Yale SHAW-BOX, Operation & Service Manual

Page 1: ..._______________ 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 ma...

Page 2: ...esto 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 cmw...

Page 3: ...lations 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 Attachme...

Page 4: ...e 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 stand...

Page 5: ...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 co...

Page 6: ...ituation 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 me...

Page 7: ...rsons 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 ...

Page 8: ...t 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 carrie...

Page 9: ...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 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...

Page 10: ...ient 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 ...

Page 11: ...s 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 h...

Page 12: ...alue 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 ...

Page 13: ...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 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 3...

Page 14: ... 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 te...

Page 15: ...A 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 ...

Page 16: ...ious 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 MT from the r...

Page 17: ... 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 ...

Page 18: ...4 Installation 18 03 2018 ba o 2 6 0 us 1 1 y A11867501 Rev AA Type YKE SKE 1PS pcs 1 Nut M24 8 8 2 SCHNORR Safety Washer S24 16 3 Screw M24 8 8 8 Fig 8 ...

Page 19: ...ut 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 ...

Page 20: ...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 ...

Page 21: ...A 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 ...

Page 22: ...KE 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 ...

Page 23: ...ceed 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...

Page 24: ... 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 ...

Page 25: ... 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 driv...

Page 26: ...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 Loc...

Page 27: ...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 ch...

Page 28: ... 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 ...

Page 29: ...en 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 ...

Page 30: ...t 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 ...

Page 31: ...k flange width B and clearance c against Tab 13 and set trolley to beam width if necessary 2 Ensure that the connection piece square tube 6 is in the center of dimension c between the trolley side cheeks 3 After unscrewing nuts 3 together with nuts 2 adjust clearance c and tighten nuts 3 4 Tighten nuts 3 with a torque spanner to the specified tightening torque see table above 5 Clearance c results...

Page 32: ...ft trolley onto runway from below 4 Slide trolley onto the bottom flange of the runway beam on the hoist side and secure against shifting 5 Push trolley side cheeks 4 back to nuts 2 retighten nuts 3 6 Check track gage c and play of guide rollers f 2 7 Tighten nuts 3 with a torque spanner to the specified tightening torque see table above Centering bogie 1 Loosen nuts 5 and shift bogie 6 on connect...

Page 33: ... 5 4 7 11 19 5 11 1 11 8 28 Tab 14 The drive shaft D is suitable for beam widths B from 3 5 in to 11 8 in 1 Fit lock washers S acc to dimension L4 The mounting position of the drive shaft does not change over the corresponding beam range B Trolleys with two travel drives Ø D 3 9 in Ø D 5 5 in Fig 22 The drive shaft is completely independent of the beam width 1 Mount lock washers S acc To Fig 21 an...

Page 34: ...B 134 5 28 C 56 2 2 D 15 0 59 E 70 2 76 F 63 2 48 G 33 1 3 H see table below 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 R 56 2 2 S 105 4 13 T 190 7 48 Fig 23 Type1 b max Weight Trolley E max Max buffer force Order No in lb Type max ton lbf ft lbf PA1 300 11 8 13 YKD SKD 4PS KE S76 17 6 207 9663 01 740 57 27 0 PA1 500 11 8 19 7 14 01 740 58 ...

Page 35: ...y must meet 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 Ø D S in in 3 9 0 1 0 2 4 9 0 1 0 2 6 3 0 14 0 24 7 9 0 18 0 28 Tab 15 Fig 24 1 Check track gage S on trolley and rail Smax Smin 0 197 in 2 Check lateral play S between rail and flange 3 S as per Tab 15 if trolley is positioned symmetrica...

Page 36: ...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 87 C 88 3 46 D Ø100 3 94 Fig 26 4 6 2 Wheel diameter D 4 9 7 9 in Pos mm in D Ø 125 Ø 3 94 Ø 160 Ø 6 3 Ø 200 Ø 7 87 H 97 3 82 100 3 94 100 3 94 Tab 16 Fig 27 ...

Page 37: ...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 the actual runway situation Fig 30 1 Unscrew fixing screws 1 of anti jump catch 2 Swivel the whole unit by 90 and re screw Tightening torque M8 8 4 lbf ft M10 37 6 lbf ft Trolley type OE S07 4PD Fig 31 Th...

Page 38: ... OE S05 Hook position 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 Eccentric in 1 57 1 69 1 B 1 71 1 81 C 1 83 1 95 2 A 1 97 2 09 B 2 11 2 2 C 2 22 2 34 3 A 2 36 2 48 B 2 5 2 6 C 2 62 2 74 4 A 2 76 2 87 B 2 89 2 99 C 3 01 3 13 5 A 3 15 3 27 B Fig 33 Troll...

Page 39: ... Insert adjusting screws S in the hook position determined from the table 6 Position eccentric plates 4 in slot as specified by the table 7 Tighten fixing elements 1 and 2 finger tight Horizontal adjustment Fig 39 Pos OE S04 OE S05 OE S06 OE S07 in in Z 0 39 0 59 Y 1 18 1 18 1 Adjust final hook position according to Fig and table 2 Tighten fixing elements 1 and 2 with tightening torque M10 38 lbf ...

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 switching and limit switching in both directions of travel 1 two way switch 4 ramps The speed is switched over from fast to slow before the end of the runway is reached and is cut off at the end of the r...

Page 41: ...ces mounted on the hoist control pendant radio transmitter 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 drives sensors load suspension equipment actuators 4 9 1 Supply cables Electrical service can be either power by cable or guarded system having ...

Page 42: ...necting and switching the power supply This function is performed by the following devices 4 9 4 Emergency stop It must be possible to disconnect the system electrically from the operating position This function 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 ...

Page 43: ...nic control devices of the overload protection and any frequency inverters installed are interference suppressed You will find further information in the relevant operating instructions of the devices The contacts of power contactors and rectifiers for motor brakes may generate interference exceeding the permissible values depending on output cable length and other system parameters Ready to conne...

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 of the electrical equipment installed in the scope of supply must in no case be removed replaced by different devices or bridged Fig 42 Load sensor Safety device Contactor or inverter control Fig 43 ...

Page 45: ...n 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 tapping point must be selected on the primary side of the control transformer 5 Do not connect any live lead to the temperature sensors Damaged temperature sensors cannot protect the motor WARNING On three ...

Page 46: ...s The general description of the control merely provides an outline Detailed information on technical data functions integrating the control supplied into superordinate crane controls and troubleshooting are described in separate operating instructions for the electronic control devices and shown in the circuit diagrams The same applies for frequency inverter controls Controls by others If the uni...

Page 47: ...raking 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 thermal overload protection Specification Thermal class F H Utilization insulation system Construction IM B5 flange mounting on drive side Cooling IC 411 surface cooling with integrated fan Standard o...

Page 48: ...ide Reeve the end 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 checking 2 Fasten the end of the rope in the rope anchorage 3 Perform several runs over the full height of lift without load 4 Repeat with increasing loads 5 Make any twisting in the...

Page 49: ... 1 1 2PS 2 4 4PS 3 5 1PD 6 6 2PD 7 8 4PD 9 Tab 17 YKA SKA YKC SKC YKE SKE 2PS 4 4 4PS 5 5 2PD 8 8 Tab 18 YKA SKA YKC SKC YKE SKE 2PS 4 4 4PS 5 5 2PD 8 8 4PD 9 Tab 19 1 L 2 L 3 L 4 L 5 L 6 R L 7 R L 8 R L 9 R L L left hand thread R right hand thread Fig 47 1PS 2PS 4PS 2PS 4PS 1PD 2PD 2PD 4PD ...

Page 50: ...ft for tightening torque 5 Max projection of rope wedge YKA SKA YKB SKB Xmax 0 24 in YKC SKC YKE SKE Xmax 0 59 in 6 Replace split pin 4 after dismantling it Bend ends of split pin up WARNING Falling parts hazard Ropes which are not secured as specified may lead to the rope slipping and the load falling Always insert the rope correctly into the rope anchorage and secure Replace split pin every time...

Page 51: ...h L YKA SKA YKB SKB YKC SKC 2PS 24 24 24 4PS 23 23 23 2PD L2 L3 L4 25 26 25 26 25 26 26 Tab 23 Length L YKA SKA YKB SKB YKC SKC 2PS 28 28 28 4PS 27 27 27 2PD L2 L3 L4 29 29 29 30 29 29 29 Tab 24 21 Fig 53 26 Fig 54 22 Fig 55 27 Fig 56 a 0 12 b 0 12 in in YKA 8 5 9 5 YKB 10 4 11 4 YKC 13 1 14 4 Tab 25 23 Fig 57 A 0 12 b 0 12 in in YKA 8 5 9 5 YKB 10 4 11 4 YKC 13 1 14 4 Tab 26 28 Fig 58 24 Fig 59 2...

Page 52: ... YKE SKE Length L YKE SKE 2PS L2 L5 32 4PS L2 L5 31 1PD 2PD L2 L5 34 4PD L3 L5 35 Tab 27 Length L YKE SKE 2PS L2 L5 32 4PS L2 L5 31 2PD L2 L5 34 Tab 28 Length L YKE SKE 2PS L2 L5 32 4PS L2 L5 31 2PD L2 L5 34 4PD L3 L5 35 Tab 29 31 Fig 63 32 Fig 64 34 Fig 65 35 Fig 66 1 Gear side ...

Page 53: ...functioning of runway end stops WARNING Safety hazard On three phase hoists it is possible to have Reverse Phasing causing the block to lower when the UP button is depressed When this condition exists the hoist operation will be dangerous 9 The direction of motion of the load hook must correspond to the symbols on the control pendant 10 Presence and correct functioning of all safety devices 11 Eme...

Page 54: ...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 parts when repairing a hoist 17 DO use hook latches 18 DO apply lubricant to the wire rope as recommended 19 DO NOT lift more than rated load 20 DO NOT use the hoist load limiting device to measure the ...

Page 55: ...ling hoist 44 DO operate hoist within recommended 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 supporting structure that has an appropriate design factor based on the load rating and dead weight of the hoist If in doubt of the supporting structure s strength con...

Page 56: ...ng 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 work secure cranes which are exposed to wind with the wind safeguard mechanism 9 The rope drum and rope must be free of coarse foreign matter 10 Do not move loads above people 11 Before starting wor...

Page 57: ...l motion does not correspond to the motion intended in activating the rocker switch release the rocker switch immediately If the motion continues press the emergency stop If this also fails to bring the hoist to a standstill the emergency stop switch mains connection switch should be immediately switched off and secured to prevent re activation STH Fig 67 Emergency stop Cross travel right left 1st...

Page 58: ...hen released the speed is reduced If the 1st step is activated before the motion is stopped the current speed is maintained Fig 68 6 5 Emergency stop WARNING Safety hazard After an emergency stop the operator must not restart the hoist crane system until a qualified person has determined that the fault which led to this function being activated has been eliminated and no danger can arise from the ...

Page 59: ...mponents are replaced further tests must be performed Replacing components of the overload safety device sensor electronic overload device For load test of cut off values of system see separate Operating instructions Service manual Replacement of electrical equipment and renewal of electric leads and connections Insulation resistance test and testing the continuity of the PE system Correct phase c...

Page 60: ...onnections and equipotential bonding Establish remaining service life 86 Rope attachment 10 and rope sheaves 78 83 Rope guide 11 79 81 Drive parts 12 wheel flanges wheels etc 85 Bolt joints welds End stops buffers Safety clearances Power supply cable Cable glands Towing arm Switching functions All parts in the power flux 1 By user Periodic inspections including maintenance at least every 12 months...

Page 61: ...de 101 Oil change in case of ambient temperatures 131 F and engine rating M7 and higher 101 Periodic inspections including maintenance at least every 12 months possibly more frequently if so prescribed by national regulations to be performed by a qualified person 2 Heavy duty or unfavorable conditions dirt solvents multi shift operation etc entail a reduction of this inspection and maintenance int...

Page 62: ...stance must be checked after a long period of storage or shutdown if possible at a winding temperature of 68 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 resistance for new cleaned or overhauled windings 10 MΩ Critical specific insulation resista...

Page 63: ...rotor must be replaced 7 4 2 Replacing brake disk brake rotor 1 Remove fan cover 1 2 Pull off fan wheel 3 remove feather key 3 Disconnect brake 4 Unscrew fixing screws 4 5 Remove magnet piece 5 together with armature disc 6 6 Remove brake disk brake rotor 7 7 Clean brake wear a dust protection mask 8 Check friction surfaces for wear 9 Push new brake disk brake rotor 7 onto hub 8 and check radial p...

Page 64: ...e bushing with V ring IP 66 3 Disconnect brake 4 Unscrew fixing screws 4 5 Remove magnet piece 5 together with armature disc 6 6 Remove brake disk brake rotor 7 7 Clean brake wear a dust protection mask 8 Check friction surfaces for wear 9 Push new brake disk brake rotor 7 onto hub 8 and check radial play If there is increased play in the gearing between brake disk 7 and hub 8 the hub 8 must be pu...

Page 65: ...otor must be replaced 7 6 2 Replacing brake disk brake rotor 1 Remove cover of housing 3 2 Unscrew stud screw 4 short hexagon socket s2 3 Pull off shaft encoder and leave it hanging on the connecting cable 4 Remove bottom section of housing 13 5 Remove fan wheel 5 6 Unscrew stud screws 6 on adapter shaft 7 Remove adapter shaft with lifting screws M6 8 Remove circlip from fan wheel 9 Pull off fan w...

Page 66: ...ghtening torques of fixing screws 8 see table below Hoist motor type Hoist brake Smax a Tightening torque in in lbf ft 4H33 MF10MB 200 NM38720 0 024 1 7 4H42 MF10MC 200 NM38730 0 024 1 7 4H62 MF11MA 200 NM38740 0 031 1 16 4H71 MF11MB 200 NM38740 0 031 1 16 4H72 MF13Z 200 NM38741 0 031 1 2 16 4H73 MF13ZB 200 NM38753 0 035 1 2 16 4H81 MF13ZC 200 NM38753 0 035 1 2 16 4H82 MF13X 200 NM38781 0 035 1 2 ...

Page 67: ...en reached the brake disk brake rotor must be replaced 7 7 2 Replacing brake disk brake rotor 1 Remove plug 15 2 Remove fixing screws 16 3 Remove forced ventilation 5 4 Unscrew stud screw 4 short hexagon socket s2 5 Pull off shaft encoder and leave it hanging on the connecting cable 6 Unscrew stud screws 6 on adapter shaft 7 Remove adapter shaft with lifting screws M6 8 Remove V ring 7 IP66 9 Remo...

Page 68: ...stud screws 6 with locking varnish 20 Observe tightening torques of fixing screws 8 see following table Hoist motor type Hoist brake Smax a Tightening torque in in lbf ft 4HS3 NM38730 0 024 1 7 4HS5 NM40940 0 031 1 16 4HS7 NM40951 0 031 1 2 16 4HS8 NM40980 0 035 1 2 16 4HSA NM40980 0 035 1 2 16 Tab 33 21 Check brake data according to rating plate on hoist motor 7 8 Travel motor brake See instructi...

Page 69: ... More free switching elements hoist limit switch layouts are possible as an option see circuit diagram Fig 76 7 9 1 Hoist limit switch standard Version 1 Operational limit switch for top hook position standard on YK SK Description of system see next section Fig 77 Version 2 Operational hoist limit switch for top and bottom hook position standard on YK SK with VFD option on YK SK Description of sys...

Page 70: ...ated 7 10 2 Testing emergency hoist limit switch version 1 1 Test at slow speed without load 2 Activate the up button on the control pendant carefully observing the hoisting motion until the hoist limit switch disconnects in the highest operational hook position B 3 Activate the override button S260 in the control and at the same time the up button until the emergency hoist limit switch disconnect...

Page 71: ...tton S262 in the control and at the same time the up button until the emergency hoist limit switch disconnects A If the hoist does not continue to move the emergency hoist limit switch has already switched off in step 5 and the operational hoist limit switch is not working 8 Minimum clearance between rope guide S and clamping claws K for rope anchorage 0 79 in see Fig 79 if necessary reset hoist l...

Page 72: ...30 50 99 0 and without using undue force Do not use a power screwdriver Adjust the switching points in the following sequence 1 A S1 2 B S3 3 B S4 4 A S2 5 B S5 option 6 B S6 option When setting the hoist limit switch observe hook dimension C as specified on page 76 section 7 11 Hook dimensions C for KE S trolleys Switching point A S1 Emergency hoist limit switch top hook position 1 Set without lo...

Page 73: ... t is altered clearance b must be recalculated and reset Lower bottom hook block by b 5 Turn setscrew S4 to the left until contact S4 switches audibly 6 Check cut off point at fast and slow speed 7 Ensure that hoist switches over to slow speed before cut off point B is reached Switching point A S2 Emergency hoist limit switch bottom hook position Minimum clearance between rope guide S and clamping...

Page 74: ...itching for bottom hook position Type YK SK 1 Lift bottom hook block by 2xb see Fig 82 Tab 35 Tab 36 Type YK SK with VFD 1 Use formula to calculate clearance 2xb between B and B The factory setting of the brake ramp t is 1 5 s The switching point B is dependent on drum speed V and brake ramp t If brake ramp t is altered clearance b must be recalculated and reset Lift bottom hook block by 2xb 2 Tur...

Page 75: ...No maintenance or inspection is necessary for the hoist limit switch itself NOTICE Material damage hazard Any dust deposits that may be visible when the housing is opened must on no account be removed with compressed air as this would force the dust into the contacts and impair the switching function On no account use benzene or other solvents to clean the hoist limit switch ...

Page 76: ...Reeving Length Flange width 4 7 6 7 11 8 15 7 19 7 in YKA SKA 2PS L2 L3 19 3 18 5 21 3 24 2 27 2 4PS 16 5 15 9 18 9 21 9 24 6 2PD 15 4 14 8 18 5 21 3 24 2 YKB SKB 2PS L2 L3 25 24 4 22 8 25 6 28 3 4PS 20 7 20 5 19 3 24 29 1 2PD 21 3 22 8 28 9 33 7 38 4 YKC SKC Drum tensile force 2500 daN 2PS L2 L3 26 2 26 2 26 2 26 6 29 3 4PS 24 2 23 6 21 9 23 2 25 8 2PD 20 1 19 3 19 7 22 6 25 4 2PS L4 38 4 36 4 36...

Page 77: ...ement 2 Clean without dismantling and grease from the outside with a thin bodied lubricant 7 12 3 Maintenance of overload safety device with shear force sensor 1 Check plate thickness min 0 059 in 2 If necessary replace plate after removing screw D 7 13 Crane test WARNING Safety hazard Make sure that the crane test is performed by a qualified person Test loads must be provided by the owner The cra...

Page 78: ...s or equalizing pulleys and in the region of the rope anchorage 4 If any of the following damage should occur replace the rope immediately Excess visible wire fractures see page 79 section 7 14 2 Replacement of wire rope due to broken wires The rope must be free of load for testing to facilitate detecting any broken wires when bending the rope by hand approximately by radius of rope sheave Nest of...

Page 79: ...ctive plate 1 under the rope drum at points a The rope guide can then be rotated freely Do not unscrew stop with bearing 2 2 Unscrew screws 3 3 Unscrew rope guide safety cable 4 if any on one side 4 Remove half rings 5 Unhook rope tensioning spring Second method 1 Unscrew stop with bearing 2 from rope guide The rope guide can then be rotated freely Continue as described under 1 Fig 88 YKE SKE 2PS ...

Page 80: ...r loops Protect rope from dirt 2 Attach rope to rope drum with all the clamping plates do not forget the lock washers Allow the rope end to project by approx 1 2 1 6 in 3 Tightly wind about 5 10 turns onto the drum under power Let the rope run through a greased rag For type of grease see page 101 4 Fit rope guide see page 81 section 7 14 5 Fitting rope guide 5 Reeve the loose end of the rope accor...

Page 81: ...dow on the rope drum so that the rope exits from the drum groove through the window straight and without kinking The second half ring must lie flush against the first 5 Bolt the two half rings together with pressure screws and bolts 5 6 The rope guide must rest lightly on the drum and must be able to be turned by hand If this is not the case the guide has been fitted incorrectly or the rope drum i...

Page 82: ...0 098 0 24 4 91 4 72 0 094 4 88 4 69 0 106 0 26 0 28 4 91 4 69 0 11 4 88 4 65 0 126 YKB SKB 0 28 6 51 6 29 0 11 6 48 6 26 0 126 0 33 0 35 6 51 6 22 0 144 6 48 6 19 0 161 YKC SKC 0 33 0 35 8 52 8 24 0 144 8 49 8 2 0 161 0 39 8 54 8 23 0 157 8 5 8 19 0 177 0 47 0 49 8 52 8 13 0 197 8 48 8 08 0 22 YKE SKE 0 47 0 49 13 86 13 46 0 197 13 81 13 42 0 22 0 55 13 86 13 43 0 217 13 8 13 37 0 244 0 63 13 86 ...

Page 83: ...46 330 01 53 0 18 9 0 394 1 44 1 28 On one side and at base On both sides and at base Measuring depth of base of groove with depth gage On both sides and at base Measuring thickness of wall with special caliper gage Tab 40 Fig 95 Fig 96 The rope sheave must be replaced if the wall thickness as measured is t min or the groove depth as measured is h max Furthermore the rope sheave must be replaced w...

Page 84: ... 1 6 2 5 4 5 6 10 in h 0 94 1 14 1 22 1 46 1 57 1 89 2 28 2 64 2 95 3 35 4 17 h min 0 9 1 09 1 16 1 39 1 5 1 8 2 17 2 51 2 81 3 18 3 96 Tab 41 Fig 98 RSN RS Hook size 2 5 4 5 6 10 in h 1 97 2 36 2 64 2 95 3 74 h min 1 87 2 24 2 51 2 81 3 56 Tab 42 ynew see hook certificate yperm 1 1 ynew 1 If value hmin and or yperm are reached replace hook ...

Page 85: ...2 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 13 2 13 2 52 2 52 2 91 2 91 1 57 1 77 1 97 2 17 2 36 2 56 0 91 0 91 0 71 0 71 0 51 0 51 7 48 0 41 0 41 0 41 0 41 0 41 0 41 0 71 0 71 0 71 0 71 0 71 0 55 Tab 44 1 Perform visual inspection of runway ...

Page 86: ...remaining service life is calculated with reference to the mechanism group and can be read off by means of a PC laptop If the theoretical full load lifetime has expired also indicated by an illuminated red LED a general overhaul must be scheduled and carried out Reading the full load operating hours does not replace the prescribed tests including inspecting the wearing parts rope return sheaves 7 ...

Page 87: ...H92 RSM500 A0543010650 33 Tab 46 NM brake rotor Hoist motor Hoist motor brake A Tightening torque Order no lbf ft 12 2H33 MF 4H33 MF NM 38722 NM 38720 A5674770 A5674770 7 12 2H42 MF 4H42 MF 4HS3 4HA3 NM 38732 NM 38730 NM 38730 NM38730 A5674750 A5674750 A5676320 A5674780 7 12 2H62 MF 4H62 MF NM 38732 NM 38740 A5678050 A5674790 16 12 2H71 MF 4H71 MF 4HS5 4HA5 NM 38742 NM 38740 NM 40940 NM40940 A5674...

Page 88: ...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 A0643004430 A0643000430 Tab 48 Fig 105 Wire rope E See factory certificate or rope certificate for length and number of wire rope ...

Page 89: ...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 Check hoist motor connections Hoist does NOT operate motor hums Not all power phases are present 1 Check fuses replace if necessary 2 Check input power supply 3 Check control pendant Hoist does NOT s...

Page 90: ... 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 Activate UP button Limit switch faulty 1 Check operational hoist limit switch 2 Check emergency hoist limit switch 3 Replace limit switch if necessary DOWN button inoperative 1 Check button contacts and wire...

Page 91: ...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 returned to the manufacturer Dismantled components must be recycled after correct dismantling It is imperative to observe national regulations on environmentally compatible disposal Local authorities wi...

Page 92: ...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 manufacturer will be pleased to advise you Protection against dust and moisture to EN 60529 See factory certificate Permissible ambient temperatures See factory certificate ...

Page 93: ...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 DC c h IN IK IN IK cos phi k Mains fuse CC J 2 420 460 V 500 525 V 420 460 V 500 525 V HP A A 12 2H33 MF 0 5 3 2 20 60 480 240 3 4 5 5 3 0 4 8 6 1 31 2 0 78 0 83 15 15 0 5 3 9 20 50 360 180 3 5 6 4 6 9 35 5 3 0 5 6 0 7 4 8 20 40 240 120 3 7 7 5 3 3...

Page 94: ...V 575 600 V HP 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 73 0 77 15 15 0 9 5 8 20 40 240 120 4 0 8 3 3 2 6 6 12 2H42 MF 0 9 5 8 20 50 360 180 4 9 8 5 8 4 49 0 3 9 6 8 6 7 39 2 0 74 0 78 15 15 1 2 7 2 20 40 240 120 5 4 10 0 4 3 8 2 12 2H62 MF 1 6 9 7 20 60 480 240 8 5 13 5 15 0 80 0 6 8 10 8 12 0 64 0 0 68 0 75 25 20 1 9 12 1 20 50 360 180 8 7 16 0 7 0 12 8 12 2H71 MF...

Page 95: ...0 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 0 96 0 25 3 55 2 24 4H92 1 9 1 61 7 13 27 160 80 61 0 84 0 87 0 542 0 51 0 63 125 60 Hz Motor 3 Power DC c h IN IK IN IK cos phi k Mains fuse CC J 2 440 480 V 550 600 V 440 480 V 550 600 V HP A A 12 2H73 1 5 30 6 20 50 360 180 22 0 36 0 44 0 243 17 6 28 8 35 2 194 0 59 0 63 60 60 6 38 6 20 40 240 120 22 0 4...

Page 96: ...IN Mains fuse CC J 1 360 400 V 440 480 V 575 600 V 360 400 V 440 480 V 575 600 V HP 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 7 4 15 15 10 7 2 60 13 1 10 8 8 6 4H62 MF 9 7 70 20 6 17 0 13 6 20 20 10 12 1 60 23 0 19 0 15 2 4H71 MF 12 1 70 23 0 19 0 15 2 25 25 15 14 8 60 27 0 22 0 18 0 4H72 MF 18 8 70 31 5 26 0 20 8 30 30 20 24 1 60 38 0 31 0 25 0 4H73 MF 28...

Page 97: ...DC IN Mains fuse CC J 1 440 480 V 575 600 V 440 480 V 575 600 V HP 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 15 2 14 8 60 22 0 17 6 4HS7 18 8 80 23 0 18 4 50 25 24 1 70 26 0 20 8 28 2 60 36 0 28 8 4HS8 28 2 70 36 0 28 8 50 30 36 2 60 44 0 35 2 4HSA 45 6 70 56 0 44 8 80 50 56 3 60 65 0 52 0 Tab 56 1 Protection not 100 with CC J we recommen...

Page 98: ...480 V 575 600 V 12 2H33 12 239 14 235 10 76 12 75 12 171 14 167 10 12 10 81 12 79 12 120 14 118 12 2H42 10 322 12 317 8 102 10 101 12 149 14 146 8 10 10 76 12 74 12 101 14 100 12 2H62 8 334 10 328 6 106 8 104 10 155 12 152 6 8 8 79 10 78 10 105 12 103 12 2H71 8 334 10 328 6 106 8 104 10 155 12 152 6 8 8 79 10 78 10 105 12 103 12 2H72 6 362 8 356 4 115 6 113 8 169 10 166 4 6 6 88 8 86 8 114 10 112 ...

Page 99: ...nd accidents Use only original spare parts Tighten screw connection with a torque spanner to the prescribed tightening torque Metric size Screw grade 8 8 10 9 100 Standard Y Tightening torque lbf ft Tightening torque lbf ft M6 8 11 M8 18 26 M10 36 51 55 M12 63 90 64 M16 155 221 184 M20 302 M24 524 M30 1040 M36 1814 Tab 59 Values Y apply for the attachment of the mounting plate to the gear Fig 106 ...

Page 100: ...1 55 159 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 100 243 10 Axle holder trolley side cheek hoist side kBh Dg YKA SKA YKC SKC kBh YKE SKE kBh YKA SKA YKB SKB Dg YKC SKC Dg M8 M8 M8 M8 8 8 100 8 8 100 18 31 15 31 11 Threaded bolt trolley side che...

Page 101: ...s Renolit Duraplex EP3 BP Energrease LS EP3 Klüberplex 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 Klüberplex BEM 41 132 1 1 2 2 lb g Grease Fuchs Renolit FLM 0 KPF 0K Fuchs Renolit RHF1 Castrol Viscogen 0 Klüberplex AG 11 461 YKA SKA 3 5 oz YKB SKB Oil Fuchs Renolin CLP 460 CLP 460 Fuchs Renolin Unisyn CLP 22...

Page 102: ...HE 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 MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE QUALITY AND OR THOSE ARISING BY STATUTE OR OTHERWISE BY LAW OR FROM ANY COURSE OF DEALING OR USE OF TRADE ALL OF WHICH ARE HEREBY EXPRESSLY DISCLAIMED C IN NO EV...