Eccentric position X Hook position Eccentric in 1 65 1 77 1 B 1 79 1 89 C 1 91 2 05 2 A 2 07 2 17 B 2 19 2 28 C 2 3 2 44 3 A 2 46 2 56 B 2 58 2 68 C 2 7 2 83 4 A 2 85 2 95 B X Hook position Ecc...

Page 39: ...sert adjusting screws S in the hook position determined from the table Position eccentric plates 4 in slot as specified by the table Tighten fixing elements 1 2 finger tight Fig 33 Fig 34 Horizontal a...

Page 40: ...ngs of the limit switches before commissioning The switching contacts are designed for control current Switching functions Limit switching in both directions of travel 1 two way switch 2 ramps Pre swi...

Page 41: ...devices for emergency stop limit switches Hoist control electronic control devices safety devices radio receiver Drive motor controls power contactors inverters Main drives motors brakes Auxiliary dr...

Page 42: ...tion can be provided by Emergency stop button in the control pendant in conjunction with the crane switch contactor Main isolator 4 9 5 Runway conductor disconnecting means must disconnect the wire ro...

Page 43: ...ndustrial environment or 2nd environment in the case of use of frequency controlled drives The electronic control devices of the overload protection and any frequency inverters installed are interfere...

Page 44: ...ture is where the safety related signals are generated and the endpoint is the output of the power control elements The electronic control device SLE SMC acts as a safety device The protective devices...

Page 45: ...on box through the cable glands 3 Connect according to the circuit diagrams supplied 4 Measure control voltage If the measured value exceeds the rated control voltage by more than 10 a different tappi...

Page 46: ...ontrol for hoist and travel motors Display of system status The general description of the control merely provides an outline Detailed information on technical data functions integrating the control s...

Page 47: ...aking or 4 pole motor with separately controlled D C brake for frequency control The motors are equipped with closable condensation holes 1 All motors have ptc sensors integrated into the winding as t...

Page 48: ...ational hoist limit switching top The hook operated limit switch can be integrated as an optional hoist limit switch It is triggered after the standard operational hoist limit switch S3 when the hook...

Page 49: ...the same time to lower the hook by the dimension x1 see table above into position C If the ball has not yet been mounted Open the bolted connections 6 Fit the ball 5 on the rope Tighten the bolted co...

Page 50: ...ng cams 5 Retaining plate 6 Screw 7 Switch rod a min distance to first obstacle c Dimension between emergency and operational hoist limit switching top x1 Dimension between hook operated hoist limit s...

Page 51: ...tch rod on stationary wire rope hoists YKA SKA YKB SKB Hoist limit switch with attachment set for reeving 2PS 1 PLS switching unit Hoist limit switch with attachment set for reeving 4PS 1 PLS switchin...

Page 52: ...3 2 ys A11867501 Rev AE Mounting holes on the lifting beam YKA SKA drum length L2 YKA SKA drum length L3 YKB SKB drum length L2 YKB SKB drum length L3 YKB SKB drum length L4 3 Mounting holes for reevi...

Page 53: ...2 4PS 4 Observe the mounting positions of the screws 2 see figure above Fasten the PLS 1 switching unit on at the prescribed position with the bolted connections see figures above Tighten the bolted...

Page 54: ...ing hook operated hoist limit switch with switch rod on stationary wire rope hoists YKC SKC Hoist limit switch with attachment set reeving 2PS 1 PLS switching unit Hoist limit switch with attachment s...

Page 55: ...L3 Drum length L4 3 Mounting holes Reeving Assembly position 2PS 1 4PS 2 Fasten the PLS 1 switching unit on at the prescribed position with the bolted connections see figures above Tighten the bolted...

Page 56: ...2 ys A11867501 Rev AE 4 12 3 Mounting hook operated hoist limit switch with switch rod on stationary wire rope hoists YKE SKE YKD SKD 1 PLS switching unit Assembly position 1 Assembly position 2 Assem...

Page 57: ...2 4PS L2 L3 L4 L5 1 YKD SKD 2PS L2 2 2PS L3 L4 L5 3 4PS L2 L3 L4 L5 1 Observe the mounting position of the screws 2 Fasten the PLS 1 switching unit on at the prescribed position with the bolted connec...

Page 58: ...prescribed tightening torque 12 Nm Retrofitted assembly 1 Bottom hook block 2 Bracket clip 3 PLS switching unit Fasten the bracket clip 2 whilst ensuring that dimensions z1 and z2 are of equal size T...

Page 59: ...Rev AE Assembly position of the PLS switching unit Assembly position 1 Assembly position 2 Assembly position 3 Assembly position 4 1 Screw 6 Nut 2 Threaded plate 7 C profile 3 Screw 8 Threaded plate 4...

Page 60: ...AE Dimension c Measured from the centre of the bracket clip upwards Measured from the centre of the bracket clip downwards Arrangement of the mounting positions KE S33 Reeving Flange width Assembly po...

Page 61: ...0 63 11 1 19 7 4 84 0 63 15 83 31 5 2 48 0 63 30 4PS 3 2 6 22 4 76 2 4 4 7 6 22 4 76 2 4 6 7 6 22 4 76 2 4 11 8 6 22 0 43 1 89 15 7 4 76 0 16 6 81 19 7 9 57 0 2 11 54 31 5 7 2 0 2 25 71 Arrangement o...

Page 62: ...n 9 33 1 0 71 1 22 8 1 4PS 3 2 L2 L3 L4 6 38 4 76 2 36 4 7 L2 L3 L4 6 38 4 76 2 36 6 7 L2 L3 L4 6 38 4 76 2 36 11 8 L2 L3 L4 6 38 3 58 1 18 15 7 L2 L3 L4 6 97 1 06 3 5 19 7 L2 L3 L4 2 24 1 06 8 23 31...

Page 63: ...31 5 L4 8 15 0 55 12 2 YKC SKC Drum pull force 2500 daN 4 7 L2 L3 7 72 4 13 2 76 6 7 L2 L3 7 72 4 72 3 35 11 8 L2 L3 6 54 2 56 0 15 7 L2 L3 5 79 0 87 4 69 19 7 L2 L3 8 15 1 0 98 1 9 41 31 5 L2 L3 8 15...

Page 64: ...76 2 2 0 16 6 7 L2 L3 L4 7 76 2 8 0 75 11 8 L2 L3 L4 7 76 4 37 3 9 15 7 L2 L3 L4 8 94 4 76 2 32 19 7 L2 L3 L4 7 76 2 4 0 35 31 5 L2 L3 L4 7 05 0 63 13 78 YKD SKD 4 9 L2 7 76 3 98 1 93 6 7 L2 7 76 4 76...

Page 65: ...n S3 a Dimension 1 18 in 1 38 in 1 PLS switching unit 6 Switch rod 7 Bottom hook block Measure the distance between the switch rod 6 and the bottom hook block 7 Dimension a must be approx 1 18 in 1 38...

Page 66: ...hangs 0 39 in Mark the assembly position of the PLS switching unit 1 and the overhang f from the C profile 4 Disassemble the PLS switching unit 1 and secure it against falling down Disassemble the C p...

Page 67: ...imit switch with switch rod on trolleys UE S77 Fasten the PLS 1 switching unit on at the prescribed position with the bolted connections see figures above Tighten the bolted connections with the presc...

Page 68: ...20 ba o 2 6 0 us 3 2 ys A11867501 Rev AE 4 12 6 Mounting hook operated hoist limit switch with switch rod on trolleys OE S 1 PLS switching unit Assembly position 1 Assembly position 2 Assembly positio...

Page 69: ...en the PLS 1 switching unit on at the prescribed position with the bolted connections see figures above Tighten the bolted connections with the prescribed tightening torque 12 Nm Perform a functional...

Page 70: ...of the rope into the rope sheave s of the bottom hook block and return pulley s see next page for details NOTICE Material damage hazard to wire rope Do not twist the rope the color coding facilitates...

Page 71: ...KA YKB SKB YKC SKC YKE SKE 1PS A A 2PS B D 4PS C E 1PD F F 2PD G H 4PD I Tab 13 Reeving YKA SKA YKB SKB YKC SKC YKE SKE 2PS D D 4PS E E 2PD H H Tab 14 Reeving YKA SKA YKB SKB YKC SKC YKE SKE 2PS D D 4...

Page 72: ...rope end through the rope bag 1 see figure Lay rope 5 around the rope wedge 2 and draw together in the rope bag 1 The rope end must protrude out of the rope bag 1 by dimension L see table as a minimum...

Page 73: ...t be clear of grease Feed the rope end through the rope bag 1 see figure Lay rope 4 around the rope wedge 2 and draw together in the rope bag 1 The rope end must protrude out of the rope bag 1 by leng...

Page 74: ...t of the load is a rope that is firmly drawn into the rope bag Check the protruding end of the rope wedge Maximum value per x see table Check dimension a and b during annual maintenance To ensure the...

Page 75: ...13 3 Position of the rope fastening point Reeving Drum length see order Wire rope hoist type YKA SKA YKB SKB YKC SKC 2PS L2 A A A L3 A A A L4 A A 4PS L2 E B F L3 E B F L4 B F 2PD L2 C D C L3 C D C L4...

Page 76: ...0 us 3 2 ys A11867501 Rev AE Reeving Drum length see order Wire rope hoist type YKA SKA YKB SKB YKC SKC 2PS L2 A A A L3 A A A L4 A A 4PS L2 E B F L3 E B F L4 B F 2PD L2 C D C L3 C D C L4 C Tab 18 E F...

Page 77: ...Rev AE Reeving Drum length see order Wire rope hoist type YKA SKA YKB SKB YKC SKC 2PS H H H 4PS G G G 2PD L2 I I I L3 J J J L4 J Tab 19 G Fig 52 Type a in b in YKA SKA 8 5 8 4 YKB SKB 10 4 11 4 YKC SK...

Page 78: ...ng point YKA SKA YKC SKC Reeving Drum length see order Wire rope hoist type YKA SKA YKB SKB YKC SKC 2PS L L L 4PS K K K 2PD L2 M M M L3 M N M L4 M Tab 20 K Fig 56 Type a in b in YKA SKA 8 5 9 5 YKB SK...

Page 79: ...pe YKE SKE 2PS L2 L5 P 4PS L2 L5 O 1PD 2PD L2 L5 R 4PD L3 L5 S Tab 21 Reeving Drum length see order Wire rope hoist type YKE SKE 2PS L2 L5 P 4PS L2 L5 O 2PD L2 L5 R Tab 22 Reeving Drum length see orde...

Page 80: ...the wire rope hoist in accordance with the specifications in section Reeving rope Firm and secure seating of the fastening screws Runway end stops for functional safety WARNING Safety hazard On three...

Page 81: ...ion unusual performance or damage of the hoist 15 DO inspect the hoist regularly replace damaged or worn parts and keep appropriate records of maintenance 16 DO use hoist manufacturer s recommended pa...

Page 82: ...ommended duty cycle and DO NOT jog unnecessarily 45 DO conduct regular visual inspections for signs of damage and wear 46 DO NOT operate the hoist with hooks that have opened up 47 DO provide supporti...

Page 83: ...g work check brakes and limit switches and inspect the system for any visible defects 7 Stop working with the crane if there are any defects which might prejudice its safety in operation 8 At close of...

Page 84: ...switched off and secured to prevent re activation 1 Emergency stopping 2 Hoist lower Step 1 slow Step 2 fast 3 Long travel right left Step 1 slow Step 2 fast 4 Long travel forwards backwards Step 1 sl...

Page 85: ...et low speed 3 Stage II on the pushbutton is actuated Motor accelerates to maximum speed 4 Stage I on the pushbutton is actuated during acceleration the current speed is maintained 5 Stage II on the p...

Page 86: ...very 12 months possibly earlier if so prescribed by national regulations like ASME B30 16 NOTE The specified inspection and maintenance intervals apply for normal conditions of use If major components...

Page 87: ...ty device 6 125 Disconnect switch and main isolator 42 PE connections and equipotential bonding Establish remaining service life 148 Rope attachment 10 and rope sheaves 133 144 Rope guide 11 136 137 D...

Page 88: ...mode 165 Oil change in case of ambient temperatures 131 F and engine rating M7 and higher 165 Periodic inspections including maintenance at least every 12 months possibly more frequently if so prescri...

Page 89: ...F 86 F Before starting to measure the insulation resistance pay attention to the operating instructions of the insulation measurement instrument being used Measuring voltage 500 V Minimum insulation...

Page 90: ...bleeder screw 1 Collect oil in a suitable container Replace copper sealing rings Tighten the oil drain screw 2 for tightening torque see table Fill with oil For suitable oil types and quantities see s...

Page 91: ...taining rings 2 See figure above and table Travel drive D B Drive through mechanism L Installation location X3 X4 L3 0 08 L4 0 08 in in in in in SF17 1 SF17 2 3 1 3 9 3 5 5 7 15 4 3 8 5 7 7 7 1 8 7 7...

Page 92: ...drive side Slide on the spacer tube 2 and adjusting ring 3 Adjust the drive through shaft 5 Observe the following points Set the drive through shaft 5 to the specified dimensions The shaft end on the...

Page 93: ...e drive through shaft 1 to the dimension L1 dimension L2 must lie within the table values Secure the adjusting ring 4 with the adjustment screw An air gap E must be present between the adjusting ring...

Page 94: ...ys with one travel drive Assemble retaining rings 1 per dimension L4 The installation position of the drive through mechanism does not change over the respective beam area B Trolleys with two travel d...

Page 95: ...and secure against being switched on again 1 Fastening screws 2 Fan cover 3 Stopping plug 5 Retaining ring 6 Fanwheel 7 Parallel key 8 Fastening screws 9 Coil carrier 10 Brake rotor 11 Hub 12 V ring...

Page 96: ...ampening the cloths only use isopropyl alcohol The use of brake cleaner is not permissible Ensure sufficient drying time for the cleaned surfaces We cannot recommend cleaning the rotor friction lining...

Page 97: ...air gap measurement is in the lower area After tightening the fastening screws 8 for tightening torque see table mark the fastening screws 8 Hoist motor type Hoist brake S max a Tightening torque 8 in...

Page 98: ...minimum see Tab 28 and does not become caught on the ledge For the maximum permissible air gap S refer to Tab 28 The brake is not readjustable Once the max permissible air gap S has been reached the...

Page 99: ...and check the available clearance NOTICE Danger of damage If increased clearance is present in the gearing between the brake rotor 7 and hub 8 remove the hub 8 from the motor shaft and replace it Be...

Page 100: ...Stud bolts 7 Fanwheel 8 Fastening screws 9 Coil carrier 10 Anchor plate 11 Brake rotor 12 Hub 13 Enclosure lower part 14 Retaining ring 15 V ring IP66 Fig 74 7 8 1 Checking the brake Remove stopping p...

Page 101: ...ssemble enclosure lower part 13 Disassemble fan cover 5 Loosen stud bolts 6 on the adapter shaft Disassemble adapter shaft with jacking screws M6 Remove retaining ring 14 for fanwheel 7 Take off fanwh...

Page 102: ...cessary Clean coil carrier Assemble in reverse order Steps 14 to 19 are omitted Make sure that the inspection bore for the air gap measurement matches with the opening in the fan cover Secure the stud...

Page 103: ...External ventilation 6 Stud bolt 7 V ring 8 Fastening screws 9 Coil carrier 10 Anchor plate 11 Brake rotor 12 Hub 16 Fastening screws Fig 75 7 9 1 Checking the brake Remove stopping plug 1 Remove stop...

Page 104: ...5 Loosen stud bolt 4 Disassemble the encoder Disassemble the encoder bracket Loosen stud bolts 6 on the adapter shaft Disassemble adapter shaft with jacking screws M6 Remove V Ring 7 IP66 Remove retai...

Page 105: ...essure springs Check the O ring of the coil carrier for damage and replace if necessary Clean coil carrier Assemble in reverse order Steps 14 to 19 are omitted Make sure that the inspection bore for t...

Page 106: ...or Set the coil carrier 2 down on a clean work surface CAUTION The pressure springs push against the anchor plate injuries can result from incorrect loosening In order to remove the shoulder screws pr...

Page 107: ...essary Press the anchor plate 4 down against the spring force e g with a spindle press and screw in the shoulder screws with the tightening torque specified in the table Clean the friction surface of...

Page 108: ...switching points A and A for the highest and lowest hook position Additionally the geared limit switch is equipped with an operational hoist limit switch for switching off in the highest hook positio...

Page 109: ...vice versa If overtravel of the operational hoist limit switch takes place with a fault B or B the emergency hoist limit switch A or A switches off the hoisting movement Only once the error has been...

Page 110: ...YKB SKB 2 YKC SKC YKE SKE 3 9 YKD SKD 5 9 Actuate the UP button in the control pendant with caution Observe the hoisting movement until the operational hoist limit switch switches off in the top hook...

Page 111: ...on B Actuate the override button S260 in the control box and the UP button at the same time until the emergency hoist limit switch switches off A When using the optional hook operated hoist limit swit...

Page 112: ...between the rope guide ring 1 and the clamping claws 2 for the rope anchorage With emergency hoist limit switching the load hook must not be lowered onto the ground Measure the distance from the rope...

Page 113: ...the operational hoist limit switch switches off in the top hook position B Prior to reaching the switch off point B make sure that a reduction to the slow speed takes place B The minimum distance a c...

Page 114: ...3 9 YKD SKD 5 9 Check with precision hoist Actuate the UP button in the control pendant with caution Observe the hoisting movement until the operational hoist limit switch switches off in the top hook...

Page 115: ...hes off A If the wire rope hoist does not travel further the emergency hoist limit switch has already switched off during step 9 and the operational hoist limit switch is not working Do not undershoot...

Page 116: ...nction and correct setting WARNING Danger due to falling load Perform all checks and settings without load only Cordon off and secure the danger zone NOTICE Danger of material damage Never remove dust...

Page 117: ...ent screws S1 to S4 Turning clockwise Switching point is shifted upwards Turning anticlockwise Switching point is shifted downwards The switching points must be set in the following order Adjustment s...

Page 118: ...3 9 in dimension c increases in accordance with the table Type Dimension c enlargement in YKA SKA YKB SKB 2 YKC SKC YKE SKE 3 9 YKD SKD 5 9 Adjusting operational hoist limit switching top B 1st Actua...

Page 119: ...he option hook operated hoist limit switch see section 4 12 this must be overridden keep the connecting rope under tension Observe the minimum distance a between the hook block and the next obstacle s...

Page 120: ...B 2 YKC SKC YKE SKE 3 9 YKD SKD 5 9 Adjusting the fast slow switching top B Hoist the load hook to 0 39 in in front of the desired switch off point observe the minimum distance b If the load hook shou...

Page 121: ...bottom emergency hoist limit switching position has been set Checking the switching points After setting the switching points check these at a slow lifting and lowering speed and readjust the switchin...

Page 122: ...b YK SK with frequency inverter b V t 0 023 ft V Hoist speed fpm t Brake ramp s Factory setting 1 5 s Example YKC SKC L05 S264 V b 64 1 5 0 023 2 2 ft c 1 2 4 d 4 7 e Effective hook path 1 With the o...

Page 123: ...has been set Dim in a 1 50 Hz 60 Hz Reeving 1PS 1PD 5 1 5 9 1 2PS 2PD 2 8 3 1 2 4PS 4PD 1 6 2 4 b YK SK with frequency inverter b V t 0 023 ft V Hoist speed fpm t Brake ramp s Factory setting 1 5 s Ex...

Page 124: ...ntrol box and the UP button at the same time to exit the switching area The bottom emergency hoist limit switching position has been set Adjusting the fast slow switching bottom B Hoist the load hook...

Page 125: ...line for the wire rope hoist Draw a vertical line for the corresponding flange width Draw a horizontal line though the point of intersection and read off the hook dimension C 22 24 26 28 30 32 34 36...

Page 126: ...k dimensions C in Flange width in YKA SKA 4PS L2 L3 YKA SKA 4PS L2 L3 PLS YKA SKA 4PS L2 L3 BLS YKA SKA 2PD L2 L3 YKA SKA 2PD L2 L3 BLS 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 3 5 7 9 11 13...

Page 127: ...idth in YKB SKB 4PS L2 L4 YKB SKB 4PS L2 L4 PLS YKB SKB 4PS L2 L4 BLS YKB SKB 2PD L2 L3 YKB SKB 2PD L2 L3 BLS 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32...

Page 128: ...sions C in Flange width in YKC SKC 2500daN 4PS L2 L4 YKC SKC 2500daN 4PS L2 L4 PLS YKC SKC 2500daN 4PS L2 L4 BLS YKC SKC 2500daN 2PD L2 L4 YKC SKC 2500daN 2PD L2 L4 BLS 27 29 31 33 35 37 39 41 43 45 4...

Page 129: ...nge width in YKC SKC 2500daN 4PS L2 L3 YKC SKC 2500daN 4PS L2 L3 PLS YKC SKC 2500daN 4PS L2 L3 BLS YKC SKC 2500daN 2PD L2 L3 YKC SKC 2500daN 2PD L2 L3 BLS 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60...

Page 130: ...22 24 26 28 30 32 Hook dimensions C in Flange width in YKD SKD 4PS L2 L4 YKD SKD 4PS L2 L4 PLS YKD SKD 4PS L2 L4 BLS 33 35 37 39 41 43 45 47 49 51 53 55 57 59 4 6 8 10 12 14 16 18 20 22 24 26 28 30 3...

Page 131: ...e wedge 4 Bottom hook block Fig 76 Feed the rope end through the bottom hook block 4 see figure Lay rope 1 around the rope wedge 3 and draw together in the rope bag 1 The rope end must protrude out of...

Page 132: ...ement 2 Clean without dismantling and grease from the outside with a thin bodied lubricant 7 17 3 Maintenance of overload safety device with shear force sensor 1 Check plate thickness min 0 059 in 2 I...

Page 133: ...t can lead to the rope breaking and a load crash resulting in serious injuries or even death Check the wire rope regularly If a wire rope is worn out it must be replaced immediately Use only original...

Page 134: ...necessary with 100 Internal corrosion Clear visible signs of internal corrosion e g corrosion particles emerging Replacement necessary with 100 Fretting corrosion Reddish brown dust between the stran...

Page 135: ...rope loops Bends Replace wire ropes with severe bends Damage due to the effects of heat or arcs Replace wire ropes with bluish discolouration or broken or melted wires Wire breakages Relieve the rope...

Page 136: ...pring washer DIN 6796 This protection must be correctly reinstalled YKA SKA YKC SKC YKE SKE Fig 79 Fig 80 Unscrew the protective plate 1 beneath the rope drum at the points a The rope guide ring now t...

Page 137: ...groove of the rope guide ring half 1 and hook the spring ends together Place second rope guide ring half with large opening 4 on the rope drum Run the wire rope straight and free of bends from the dru...

Page 138: ...orques see table Type Thread size Tightening torque lbf ft YKA SKA YKB SKB M8 1 15 YKC SKC M10 1 30 YKE SKE M16 1 118 Install the grease pan again Observe the minimum distance f 0 79 in between the ro...

Page 139: ...ng the rope guide The rope guide ring has 2 pre drilled holes 10 and 30 Rope guide rings for other angles must be drilled according to the order Remove the rope guide see section 7 19 3 Screw bearing...

Page 140: ...with right hand groove R WARNING Danger of falling parts Cordon off and secure the danger zone Discarding a wire rope Travel with the hook block until shortly before the lowest hook position and set...

Page 141: ...vel surface When unrolling make sure no loops bends or twists arise and that no foreign objects penetrate the wire rope Fig 83 Mount the rope 6 on the rope drum with all clamping plates 9 do not forge...

Page 142: ...with a rope clamp see section 4 13 2 Rope fastening point Tighten the screws 8 for the clamping plates 9 once more for tightening torques see table Type Thread size Tightening torque lbf ft YKA SKA M...

Page 143: ...236 4 91 4 72 0 094 4 88 4 69 0 106 0 256 0 276 4 91 4 69 0 11 4 88 4 65 0 126 YKB SKB 0 276 6 51 6 29 0 11 6 48 6 26 0 126 0 335 0 354 6 51 6 22 0 144 6 48 6 19 0 161 YKC SKC 0 335 0 354 8 52 8 24 0...

Page 144: ...with a special caliper Measure groove base depth h with a depth gauge If the measured values exceed or fall short of the values in the table Replace the rope sheave Ordering no New rope sheave Max ba...

Page 145: ...ands have dug into the base of the groove Impressions of single wires are acceptable A rope sheave must also be replaced if the radius of the base of the groove R has become too small for the new rope...

Page 146: ...ook for damage corrosion and wear Check function of the hook safety latch With visible damage corrosion or wear replace the load hook Measure the dimensions y and h Compare the measured values with th...

Page 147: ...0 22 0 51 0 51 II 4 92 3 15 3 15 1 97 2 36 1 57 1 97 0 59 0 39 4 68 0 28 0 28 0 51 0 51 II 6 3 3 35 3 35 2 05 2 44 1 57 1 97 0 65 0 45 5 98 0 31 0 31 0 63 0 63 II 7 87 3 94 3 94 3 94 3 94 3 94 3 94 2...

Page 148: ...n 1 5 7 21 2 Multicontroller SMC optional Fig 91 The Multicontroller SMC has a load spectrum recorder The load specific operating hours of the hoisting mechanism are stored in the load spectrum record...

Page 149: ...wire rope hoist must be overhauled by the manufacturer NOTICE Danger of material damage Components which are in the power flux may only be overhauled by the manufacturer The rope drive is classified...

Page 150: ...der no lbf ft 12 2H73 100 822 RSM150 A0443075650 16 12 2H73 1PC3052 A70017594 24 4H92 RSM500 A0543011650 33 Tab 39 NM brake rotor Hoist motor Hoist motor brake A Tightening torque Order no lbf ft 12 2...

Page 151: ...r 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 A064...

Page 152: ...rheating 4 Check if the transformer secondary is the same voltage as the coils to which it is connected 5 Replace transformer if necessary Motor burned out 1 Replace motor 2 Check input power supply 3...

Page 153: ...circuit open 1 Check if connections are loose 2 Check if jumper wires on contactor are properly installed 3 Correct wiring if necessary Lowering NOT possible Bottom hook position is reached 1 Activat...

Page 154: ...sposal 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 re...

Page 155: ...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 The ma...

Page 156: ...50 3 4 20 1 20 40 240 120 24 0 56 0 14 0 32 0 12 2H91 MF 1 6 7 40 2 20 40 240 120 45 0 101 0 78 3 435 0 26 0 58 0 45 0 250 0 0 60 0 70 100 60 50 Hz Motor 3 Power Duration factor Switching hour Nominal...

Page 157: ...ominal current Starting current cos phi k Main fuse CC J 2 440 480 V 575 600 V 440 480 V 575 600 V HP CDF c h IN A IK A IN A IK A A 12 2H33 MF 0 7 4 7 20 50 360 180 3 9 7 3 7 3 43 0 3 1 5 8 5 8 34 4 0...

Page 158: ...e CC J 2 220 240 V 380 415 V 220 240 V 380 415 V HP CDF c h IN A IK A IN A IK A A 12 2H73 100 822 1 5 30 6 20 50 360 180 44 0 72 0 88 0 486 25 3 41 4 50 6 279 0 59 0 63 125 80 6 38 6 20 40 240 120 44...

Page 159: ...ation factor Nominal current Main fuse CC J 1 360 400 V 440 480 V 575 600 V 360 400 V 440 480 V 575 600 V HP CDF IN A A 4H33 MF 4 7 70 9 9 8 2 6 6 10 10 10 5 8 60 11 3 9 3 7 4 4H42 MF 5 8 70 11 3 9 3...

Page 160: ...Duration factor Nominal current Main fuse CC J 1 440 480 V 575 600 V 440 480 V 575 600 V HP CDF IN A A 4HS3 4 7 80 8 1 6 5 15 10 5 8 70 9 3 7 4 7 2 60 10 8 8 6 4HS5 9 7 70 17 0 13 6 25 15 12 1 60 19 0...

Page 161: ...AWG ft AWG ft AWG ft AWG AWG AWG ft AWG ft AWG ft AWG ft 50 Hz 380 415 V 500 525 V 380 415 V 500 525 V 380 415 V 500 525 V 400 V 500 V 380 415 V 500 525 V 380 415 V 500 525 V 12 2H33 12 167 14 157 10...

Page 162: ...ins along crane runway to crane control Power supply along crane bridge to hoist U 5 U 1 U 4 4 5 U 2 5 U 1 5 5 6 S L1 S L1 S L2 S L2 S L3 S L3 S S S L4 S L4 S L5 S L5 AWG ft AWG ft AWG ft AWG ft AWG f...

Page 163: ...ly for the attachment of the mounting plate to the gear WARNING Safety hazard Unsuitable installation material and incorrect tightening torques may lead to damage and accidents Use only original spare...

Page 164: ...159 7 Grease pan guide rail YKE SKE M10 100 55 8 Support plate fan side grease pan YKA SKA YKB SKB YKC SKC M8 M8 C45K S235JR 15 7 9 Support plate gear side fan side fixing tube Dg YKA SKA YKB SKB M16...

Page 165: ...hs Renolit Duraplex EP3 BP Energrease LS EP3 Kl berplex BEM 41 132 3 5 oz d Grease Mobilux EP 3 K3K Fuchs Renolit RHF1 Shell Gadus S2 V100 3 Fuchs Renolit Duraplex EP3 BP Energrease LS EP3 Kl berplex...

Page 166: ...E DATE ANY ALLEGED CLAIM ACCRUES EXCEPT FOR THE WARRANTY SET FORTH ABOVE SELLER MAKES NO OTHER WARRANTIES WITH RESPECT TO THE GOODS WHETHER EXPRESSED OR IMPLIED INCLUDING ANY WARRANTIES OF MERCHANTABI...