Yale hoists Shaw-box yka Installation and operating instructions

ba-o.2.6.0-us-3.2-ys | A11867501 Rev AE

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 product.

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-3.2-ys | A11867501 Rev AE

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 
1General information .......................................................................................................................................................................................... 7 
1 Information about safety messages ............................................................................................................................................................... 7 
1.1 Explanation of signal words and symbols................................................................... 7 
1.2 Safety instructions........................................................................................................ 7 
1.3 Section safety messages............................................................................................. 7 
1.4 Embedded safety messages....................................................................................... 7 
1.5 Safety alert symbols..................................................................................................... 8 
1.6 Additional symbol......................................................................................................... 8 
2 Spare parts ......................................................................................................................................................................................................... 8 
3 Target audience and responsibilities ............................................................................................................................................................. 8 
4 Crane logbook.................................................................................................................................................................................................... 9 
5 Transport and storage...................................................................................................................................................................................... 9 
6 Weight ................................................................................................................................................................................................................. 9 
7 Installation, commissioning, maintenance and repairs............................................................................................................................... 9 
8 After-sales service........................................................................................................................................................................................... 10 
9 Periodic inspections ....................................................................................................................................................................................... 10 
10 Environmental information ............................................................................................................................................................................ 10 
10.1 Life cycle assessment................................................................................................ 10 
10.2 Energy consumption.................................................................................................. 10 
2General safety notes....................................................................................................................................................................................... 11 
1 Use for intended purpose............................................................................................................................................................................... 11 
2 Inappropriate use............................................................................................................................................................................................. 12 
3 Residual hazards............................................................................................................................................................................................. 12 
4 Organizational safety precautions................................................................................................................................................................ 13 
5 General regulations......................................................................................................................................................................................... 13 
6 Recommended PPE........................................................................................................................................................................................ 13 
7 Working above floor level............................................................................................................................................................................... 14 
8 Sound pressure level...................................................................................................................................................................................... 14 
9 Fire safety......................................................................................................................................................................................................... 14 
10 Safety-conscious operation........................................................................................................................................................................... 15 
11 Attaching load.................................................................................................................................................................................................. 15 
3Introduction...................................................................................................................................................................................................... 16 
1 Incorporation.................................................................................................................................................................................................... 17 
4Installation........................................................................................................................................................................................................ 18 
1 Stationary hoist................................................................................................................................................................................................ 18 
1.1 Attachment at bottom................................................................................................. 19 
1.2 Attachment at top....................................................................................................... 21 
2 Fleet angle ........................................................................................................................................................................................................ 22 
2.1 Attachment at bottom................................................................................................. 22 
2.2 Attachment at top....................................................................................................... 23 
2.3 Attachment at side..................................................................................................... 24 
2.4 Fleet angle.................................................................................................................. 24 
2.5 Angle of installation.................................................................................................... 25 
3 Monorail trolleys.............................................................................................................................................................................................. 25 
3.1 Underslung trolley KE-S33 –76................................................................................ 25 
3.2 Underslung trolley UE-S4 .......................................................................................... 27 
3.3 Underslung trolley UE-S776...................................................................................... 29 
3.4 Articulated trolley (DKE-S4 / DKE-S6) ...................................................................... 31 
4 End stops for monorail trolleys..................................................................................................................................................................... 34 
5 Double rail trolley (OE-S)................................................................................................................................................................................ 35 
6 End stops for double rail trolleys.................................................................................................................................................................. 36 
6.1 Wheel diameter D = 3.9 in......................................................................................... 36 
6.2 Wheel diameter D = 4.9 - 7.9 in................................................................................. 36 
7 Anti-jump catch (option)................................................................................................................................................................................. 37 
7.1 Description of system................................................................................................. 37 
7.2 Procedure................................................................................................................... 37 
8 Travel limit switches........................................................................................................................................................................................ 40 
8.1 Monorail trolley........................................................................................................... 40 

 
 
 
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8.2 Double rail trolley........................................................................................................ 40 
9 Electrical equipment ....................................................................................................................................................................................... 41 
9.1 Supply cables............................................................................................................. 41 
9.2 Terminals.................................................................................................................... 41 
9.3 Protection of equipment............................................................................................. 42 
9.4 Emergency stop......................................................................................................... 42 
9.5 Runway conductor disconnecting means................................................................. 42 
9.6 Disconnect switch ...................................................................................................... 42 
9.7 Protective conductor.................................................................................................. 42 
9.8 Connection fuses ....................................................................................................... 43 
9.9 Electromagnetic compatibility.................................................................................... 43 
9.10 Overload safety device .............................................................................................. 44 
9.11 Connecting to mains.................................................................................................. 45 
9.12 Control and control functions..................................................................................... 46 
9.13 Electric motors and related equipment...................................................................... 47 
10 YK/SK hoists with frequency inverter (VFD)................................................................................................................................................ 47 
11 Hook operated hoist limit switch with weight ball “BLS” (option)........................................................................................................... 48 
11.1 Adjusting/mounting hook operated hoist limit switch with weight ball...................... 49 
12 Hook operated hoist limit switch with switch rod “PLS” (option)............................................................................................................ 50 
12.1 Mounting hook operated hoist limit switch with switch rod on stationary wire rope 
hoists (YKA/SKA / YKB/SKB).................................................................................... 51 
12.2 Mounting hook operated hoist limit switch with switch rod on stationary wire rope 
hoists (YKC/SKC) ...................................................................................................... 54 
12.3 Mounting hook operated hoist limit switch with switch rod on stationary wire rope 
hoists (YKE/SKE / YKD/SKD) ................................................................................... 56 
12.4 Mounting hook operated hoist limit switch with switch rod on trolleys (KE-S..) ....... 58 
12.5 Mounting hook operated hoist limit switch with switch rod on trolleys (UE-S77)..... 67 
12.6 Mounting hook operated hoist limit switch with switch rod on trolleys (OE-S)......... 68 
13 Reeving rope.................................................................................................................................................................................................... 70 
13.1 Overview of reeving................................................................................................... 71 
13.2 Rope fastening point (YKA/SKA - YKE/SKE) ........................................................... 72 
13.3 Position of the rope fastening point........................................................................... 75 
5Commissioning................................................................................................................................................................................................ 80 
6Operating.......................................................................................................................................................................................................... 81 
1 Operating precautions.................................................................................................................................................................................... 81 
2 Duties of crane operator................................................................................................................................................................................. 83 
3 Control pendant............................................................................................................................................................................................... 84 
4 Emergency stop............................................................................................................................................................................................... 84 
5 Hoists with frequency converter................................................................................................................................................................... 85 
7Inspection and maintenance.......................................................................................................................................................................... 86 
1 Inspection intervals......................................................................................................................................................................................... 87 
2 Maintenance intervals..................................................................................................................................................................................... 88 
3 Motors............................................................................................................................................................................................................... 89 
4 Gears................................................................................................................................................................................................................. 89 
4.1 Changing the gear oil................................................................................................. 90 
5 Drive-through mechanism conversion or replacement (single girder trolleys)..................................................................................... 91 
5.1 Drive-through mechanism for travel drive (trolleys KE-S33 - KE-S65) .................... 91 
5.2 Underslung trolley UE-S4 .......................................................................................... 91 
5.3 Drive-through mechanism for travel drive (trolley KE-S76)...................................... 92 
5.4 Drive-through mechanism for travel drive (UE-S776)............................................... 93 
5.5 Underslung trolley UE-S776 with wire rope hoists YKE/SKE 4PS (4-strand).......... 93 
5.6 Drive-through mechanism for travel drive (DKE-S4 / DKE-S6)................................ 94 
6 Hoist motor brake (RSM)................................................................................................................................................................................ 95 
6.1 Checking the brake.................................................................................................... 95 
6.2 Replacing the brake rotor .......................................................................................... 96 
7 Hoist motor brake (NM) 12/2H…-MF ............................................................................................................................................................. 98 
7.1 Checking the brake.................................................................................................... 98 
7.2 Replacing the brake rotor .......................................................................................... 98 
8 Hoist motor brake (NM) 4H..-MF .................................................................................................................................................................. 100 
8.1 Checking the brake.................................................................................................. 100 
8.2 Replacing the brake rotor ........................................................................................ 101 

 
 
 
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ba-o.2.6.0-us-3.2-ys | A11867501 Rev AE 
9 Hoist motor brake (NM) 4HS. ....................................................................................................................................................................... 103 
9.1 Checking the brake.................................................................................................. 103 
9.2 Replacing the brake rotor ........................................................................................ 104 
10 Replacing the pressure springs.................................................................................................................................................................. 106 
11 Travel motor brake........................................................................................................................................................................................ 107 
12 Geared limit switch........................................................................................................................................................................................ 108 
12.1 System description for geared limit switch - version 1............................................ 108 
12.2 System description for geared limit switch - version 2............................................ 109 
12.3 Maintenance work on the geared limit switch......................................................... 109 
13 Checking the geared limit switch................................................................................................................................................................ 110 
13.1 Checking the operational hoist limit switch - version 1 (S3) ................................... 110 
13.2 Checking the emergency hoist limit switch - version 1 (S1)................................... 111 
13.3 Checking the operational hoist limit switch - version 2 (S3) ................................... 113 
13.4 Checking the emergency hoist limit switch - version 2 (S1)................................... 114 
14 Adjusting the geared limit switch................................................................................................................................................................ 116 
14.1 Geared limit switch - version 1................................................................................. 117 
14.2 Geared limit switch - version 2................................................................................. 121 
15 Hook dimensions C for KE-S.. trolleys....................................................................................................................................................... 124 
16 Assembling the bottom hook block............................................................................................................................................................ 131 
17 Overload safety device................................................................................................................................................................................. 132 
17.1 Testing overload safety device................................................................................ 132 
17.2 Maintenance of overload safety device with pressure sensor................................ 132 
17.3 Maintenance of overload safety device with shear force sensor............................ 132 
18 Crane test........................................................................................................................................................................................................ 132 
19 Rope drive ...................................................................................................................................................................................................... 133 
19.1 Rope and rope attachment - general information................................................... 133 
19.2 Replacement of wire rope due to broken wires....................................................... 134 
19.3 Removing the rope guide......................................................................................... 136 
19.4 Installing the rope guide........................................................................................... 137 
19.5 Replacing the rope guide......................................................................................... 139 
19.6 Changing the wire rope............................................................................................ 140 
19.7 Checking rope drum for wear.................................................................................. 143 
19.8 Checking and maintaining the rope sheave............................................................ 144 
19.9 Checking the load hook........................................................................................ 146 
20 Trolley.............................................................................................................................................................................................................. 147 
21 Remaining service life................................................................................................................................................................................... 148 
21.1 Operating hours counter in SLE load monitor......................................................... 148 
21.2 Multicontroller SMC (optional) ................................................................................. 148 
22 General overhaul ........................................................................................................................................................................................... 149 
8Wearing parts................................................................................................................................................................................................. 150 
1 Serial number................................................................................................................................................................................................. 150 
2 Hoist ................................................................................................................................................................................................................ 150 
9Troubleshooting ............................................................................................................................................................................................ 152 
Decommissioning.......................................................................................................................................................................................... 154 
1 Dismantling .................................................................................................................................................................................................... 154 
2 Scrap disposal............................................................................................................................................................................................... 154 
Technical data................................................................................................................................................................................................ 155 
1 Conditions of use .......................................................................................................................................................................................... 155 
2 Hoist ................................................................................................................................................................................................................ 156 
2.1 Pole-changing hoist motors 12/2H..-MF 50Hz........................................................ 156 
2.2 Pole-changing hoist motors 12/2H..-MF 60Hz........................................................ 157 
2.3 Pole-changing hoist motors ../.H.. 50Hz.................................................................. 158 
2.4 Pole-changing hoist motors ../.H.. 60Hz.................................................................. 158 
2.5 Frequency-controlled hoist motors 4H..-MF 100 Hz............................................... 159 
2.6 Frequency-controlled hoist motors 4H..-MF 120 Hz............................................... 159 
2.7 Frequency-controlled hoist motors 4HS.-MF 100 Hz ............................................. 160 
2.8 Frequency-controlled hoist motors 4HS.-MF 120 Hz ............................................. 160 
3 Cable cross sections and lengths of supply cable................................................................................................................................... 161 
3.1 Cable cross sections and lengths of supply cable for pole-changing hoist motors 
12/2H..-MF ............................................................................................................... 161 

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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

11.7 Circuit diagrams ............................................................................................................................................................................................ 165

1General information

07.2020 7

ba-o.2.6.0-us-3.2-ys | A11867501 Rev AE

1General 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,

1General information

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ba-o.2.6.0-us-3.2-ys | A11867501 Rev AE

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.

1General information

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ba-o.2.6.0-us-3.2-ys | A11867501 Rev AE

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 chapter “Installation”.

•For detailed information about commissioning see chapter “Commissioning”.

•For detailed information and about maintenance and repairs see chapter “Inspection

and maintenance”.

1General information

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ba-o.2.6.0-us-3.2-ys | A11867501 Rev AE

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.

This manual suits for next models

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