Yale SHAW-BOX Installation and operating instructions

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Before installing hoist, fill in the information below.
Refer to the Hoist and Motor data plates.
Model No. ____________________________________________
Serial No. ____________________________________________
Purchase Date ____________________________________________
Voltage ____________________________________________
Rated Load ____________________________________________
Follow all instructions and warnings for inspecting, maintaining and operating this hoist.
The use of any hoist presents some risk of personal injury or property damage. That risk is greatly increased if proper
instructions and warnings are not followed. Before using this hoist, each operator should become thoroughly familiar with all
warnings, instructions and recommendations in this manual. Retain this manual for future reference and use.
Forward this manual to operator. Failure to operate equipment as directed in manual may cause injury.
Wire Rope Hoists
Operation & Service Manual

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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 [phone], Fax: [phone], 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 [phone].
Fax: [phone], 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 [phone], 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 ................................................................................................................................................................................................6
1.1 Information about safety messages ....................................................................................................................................................................6
1.1.1 Explanation of signal words and symbols .....................................................................6
1.1.2 Safety instructions ...........................................................................................................6
1.1.3 Section safety messages................................................................................................6
1.1.4 Embedded safety messages..........................................................................................6
1.1.5 Safety alert symbols........................................................................................................7
1.1.6 Additional symbol ............................................................................................................7
1.2 Spare parts................................................................................................................................................................................................................7
1.3 Target audience and responsibilities ..................................................................................................................................................................7
1.4 Crane logbook..........................................................................................................................................................................................................8
1.5 Transport and storage............................................................................................................................................................................................8
1.6 Weight........................................................................................................................................................................................................................ 8
1.7 Installation, commissioning, maintenance and repairs...................................................................................................................................8
1.8 After-sales service...................................................................................................................................................................................................9
1.9 Periodic inspections ...............................................................................................................................................................................................9
1.10 Environmental information....................................................................................................................................................................................9
1.10.1 Life cycle assessment..................................................................................................... 9
1.10.2 Energy consumption .......................................................................................................9
2General safety notes.............................................................................................................................................................................................10
2.1 Use for intended purpose ....................................................................................................................................................................................10
2.2 Inappropriate use...................................................................................................................................................................................................10
2.3 Residual hazards...................................................................................................................................................................................................11
2.4 Organizational safety precautions .....................................................................................................................................................................11
2.5 General regulations...............................................................................................................................................................................................11
2.6 Recommended PPE..............................................................................................................................................................................................11
2.7 Working above floor level....................................................................................................................................................................................12
2.8 Sound pressure level............................................................................................................................................................................................12
2.9 Fire safety................................................................................................................................................................................................................12
2.10 Safety-conscious operation ................................................................................................................................................................................13
2.11 Attaching load........................................................................................................................................................................................................13
3Introduction ............................................................................................................................................................................................................14
3.1 Incorporation..........................................................................................................................................................................................................15
4Installation...............................................................................................................................................................................................................16
4.1 Stationary hoist......................................................................................................................................................................................................16
4.1.1 Attachment at bottom....................................................................................................17
4.1.2 Attachment at top ..........................................................................................................19
4.2 Fleet angle...............................................................................................................................................................................................................20
4.2.1 Attachment at bottom....................................................................................................20
4.2.2 Attachment at top ..........................................................................................................21
4.2.3 Attachment at side.........................................................................................................22
4.2.4 Fleet angle .....................................................................................................................23
4.2.5 Angle of installation .......................................................................................................23
4.3 Monorail trolleys....................................................................................................................................................................................................24
4.3.1 Monorail trolley (KE-S33 - 76) ......................................................................................24
4.3.2 Drive shaft for travel drive (trolleys KE-S33 - KE-S65)...............................................25
4.3.3 Drive shaft for trolley drive (trolley KE-S76).................................................................26
4.3.4 Monorail trolley (UE-S4)................................................................................................27
4.3.5 Monorail trolley (UE-S776) ...........................................................................................29
4.3.6 Articulated trolley (DKE-S4 / DKE-S6).........................................................................31
4.4 End stops for monorail trolleys ..........................................................................................................................................................................34
4.5 Double rail trolley (OE-S)......................................................................................................................................................................................35
4.6 End stops for double rail trolleys .......................................................................................................................................................................36
4.6.1 Wheel diameter D = 3.9 in............................................................................................36
4.6.2 Wheel diameter D = 4.9 - 7.9 in....................................................................................36
4.7 Anti-jump catch......................................................................................................................................................................................................37
4.7.1 Description of system....................................................................................................37
4.7.2 Procedure.......................................................................................................................37

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4.8 Travel limit switches .............................................................................................................................................................................................40
4.8.1 Monorail trolley...............................................................................................................40
4.8.2 Double rail trolley...........................................................................................................40
4.9 Electrical equipment .............................................................................................................................................................................................41
4.9.1 Supply cables.................................................................................................................41
4.9.2 Terminals........................................................................................................................41
4.9.3 Protection of equipment................................................................................................42
4.9.4 Emergency stop.............................................................................................................42
4.9.5 Runway conductor disconnecting means....................................................................42
4.9.6 Disconnect switch..........................................................................................................42
4.9.7 Connection fuses...........................................................................................................42
4.9.8 Electromagnetic compatibility.......................................................................................43
4.9.9 Overload safety device..................................................................................................44
4.9.10 Connecting to mains......................................................................................................45
4.9.11 Control and control functions........................................................................................46
4.9.12 Electric motors and related equipment........................................................................47
4.10 YK/SK hoists with frequency inverter (VFD) ....................................................................................................................................................47
4.11 Reeving rope ..........................................................................................................................................................................................................48
5Commissioning......................................................................................................................................................................................................53
6Operating.................................................................................................................................................................................................................54
6.1 Operating precautions..........................................................................................................................................................................................54
6.2 Duties of crane operator.......................................................................................................................................................................................56
6.3 Using control pendant..........................................................................................................................................................................................57
6.4 Operating hoist with frequency inverter ...........................................................................................................................................................58
6.5 Emergency stop.....................................................................................................................................................................................................58
7Inspection and maintenance...............................................................................................................................................................................59
7.1 Inspection intervals...............................................................................................................................................................................................60
7.2 Maintenance intervals...........................................................................................................................................................................................61
7.3 Motors......................................................................................................................................................................................................................62
7.4 Hoist motor brake (RSM)......................................................................................................................................................................................63
7.4.1 Checking brake..............................................................................................................63
7.4.2 Replacing brake disk (brake rotor)...............................................................................63
7.5 Hoist motor brake (NM) (pole-changing)...........................................................................................................................................................64
7.5.1 Checking brake..............................................................................................................64
7.5.2 Replacing brake disk (brake rotor)...............................................................................64
7.6 Hoist motor brake (NM) (4-pole)..........................................................................................................................................................................65
7.6.1 Checking brake..............................................................................................................65
7.6.2 Replacing brake disk (brake rotor ................................................................................65
7.7 Hoist motor brake (NM) 4HS................................................................................................................................................................................67
7.7.1 Checking brake..............................................................................................................67
7.7.2 Replacing brake disk (brake rotor)...............................................................................67
7.8 Travel motor brake ................................................................................................................................................................................................68
7.9 Hoist limit switch ...................................................................................................................................................................................................69
7.9.1 Hoist limit switch (standard)..........................................................................................69
7.10 Hoist limit switch ...................................................................................................................................................................................................70
7.10.1 Description of hoist limit switch system........................................................................70
7.10.2 Testing emergency hoist limit switch, version 1..........................................................70
7.10.3 Testing operational hoist limit switch, version 1..........................................................70
7.10.4 Testing emergency hoist limit switch, version 2..........................................................71
7.10.5 Testing operational hoist limit switch, version 2..........................................................71
7.10.6 Setting hoist limit switch................................................................................................72
7.10.7 Servicing hoist limit switch ............................................................................................75
7.11 Hook dimensions C for KE-S.. trolleys..............................................................................................................................................................76
7.12 Overload safety device.........................................................................................................................................................................................77
7.12.1 Testing overload safety device.....................................................................................77
7.12.2 Maintenance of overload safety device with pressure sensor...................................77
7.12.3 Maintenance of overload safety device with shear force sensor...............................77
7.13 Crane test................................................................................................................................................................................................................77
7.14 Rope drive...............................................................................................................................................................................................................78
7.14.1 Rope and rope attachment - general information .......................................................78
7.14.2 Replacement of wire rope due to broken wires...........................................................79

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7.14.3 Removing rope guide....................................................................................................79
7.14.4 Replacing wire rope.......................................................................................................80
7.14.5 Fitting rope guide...........................................................................................................81
7.14.6 Checking rope drum for wear.......................................................................................82
7.14.7 Inspection and maintenance of rope sheave ..............................................................83
7.14.8 Checking load hook.......................................................................................................84
7.15 Trolley......................................................................................................................................................................................................................85
7.16 Remaining service life ..........................................................................................................................................................................................86
7.16.1 Operating hours counter in SLE load monitor.............................................................86
7.16.2 SMC multi-controller (optional).....................................................................................86
7.17 General overhaul ...................................................................................................................................................................................................86
8Wearing parts.........................................................................................................................................................................................................87
8.1 Serial number.........................................................................................................................................................................................................87
8.2 Hoist.........................................................................................................................................................................................................................87
9Troubleshooting ....................................................................................................................................................................................................89
10 Decommissioning .................................................................................................................................................................................................91
10.1 Dismantling.............................................................................................................................................................................................................91
10.2 Scrap disposal .......................................................................................................................................................................................................91
11 Technical data........................................................................................................................................................................................................92
11.1 Conditions of use ..................................................................................................................................................................................................92
11.2 Hoist.........................................................................................................................................................................................................................93
11.2.1 Pole-changing hoist motors ../…-MF 50Hz .................................................................93
11.2.2 Pole-changing hoist motors ../…-MF 60Hz .................................................................94
11.2.3 Pole-changing hoist motors 50Hz................................................................................95
11.2.4 Pole-changing hoist motors 60Hz................................................................................95
11.2.5 Frequency-controlled hoist motors ../4H..-MF 100 Hz................................................96
11.2.6 Frequency-controlled hoist motors ../4H..-MF 120 Hz................................................96
11.2.7 Frequency-controlled hoist motors ../4HS.-MF 100 Hz..............................................97
11.2.8 Frequency-controlled hoist motors ../4HS.-MF 120 Hz..............................................97
11.3 Cable cross sections and lengths of supply cable.........................................................................................................................................98
11.3.1 Cable cross sections and lengths of supply cable for pole-changing hoist motors …-
MF...................................................................................................................................98
11.3.2 Cable cross sections and lengths of supply cable for pole-changing hoist motors..98
11.4 Tightening torques................................................................................................................................................................................................99
11.5 Lubricants.............................................................................................................................................................................................................101
11.6 Lubricants for travel drive..................................................................................................................................................................................101
11.7 Circuit diagrams ..................................................................................................................................................................................................101

1 General information
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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,

1 General information
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1.1.5 Safety alert symbols
Symbol
Meaning
General hazard
Electric shock hazard
Falling parts hazard
Suspended load hazard
Hand injury hazard
1.1.6 Additional symbol
Symbol
Meaning
Important note
1.2 Spare parts
WARNING
Safety hazard. Incorrect or defective spare parts may lead to damage, malfunctions or
the complete failure of the machine.
➢Use only original spare parts.
1.3 Target audience and responsibilities
Owner
Whoever uses and employs the product or has it operated by suitable trained personnel
is considered to be the owner (employer/company).
Trained personnel
Trained personnel are persons who have been instructed and trained in the duties with
which they are entrusted and the risks which may arise from incorrect behavior, have
been advised on the necessary protective devices, precautions, applicable regulations,
accident prevention regulations and prevailing conditions and have proven their ability.
Qualified person
A qualified person is a person who by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, training, and experience,
successfully demonstrates the ability to solve/resolve problems relating to the subject
matter, the work, or the project.
Electrical qualified person
An electrical qualified person is defined as:
One who has received training in and has demonstrated skills and knowledge in the
construction and operation of electric equipment and installations and the hazard
involved.

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1.4 Crane logbook
A completed crane logbook must be kept for each hoist. The results of the periodic
inspections must be entered in the logbook.
1.5 Transport and storage
Transport
Fig. 1
The product is delivered on a special pallet. This enables it to be loaded and unloaded
safely with a fork-lift truck.
1. WARNING Falling parts hazard. If the product is to be transported suspended,
attach the product to the sling points provided. The sling points are designed for a
max. diagonal pull ≥45°.
2. Do not allow the hoist to drop. Set the product down on the ground correctly.
3. Avoid damage to the product and its components by loading and unloading it
correctly.
Storage
1. Store the product and its accessories in a dry place.
2. Store it in a stable position, secure it against toppling or overturning.
3. Observe environmental protection laws for storage (do not allow oil etc. to leak).
4. Make sure that the ground is firm and does not permit the machine to sink in.
5. Ensure the load is evenly distributed, support the hoist at several points.
6. Do not kink the ropes and avoid contact with the ground.
1.6 Weight
See factory certificate.
1.7 Installation, commissioning, maintenance and repairs
1. Make sure that installation, commissioning, maintenance and repairs are carried out
by qualified persons only.
2. We recommend having installation carried out by qualified personnel engaged by the
manufacturer.
3. Do not carry out any alterations or modifications.
4. Make sure that additional fitments are approved by the manufacturer.
(During welding work, electrode and ground must be in contact with the same
component!)
5. Use only original spare parts for repairs.
6. Make sure that dismantled guards are screwed down again and locked.
If the wire rope hoist is constantly operated out of doors and exposed to the elements
without protection, we recommend fitting a canopy or at least “parking” the hoist under a
roof.
•For detailed information about installation see section “Installation”.
•For detailed information about commissioning see section “Commissioning”.
•For detailed information and about maintenance and repairs see section “Inspection
and maintenance”.

1 General information
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1.8 After-sales service
You have purchased a high-quality product. Our after sales service will give you advice
on its correct use.
In order to maintain the safety and constant availability of the product, we recommend
concluding a maintenance agreement.
Seminars:
Comprehensive understanding of material handling products is a prerequisite for the
correct use of equipment. Competent and practically oriented, we impart the specialist
knowledge required for the correct use, monitoring and care of your system.
Ask for our seminar program.
1.9 Periodic inspections
•Hoists and cranes must be inspected by a qualified person least once a year, more
frequently if so specified by national regulations.
•The results of the inspections must be recorded and filed in the test logbook.
•The remaining service life of the hoist must also be established during this inspection.
•The periodic inspections must be adapted to the hoist’s use. Intensive use or adverse
environmental conditions entail shorter maintenance intervals.
All tests must always be initiated by the owner!
1.10 Environmental information
Environmental aspects have been taken into account when developing and
manufacturing this equipment. Please note the instructions on safe lubrication and waste
disposal to avoid pollution risks during use. Appropriate use and correct maintenance will
improve the environmental performance of this product.
1.10.1 Life cycle assessment
The stages of the product service life are:
•Production of materials,
•components and energy,
•transport to factory,
•manufacture and assembly,
•transport to customer,
•on-site installation,
•operating phase including maintenance and modernization,
•dismantling and recycling of materials at end of service life.
1.10.2 Energy consumption
The energy consumption during the operating phase has the highest impact on the
environment. Electricity is required for starting and running the motors and for lighting,
heating, cooling and other optional electrical components and parts of the hoist.

2 General safety notes
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2General safety notes
The products are constructed according to the state of the art and recognised safety
rules. However, during use danger to the life and limb of the user or a third party can
arise, or adverse effects can affect the product and other property.
2.1 Use for intended purpose
•Wire rope hoists are intended for lifting freely movable loads. Depending on their
design, they are for stationary or mobile use.
•In the case of wire rope hoists with multiple load-bearing equipment, ensure that the
load is distributed evenly between the falls.
•Any fundamental alterations and modifications to the product, such as e.g. welding on
load-bearing components, structural alterations to load-bearing components,
alteration of drives, alteration of speeds and motor outputs, replacing trolleys, etc.
must be authorized by the manufacturer, otherwise the declaration of
conformity/declaration of incorporation will be invalidated.
•Also any work on or additions to the control must be authorized by the manufacturer.
The manufacturer cannot accept any liability for malfunctioning after unauthorized
work on the control.
•The conditions in the place of use of the hoist must correspond to the operating
conditions for which the hoist was designed (including indoor/outdoor use, ambient
temperature, radiation temperature, wind, dust, splash water, snow, water, etc.
•For hoists which work in combination and have more than one control (tandem
operation), action must be taken to coordinate the controls. This applies also to the
reaction of the protective devices. Controls must be constructed accordingly.
•For hoists intended for automatic operation, the control must be designed
accordingly.
2.2 Inappropriate use
•Use in areas with potentially explosive atmosphere.
•Transporting molten metal.
•Exceeding the maximum working load.
•Transporting persons.
•Pulling/towing or raising/lowering of a guided load.
•Using the hoist in applications in which the working load changes with the position of
the load, as the hoist is not equipped with a load display and additional warning
device when it cuts off at overload.
•Breaking away, pulling or towing of loads.
•Use of rope drive for “guided loads” without being designed for this type of
application.
•Breaking away of tilted loads if the rope drive is designed for the “guided load”
application.
•Pulling loads at an angle, dragging loads or moving vehicles with the load or load
suspension equipment.
•Do not knot load ropes or chains or shorten them with devices such as bolts, screws
or similar.
•Removing the safety latch from suspension and load hooks.
•Manipulating the overload safety device.
•Operation with slack rope (loose windings on the rope drum).
•If the product forms “part of a machine”, the person placing it on the market must
ensure that the product meets the specific regulations of the application.