Yale HOISTS SHAW-BOX SKA Page 164 Operation & Service Manual Download

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Technical data

164

07.2020

-o

-us

-3

-ys

1 Re

v A

Other screw connections and applicable tightening torques

No.

Screw connection

Wire rope type

Screw connection

Tightening torque

Part 1 / Part 2

Thread size

Grade

Gear casing/panel box

YKA/SKA

–

YKB/SKB

8.8

Gear casing/support plate

YKA/SKA
YKB/SKB

YKC/SKC

M10
M12
M16

100

55
64

229

Rope drum/gear drive shaft

YKC/SKC

M12

100

Rope drum/clamping plate

YKA/SKA

M6 / 8

8.8

7 / 18

Rope drum bearing journal/holding washer

YKA/SKA

YKB/SKB

–

YKC/SKC

YKE/SKE

M10
M16

100

31
55

192

Rope drum flange bearing/support plate (fan side)

YKA/SKA

YKB/SKB

–

YKC/SKC

YKE/SKE

M10
M16

100

31
55

159

Grease pan/guide rail

YKE/SKE

M10

100

Support plate (fan side)/grease pan

YKA/SKA

–

YKB/SKB

YKC/SKC

M8
M8

C45K

S235JR

Support plate (gear side, fan side)/fixing tube (Dg)

YKA/SKA

–

YKB/SKB

M16

100

243

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

Threaded bolt/trolley side cheek (hoist side/counterweight)

YKA/SKA

–

YKE/SKE

M16

100

159

Return pulley bearing plate/bearing pedestal (kBh)

YKE/SKE

M12

100

Suspension bearing plate/bearing pedestal (kBh)

YKE/SKE

M12

100

Pivot pin/mounting bracket (Dg)

YKA/SKA

–

YKC/SKC

M12

8.8

Pivot pin/pivot pin (Dg)

YKA/SKA

–

YKC/SKC

M12

8.8

Guide roller holder/trolley side cheek (Dg)

YKA/SKA

–

YKC/SKC

100

Tab. 53

kBh = underhung low headroom trolley

Og = double rail trolley

Dg = articulated trolley

Summary of Contents for SHAW-BOX SKA

Page 1: ...llow 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...

Page 2: ...uesto 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 cm...

Page 3: ...utions 13 2 5 General regulations 13 2 6 Recommended PPE 13 2 7 Working above floor level 14 2 8 Sound pressure level 14 2 9 Fire safety 14 2 10 Safety conscious operation 15 2 11 Attaching load 15 3 Introduction 16 3 1 Incorporation 17 4 Installation 18 4 1 Stationary hoist 18 4 1 1 Attachment at bottom 19 4 1 2 Attachment at top 21 4 2 Fleet angle 22 4 2 1 Attachment at bottom 22 4 2 2 Attachmen...

Page 4: ...eys KE S 58 4 12 5 Mounting hook operated hoist limit switch with switch rod on trolleys UE S77 67 4 12 6 Mounting hook operated hoist limit switch with switch rod on trolleys OE S 68 4 13 Reeving rope 70 4 13 1 Overview of reeving 71 4 13 2 Rope fastening point YKA SKA YKE SKE 72 4 13 3 Position of the rope fastening point 75 5 Commissioning 80 6 Operating 81 6 1 Operating precautions 81 6 2 Duti...

Page 5: ...e test 132 7 19 Rope drive 133 7 19 1 Rope and rope attachment general information 133 7 19 2 Replacement of wire rope due to broken wires 134 7 19 3 Removing the rope guide 136 7 19 4 Installing the rope guide 137 7 19 5 Replacing the rope guide 139 7 19 6 Changing the wire rope 140 7 19 7 Checking rope drum for wear 143 7 19 8 Checking and maintaining the rope sheave 144 7 19 9 Checking the load...

Page 6: ... 2 ys A11867501 Rev AE 11 3 2 Cable cross sections and lengths of supply cable for pole changing hoist motors H 162 11 4 Tightening torques 163 11 5 Lubricants 165 11 6 Lubricants for travel drive 165 11 7 Circuit diagrams 165 ...

Page 7: ...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 8: ...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 9: ...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 10: ...he 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 avoi...

Page 11: ...ng 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 ...

Page 12: ...ure that the product meets the specific regulations of the application Application of external torques due to forces that are exercised from outside the system e g with gripper operation or through tilting bumping of the load in particular with the option 4 90 hook locking 2 3 Residual hazards The machine has been subjected to a risk analysis The design and construction based on this correspond to...

Page 13: ...that work is being carried out in a safety conscious manner Observe the intervals specified for periodic inspections File the test reports in the logbook 2 5 General regulations Safety and accident prevention regulations All national state and local regulations 2 6 Recommended PPE Fig 2 Personal protective equipment to be provided by the owner Safety shoes Gloves only if there is no danger of them...

Page 14: ...ng an emission value based on a workplace the values from Tab 1 and Tab 2 at measuring distance h can be used Fig 4 Type db A 3 h ft 3 ft 7 ft 13 ft 26 ft 52 ft YKA SKA 76 73 70 67 64 YKB SKB 76 73 70 67 64 YKC SKC 78 75 72 69 66 YKE SKE 78 75 72 69 66 Tab 1 Type db A 3 h ft 3 ft 7 ft 13 ft 26 ft 52 ft YKA SKA 76 70 64 58 52 YKB SKB 76 70 64 58 52 YKC SKC 78 72 66 60 50 YKE SKE 78 72 66 60 50 Tab ...

Page 15: ...ded 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 ...

Page 16: ...e 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 t...

Page 17: ...AE 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 18: ...ith straps so that they cannot fall 4 1 Stationary hoist Fig 6 Type MT rope drum torque lbf in YKA SKA MT 0 5 F 5 in YKB SKB MT 0 5 F 6 6 in YKC SKC MT 0 5 F 8 6 in YKE SKE MT 0 5 F 14 in Possible mounting positions and fleet angles Feet at bottom and at top are possible for designs with bottom hook block rope lead off vertically downwards The YK SK wire rope hoist with 1PS and 1PS twin hook rope ...

Page 19: ... 6 Screw M16 8 8 2 12 SCHNORR Safety Washer S16 3 6 Nut M16 8 ø D 0 83 in 1 6 Screw M20 8 8 2 12 SCHNORR Safety Washer S20 3 6 Nut M20 8 YKC SKC YKD SKD YKE SKE 2PS 4PS 2PD ø D 0 98 in 1 6 Screw M24 8 8 2 12 SCHNORR Safety Washer S24 3 6 Nut M24 8 ø D 1 34 in 1 4 Screw M30 8 8 2 8 SCHNORR Safety Washer S30 3 4 Nut M30 8 ...

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

Page 21: ...8 Screw M16 8 8 2 16 SCHNORR Safety Washer S16 3 8 Nut M16 8 ø D 0 83 in 1 7 8 Screw M20 8 8 2 14 16 SCHNORR Safety Washer S20 3 7 8 Nut M20 8 YKC SKC YKE SKE 1PS ø D 0 98 in 1 7 8 Screw M24 8 8 2 14 16 SCHNORR Safety Washer S24 3 7 8 Nut M24 8 ø D 1 02 in 1 8 Screw M24 8 8 2 16 SCHNORR Safety Washer S24 3 8 Nut M24 8 ...

Page 22: ... 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 8 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 23: ...KA 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 9 1 Standard 2 By turning rope guide 4 By turning rope guide and grease pan Type YKE SKE Version H not possible ...

Page 24: ... 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 10 2 By turning rope guide 4 By turning rope guide and grease pan Type YKE SKE Version H not possible 4 2 4 Fleet angle Wire rope hoist type γ YKA SKA 39 YKB SKB 39 YKC SKC 39 YKE SKE 39 Tab 6 1 Adjust the rope guide to the fleet angle 2 Observe also th...

Page 25: ...ther additional stresses The rope suspension for non rotation resistant wire ropes must be designed so that it cannot rotate around its longitudinal axis The rope spread angle of 45 in top hook position must not be exceeded 4 3 Monorail trolleys The trolleys are constructed according to the state of the art and supplied with mounted buffers NOTICE Danger of material damage When using the optional ...

Page 26: ...he nuts 2 on the threaded bolts 5 and unscrew by dimension x Slide the trolley side cheek 3 apart parallel to the unscrewed nut 2 until the dimension B y is reached Mount the trolley on the wire rope hoist in the bottom flange of the runway beam and secure against slipping out Slide the trolley side cheek 3 back against the nut 1 When doing so thread in the drive through mechanism see section 7 5 ...

Page 27: ...67501 Rev AE 4 3 2 Underslung trolley UE S4 Fig 13 WARNING If the setting is established with the incorrect nuts marked in the figure on the threaded rod end with an X there is a risk of the load toppling Only perform setting work with the nuts 1 and 2 ...

Page 28: ...mension c with the nut 1 Tighten the nut 2 to the prescribed tightening torque 159 lbf ft Adjustment work connection part Loosen the nuts 5 and slide the connection part 6 on the connecting pin 7 such that the dimensions e1 and e2 are equal on the left and right between the trolley side cheeks 4 and the connection piece 6 Tighten the nuts 5 to the prescribed tightening torque 159 lbf ft Assembly w...

Page 29: ...e section 7 5 Tighten the nuts 3 to the prescribed tightening torque 159 lbf ft Check the track clearance f 2 with a feeler gauge and adjust if necessary see Preparatory work The dimension f 2 must be 0 02 0 04 in at the widest point of the runway The dimension f 2 may be max 0 1 in at the narrowest point of the runway Type Ø D Trolley B c x y zmax in in YKA SKA YKB SKB YKC SKC 3 9 UE S4 3 5 19 7 ...

Page 30: ...torque 159 lbf ft Adjustment work connection part Loosen the nuts 5 and 9 then slide the connection part 6 on the connecting pin 7 such that the dimensions e1 and e2 are equal on the left and right between the trolley side cheeks 4 and the connection piece 6 Do not tension panel 10 To do so lightly tighten the nuts 5 and then loosen once more by one 1 4 revolution respectively Tighten the nuts 9 a...

Page 31: ...sm see section 7 5 Tighten the nuts 3 to the prescribed tightening torque 159 lbf ft Check the track clearance f 2 with a feeler gauge and adjust if necessary see Preparatory work The dimension f 2 must be 0 02 0 04 in at the widest point of the runway The dimension f 2 may be max 0 1 in at the narrowest point of the runway Type Ø D Trolley B c x y zmax in in YKE SKE 7 9 UE S776 7 3 19 7 B 3 6 1 3...

Page 32: ... the nut 1 Tighten the nut 2 to the prescribed tightening torque 159 lbf ft Adjustment work lifting beam Loosen the nuts 6 and slide the lifting beam 7 on the connecting pin 2 such that the dimensions e1 and e2 are equal on the left and right between the trolley side cheeks 1 and the lifting beam 7 Tighten the nuts 6 to the prescribed tightening torque 63 lbf ft Assembly with a freely accessible r...

Page 33: ... 5 back against the nuts 2 When doing so thread in the drive through mechanism see section 7 5 Screw the nuts 2 back and tighten to the prescribed tightening torque 159 lbf ft Check the track clearance f 2 with a feeler gauge and adjust if necessary see Preparatory work The dimension f 2 must be 0 02 0 04 in at the widest point of the runway The dimension f 2 may be max 0 1 in at the narrowest poi...

Page 34: ...134 5 28 C 56 2 2 D 15 0 59 E 70 2 76 F 63 2 48 G 33 1 3 H flange width see table below flange width see table below J 7 35 0 28 1 38 K 25 40 0 98 1 57 L 70 2 76 M 40 1 57 N 94 3 7 P 134 5 28 Q 15 0 59 R 56 2 2 S 105 4 13 T 190 7 48 Fig 19 Type1 H 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 A0174057270 PA1 500 11...

Page 35: ...the requirements of ISO 12488 1 2 Make sure that the rail joints are even on both running and guide surfaces Grind down if necessary Check track gage Ø D a b min in in in 3 9 0 1 0 2 1 2 4 9 0 1 0 2 1 2 6 3 0 14 0 24 1 2 7 9 0 18 0 28 1 2 Tab 11 Fig 20 1 Check track gage S on trolley and rail Smax Smin 0 197 in 2 Check lateral play a between rail and flange 3 a as per Tab 15 if trolley is position...

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 22 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 12 Fig 23 ...

Page 37: ...7 2 Procedure WARNING Falling parts hazard Cordon off and secure danger area during installation and dismantling work The anti jump catch is supplied pre mounted on the trolley and must be adapted to the actual runway situation Fig 26 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 2...

Page 38: ...osition 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 29 Trolley type OE S05...

Page 39: ...nsert adjusting screws S in the hook position determined from the table Position eccentric plates 4 in slot as specified by the table Tighten fixing elements 1 2 finger tight Fig 33 Fig 34 Horizontal adjustment Fig 35 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 ...

Page 40: ...ings 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 ...

Page 41: ...r 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 sliding show contacts or wheel type collectors 1 See sect...

Page 42: ...ction can be provided by Emergency stop button in the control pendant in conjunction with the crane switch contactor Main isolator 4 9 5 Runway conductor disconnecting means must disconnect the wire rope hoist on all poles must be lockable in OFF position must be installed in an easily accessible place in the system must be marked as such to avoid mistakes 4 9 6 Disconnect switch Required for one ...

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

Page 44: ...rture 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 38 Load sensor Safety device Contactor or inverter control Fig 39...

Page 45: ...ion 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 thre...

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

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: ...rational hoist limit switching top The hook operated limit switch can be integrated as an optional hoist limit switch It is triggered after the standard operational hoist limit switch S3 when the hook block relieves the weight loaded limit switch If this option is used the C dimension increases in accordance with the table Type Hook dimension C enlargement x1 in in YKA SKA YKB SKB 5 9 2 YKC SKC YK...

Page 49: ...t the same time to lower the hook by the dimension x1 see table above into position C If the ball has not yet been mounted Open the bolted connections 6 Fit the ball 5 on the rope Tighten the bolted connections 6 to the prescribed tightening torque see the Tightening torques for screws section If the ball has already been mounted Loosen the rope clamp on the connecting rope 4 to adjust Draw the co...

Page 50: ...ing cams 5 Retaining plate 6 Screw 7 Switch rod a min distance to first obstacle c Dimension between emergency and operational hoist limit switching top x1 Dimension between hook operated hoist limit switching and emergency hoist limit switching top S C Hook operated hoist limit switch S1 A Emergency hoist limit switching top S3 B Operational hoist limit switching top Function The bottom hook bloc...

Page 51: ...itch rod on stationary wire rope hoists YKA SKA YKB SKB Hoist limit switch with attachment set for reeving 2PS 1 PLS switching unit Hoist limit switch with attachment set for reeving 4PS 1 PLS switching unit Assembly position 1 Assembly position 2 Assembly position 3 Assembly position 4 2 Mounting position of the screws ...

Page 52: ... 3 2 ys A11867501 Rev AE Mounting holes on the lifting beam YKA SKA drum length L2 YKA SKA drum length L3 YKB SKB drum length L2 YKB SKB drum length L3 YKB SKB drum length L4 3 Mounting holes for reeving 2PS 4 Mounting holes for reeving 4PS ...

Page 53: ...S 2 4PS 4 Observe the mounting positions of the screws 2 see figure above Fasten the PLS 1 switching unit on at the prescribed position with the bolted connections see figures above Tighten the bolted connections with the prescribed tightening torque 12 Nm Perform a functional test see the Performing a functional test section ...

Page 54: ...ting hook operated hoist limit switch with switch rod on stationary wire rope hoists YKC SKC Hoist limit switch with attachment set reeving 2PS 1 PLS switching unit Hoist limit switch with attachment set reeving 4PS 1 PLS switching unit Assembly position 1 Assembly position 2 ...

Page 55: ... L3 Drum length L4 3 Mounting holes Reeving Assembly position 2PS 1 4PS 2 Fasten the PLS 1 switching unit on at the prescribed position with the bolted connections see figures above Tighten the bolted connections with the prescribed tightening torque 12 Nm Perform a functional test see the Performing a functional test section ...

Page 56: ... 2 ys A11867501 Rev AE 4 12 3 Mounting hook operated hoist limit switch with switch rod on stationary wire rope hoists YKE SKE YKD SKD 1 PLS switching unit Assembly position 1 Assembly position 2 Assembly position 3 dimension in f 7 05 g 11 81 ...

Page 57: ... 2 4PS L2 L3 L4 L5 1 YKD SKD 2PS L2 2 2PS L3 L4 L5 3 4PS L2 L3 L4 L5 1 Observe the mounting position of the screws 2 Fasten the PLS 1 switching unit on at the prescribed position with the bolted connections see figures above Tighten the bolted connections with the prescribed tightening torque 12 Nm Perform a functional test see the Performing a functional test section ...

Page 58: ...e prescribed tightening torque 12 Nm Retrofitted assembly 1 Bottom hook block 2 Bracket clip 3 PLS switching unit Fasten the bracket clip 2 whilst ensuring that dimensions z1 and z2 are of equal size Tighten the bracket clips 2 to the prescribed tightening torque 12 Nm Position the PLS switching unit 3 as specified see the Mounting position of the DCS switching unit section Ensure that the switch ...

Page 59: ... Rev AE Assembly position of the PLS switching unit Assembly position 1 Assembly position 2 Assembly position 3 Assembly position 4 1 Screw 6 Nut 2 Threaded plate 7 C profile 3 Screw 8 Threaded plate 4 Bracket clip 9 Plate 5 Retaining plate 10 Spacer sleeve ...

Page 60: ... AE Dimension c Measured from the centre of the bracket clip upwards Measured from the centre of the bracket clip downwards Arrangement of the mounting positions KE S33 Reeving Flange width Assembly position in 2PS 3 2 8 4 1 8 4 31 5 2 4PS 3 2 12 1 1 12 1 31 5 2 ...

Page 61: ...7 0 63 11 1 19 7 4 84 0 63 15 83 31 5 2 48 0 63 30 4PS 3 2 6 22 4 76 2 4 4 7 6 22 4 76 2 4 6 7 6 22 4 76 2 4 11 8 6 22 0 43 1 89 15 7 4 76 0 16 6 81 19 7 9 57 0 2 11 54 31 5 7 2 0 2 25 71 Arrangement of the mounting positions KE S44 Reeving Flange width Drum length Assembly position in 2PS 3 2 9 8 L2 L3 1 9 9 31 5 L2 L3 2 3 2 13 8 L4 1 13 8 31 5 L4 2 4PS 3 2 13 8 L2 1 13 8 31 5 L2 2 3 2 13 8 L3 L4...

Page 62: ...in 9 33 1 0 71 1 22 8 1 4PS 3 2 L2 L3 L4 6 38 4 76 2 36 4 7 L2 L3 L4 6 38 4 76 2 36 6 7 L2 L3 L4 6 38 4 76 2 36 11 8 L2 L3 L4 6 38 3 58 1 18 15 7 L2 L3 L4 6 97 1 06 3 5 19 7 L2 L3 L4 2 24 1 06 8 23 31 5 L2 L3 L4 9 33 1 1 22 4 1 Dimensions for shortened C profile Arrangement of the mounting positions KE S65 Type Reeving Flange width Drum length Assembly position in YKC SKC Drum pull force 2500 daN ...

Page 63: ... 31 5 L4 8 15 0 55 12 2 YKC SKC Drum pull force 2500 daN 4 7 L2 L3 7 72 4 13 2 76 6 7 L2 L3 7 72 4 72 3 35 11 8 L2 L3 6 54 2 56 0 15 7 L2 L3 5 79 0 87 4 69 19 7 L2 L3 8 15 1 0 98 1 9 41 31 5 L2 L3 8 15 0 98 23 58 YKC SKC Drum pull force 2500 daN 4PS 4 7 L2 L3 L4 6 54 4 53 1 97 6 7 L2 L3 L4 7 72 3 94 2 56 11 8 L2 L3 L4 7 72 4 72 3 35 15 7 L2 L3 L4 7 72 3 74 2 36 19 7 L2 L3 L4 6 54 0 2 2 32 31 5 L2 ...

Page 64: ... 76 2 2 0 16 6 7 L2 L3 L4 7 76 2 8 0 75 11 8 L2 L3 L4 7 76 4 37 3 9 15 7 L2 L3 L4 8 94 4 76 2 32 19 7 L2 L3 L4 7 76 2 4 0 35 31 5 L2 L3 L4 7 05 0 63 13 78 YKD SKD 4 9 L2 7 76 3 98 1 93 6 7 L2 7 76 4 76 2 72 11 8 L2 7 76 2 01 0 15 7 L2 6 97 0 2 4 72 19 7 L2 2 24 0 2 9 45 31 5 L2 9 41 0 24 23 62 4 9 L3 L4 8 23 0 83 12 4 6 7 L3 L4 9 41 0 04 12 01 11 8 L3 L4 10 59 0 04 10 83 15 7 L3 L4 10 59 1 22 9 65...

Page 65: ...on S3 a Dimension 1 18 in 1 38 in 1 PLS switching unit 6 Switch rod 7 Bottom hook block Measure the distance between the switch rod 6 and the bottom hook block 7 Dimension a must be approx 1 18 in 1 38 in Actuate the override button S260 on the control box and the UP button at the same time until the bottom hook block stops The switch off position must be set by the dimension x1 0 39 in before the...

Page 66: ...rhangs 0 39 in Mark the assembly position of the PLS switching unit 1 and the overhang f from the C profile 4 Disassemble the PLS switching unit 1 and secure it against falling down Disassemble the C profile 4 and shorten it accordingly Assemble the parts in reverse order Check the switch off position again ...

Page 67: ...limit switch with switch rod on trolleys UE S77 Fasten the PLS 1 switching unit on at the prescribed position with the bolted connections see figures above Tighten the bolted connections with the prescribed tightening torque 12 Nm Perform a functional test see the Performing a functional test section ...

Page 68: ...020 ba o 2 6 0 us 3 2 ys A11867501 Rev AE 4 12 6 Mounting hook operated hoist limit switch with switch rod on trolleys OE S 1 PLS switching unit Assembly position 1 Assembly position 2 Assembly position 3 Assembly position 4 ...

Page 69: ...ten the PLS 1 switching unit on at the prescribed position with the bolted connections see figures above Tighten the bolted connections with the prescribed tightening torque 12 Nm Perform a functional test see the Performing a functional test section Perform the functional test Move the operational limit switch B to the top Movement stops Actuate the override button S260 on the control box and the...

Page 70: ... of the rope into the rope sheave s of the bottom hook block and return pulley s see next page for details NOTICE Material damage hazard to wire rope Do not twist the rope the color coding facilitates checking Fasten the end of the rope in the rope anchorage Perform several runs over the full height of lift without load Repeat with increasing loads Make any twisting in the rope which may occur vis...

Page 71: ...SKA YKB SKB YKC SKC YKE SKE 1PS A A 2PS B D 4PS C E 1PD F F 2PD G H 4PD I Tab 13 Reeving YKA SKA YKB SKB YKC SKC YKE SKE 2PS D D 4PS E E 2PD H H Tab 14 Reeving YKA SKA YKB SKB YKC SKC YKE SKE 2PS D D 4PS E E 2PD H H 4PD I Tab 15 A B C 2PS 4PS 1PD D E F 2PD 2PD 4PD G H I Fig 43 Left handed thread Right handed thread ...

Page 72: ...rope end through the rope bag 1 see figure Lay rope 5 around the rope wedge 2 and draw together in the rope bag 1 The rope end must protrude out of the rope bag 1 by dimension L see table as a minimum Secure rope end with rope clamp 3 dimension a away from the rope bag The rope clamp must not be mounted at the rope binding For tightening torque see table Check the protruding end of the rope wedge ...

Page 73: ...ust be clear of grease Feed the rope end through the rope bag 1 see figure Lay rope 4 around the rope wedge 2 and draw together in the rope bag 1 The rope end must protrude out of the rope bag 1 by length L see table Secure rope end with rope clamps away from the rope bag at the specified points The rope clamp must not be mounted at the rope binding Secure For dimension a and b and the tightening ...

Page 74: ...t of the load is a rope that is firmly drawn into the rope bag Check the protruding end of the rope wedge Maximum value per x see table Check dimension a and b during annual maintenance To ensure the rope does not slip out of the rope bag With deviations assemble the rope again as described Rope Ø Part number L a b x Tightening torque in in lbf ft 0 354 A70009035 5 9 0 98 0 98 0 24 15 0 492 A70009...

Page 75: ...4 13 3 Position of the rope fastening point Reeving Drum length see order Wire rope hoist type YKA SKA YKB SKB YKC SKC 2PS L2 A A A L3 A A A L4 A A 4PS L2 E B F L3 E B F L4 B F 2PD L2 C D C L3 C D C L4 C Tab 17 A Fig 46 B Fig 47 C Fig 48 D Fig 49 Z on the gear side ...

Page 76: ...6 0 us 3 2 ys A11867501 Rev AE Reeving Drum length see order Wire rope hoist type YKA SKA YKB SKB YKC SKC 2PS L2 A A A L3 A A A L4 A A 4PS L2 E B F L3 E B F L4 B F 2PD L2 C D C L3 C D C L4 C Tab 18 E Fig 50 F Fig 51 Z on the gear side ...

Page 77: ... Rev AE Reeving Drum length see order Wire rope hoist type YKA SKA YKB SKB YKC SKC 2PS H H H 4PS G G G 2PD L2 I I I L3 J J J L4 J Tab 19 G Fig 52 Type a in b in YKA SKA 8 5 8 4 YKB SKB 10 4 11 4 YKC SKC 13 1 14 4 H Fig 53 I Fig 54 J Fig 55 Z on the gear side ...

Page 78: ...ing point YKA SKA YKC SKC Reeving Drum length see order Wire rope hoist type YKA SKA YKB SKB YKC SKC 2PS L L L 4PS K K K 2PD L2 M M M L3 M N M L4 M Tab 20 K Fig 56 Type a in b in YKA SKA 8 5 9 5 YKB SKB 10 4 11 4 YKC SKC 13 1 14 4 L Fig 57 M Fig 58 N Fig 59 Z on the gear side ...

Page 79: ...ype YKE SKE 2PS L2 L5 P 4PS L2 L5 O 1PD 2PD L2 L5 R 4PD L3 L5 S Tab 21 Reeving Drum length see order Wire rope hoist type YKE SKE 2PS L2 L5 P 4PS L2 L5 O 2PD L2 L5 R Tab 22 Reeving Drum length see order Wire rope hoist type YKE SKE 2PS L2 L5 P 4PS L2 L5 O 2PD L2 L5 R 4PD L3 L5 S Tab 23 O Fig 60 P Fig 61 R Fig 62 S Fig 63 Z on the gear side ...

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

Page 81: ...tion 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 82: ...commended 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 consult a structural engineer 48 DO NOT use...

Page 83: ...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 84: ... switched off and secured to prevent re activation 1 Emergency stopping 2 Hoist lower Step 1 slow Step 2 fast 3 Long travel right left Step 1 slow Step 2 fast 4 Long travel forwards backwards Step 1 slow Step 2 fast Fig 64 6 4 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 whic...

Page 85: ...set low speed 3 Stage II on the pushbutton is actuated Motor accelerates to maximum speed 4 Stage I on the pushbutton is actuated during acceleration the current speed is maintained 5 Stage II on the pushbutton is actuated Motor accelerates to maximum speed 6 Stage I on the pushbutton is actuated the current or maximum speed is maintained 7 Pushbutton is released Motor decelerates 8 Stage I on the...

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

Page 87: ...ety device 6 125 Disconnect switch and main isolator 42 PE connections and equipotential bonding Establish remaining service life 148 Rope attachment 10 and rope sheaves 133 144 Rope guide 11 136 137 Drive parts 12 wheel flanges wheels etc 147 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 P...

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

Page 89: ... F 86 F Before starting to measure the insulation resistance pay attention to the operating instructions of the insulation measurement instrument being used Measuring voltage 500 V Minimum insulation resistance for new cleaned or overhauled windings 10 MΩ Critical specific insulation resistance after a long period of operation 0 5 MΩ kV If the critical insulation resistance is reached or undershot...

Page 90: ... bleeder screw 1 Collect oil in a suitable container Replace copper sealing rings Tighten the oil drain screw 2 for tightening torque see table Fill with oil For suitable oil types and quantities see section Lubricants Tighten the oil filler plug bleeder screw 1 for tightening torque see table The bleeder screw 1 must always be at the highest point of the gear Thread size Tightening torque lbf ft ...

Page 91: ...taining rings 2 See figure above and table Travel drive Ø D B Drive through mechanism L Installation location X3 X4 L3 0 08 L4 0 08 in in in in in SF17 1 SF17 2 3 1 3 9 3 5 5 7 15 4 3 8 5 7 7 7 1 8 7 7 9 8 19 5 3 8 9 9 12 1 8 12 1 13 8 23 4 3 8 13 8 15 7 1 8 15 8 17 7 27 4 3 8 17 8 19 7 1 8 SF17 2 5 5 4 7 7 9 19 9 4 9 7 9 12 2 1 8 12 2 15 7 27 4 4 9 15 8 19 7 1 8 SF17 2 7 9 4 9 8 7 20 1 see next p...

Page 92: ...l drive side Slide on the spacer tube 2 and adjusting ring 3 Adjust the drive through shaft 5 Observe the following points Set the drive through shaft 5 to the specified dimensions The shaft end on the wire rope side is permitted to protrude from the drive pinion into the trolley side cheek 6 by dimension A The shaft end on the travel drive side must protrude beyond the trolley side cheek 4 by the...

Page 93: ...he drive through shaft 1 to the dimension L1 dimension L2 must lie within the table values Secure the adjusting ring 4 with the adjustment screw An air gap E must be present between the adjusting ring 4 and spacer tube 3 After assembly of the travel drive check that the drive through shaft 1 slides easily B L L1 L2 E in 7 3 8 7 20 1 3 3 5 1 3 7 0 08 0 16 8 7 14 2 24 4 3 3 6 8 1 3 14 2 17 7 29 1 5 ...

Page 94: ... with one travel drive Assemble retaining rings 1 per dimension L4 The installation position of the drive through mechanism does not change over the respective beam area B Trolleys with two travel drives Ø D3 9 Fig 72 Ø D5 5 Drive through mechanism is fully independent of the beam width Assemble retaining rings 1 per Fig 71 and Fig 72 Ø D B Drive through mechanism D L L4 0 079 in 3 9 3 5 5 15 4 1 ...

Page 95: ...h and secure against being switched on again 1 Fastening screws 2 Fan cover 3 Stopping plug 5 Retaining ring 6 Fanwheel 7 Parallel key 8 Fastening screws 9 Coil carrier 10 Brake rotor 11 Hub 12 V ring IP66 13 Retaining ring 14 Motor shaft Fig 73 7 6 1 Checking the brake Remove fan cover 2 Remove stopping plug 3 Measure the air gap S with a feeler gauge b NOTICE When measuring ensure that the feele...

Page 96: ...dampening the cloths only use isopropyl alcohol The use of brake cleaner is not permissible Ensure sufficient drying time for the cleaned surfaces We cannot recommend cleaning the rotor friction linings because oil grease has usually worked into the lining and this can only be removed from the surface area to a limited degree Furthermore it is not possible to fully exclude negative reactions betwe...

Page 97: ... air gap measurement is in the lower area After tightening the fastening screws 8 for tightening torque see table mark the fastening screws 8 Hoist motor type Hoist brake S max a Tightening torque 8 in in lbf ft 12 2H73 100 822 RSM150 0 063 1 2 16 12 2H73 1PC3052 0 035 1 2 24 4H92 RSM500 0 079 1 6 33 Tab 27 Check the brake data against the rating plate on the hoist motor ...

Page 98: ...a minimum see Tab 28 and does not become caught on the ledge For the maximum permissible air gap S refer to Tab 28 The brake is not readjustable Once the max permissible air gap S has been reached the brake rotor must be replaced 7 7 2 Replacing the brake rotor CAUTION Brake dust is hazardous to health Do not clean brakes with compressed air brushes or similar Use a vacuum system or a damp cloth t...

Page 99: ...8 and check the available clearance NOTICE Danger of damage If increased clearance is present in the gearing between the brake rotor 7 and hub 8 remove the hub 8 from the motor shaft and replace it Be sure to consult the production factory before removing the hub 8 Clean coil carrier Replace the brake pressure springs see section Replacing the pressure springs Check the O ring of the coil carrier ...

Page 100: ... Stud bolts 7 Fanwheel 8 Fastening screws 9 Coil carrier 10 Anchor plate 11 Brake rotor 12 Hub 13 Enclosure lower part 14 Retaining ring 15 V ring IP66 Fig 74 7 8 1 Checking the brake Remove stopping plug from the fan cover Remove stopping plug 2 with pliers Measure the air gap S with a feeler gauge b NOTICE When measuring ensure that the feeler gauge b is slid up to insertion depth a as a minimum...

Page 101: ...assemble enclosure lower part 13 Disassemble fan cover 5 Loosen stud bolts 6 on the adapter shaft Disassemble adapter shaft with jacking screws M6 Remove retaining ring 14 for fanwheel 7 Take off fanwheel 7 remove V ring 15 Remove retaining ring 14 Disconnect electrical connection of the brake Unscrew the fastening screws 8 Remove coil carrier 9 Take off brake rotor 11 NOTICE When dampening the cl...

Page 102: ...ecessary Clean coil carrier Assemble in reverse order Steps 14 to 19 are omitted Make sure that the inspection bore for the air gap measurement matches with the opening in the fan cover Secure the stud bolts 6 with thread locker After tightening the fastening screws 8 for tightening torque see Tab 29 mark the fastening screws 8 Hoist motor type Hoist brake S max a Tightening torque 8 in in lbf ft ...

Page 103: ... External ventilation 6 Stud bolt 7 V ring 8 Fastening screws 9 Coil carrier 10 Anchor plate 11 Brake rotor 12 Hub 16 Fastening screws Fig 75 7 9 1 Checking the brake Remove stopping plug 1 Remove stopping plug 2 with pliers Measure the air gap S with a feeler gauge b NOTICE When measuring ensure that the feeler gauge b is slid up to insertion depth a as a minimum and does not become caught on the...

Page 104: ... 5 Loosen stud bolt 4 Disassemble the encoder Disassemble the encoder bracket Loosen stud bolts 6 on the adapter shaft Disassemble adapter shaft with jacking screws M6 Remove V Ring 7 IP66 Remove retaining ring 14 Disassemble electrical connection of the brake Unscrew the fastening screws 8 Remove coil carrier 9 Take off brake rotor 11 NOTICE When dampening the cloths only use isopropyl alcohol Th...

Page 105: ...ressure springs Check the O ring of the coil carrier for damage and replace if necessary Clean coil carrier Assemble in reverse order Steps 14 to 19 are omitted Make sure that the inspection bore for the air gap measurement matches with the opening in the fan cover Secure the stud bolts 6 with thread locker After tightening the fastening screws 8 for tightening torque see Tab 30 mark the fastening...

Page 106: ...tor Set the coil carrier 2 down on a clean work surface CAUTION The pressure springs push against the anchor plate injuries can result from incorrect loosening In order to remove the shoulder screws press the anchor plate against the coil carrier with larger sizes use a spindle press if necessary to avoid sudden relief of the spring pressure Observe the installation of the anchor plate Unscrew bot...

Page 107: ...cessary Press the anchor plate 4 down against the spring force e g with a spindle press and screw in the shoulder screws with the tightening torque specified in the table Clean the friction surface of the anchor plate 4 so that this is clear of grease For subsequent work see hoist motor brake chapter for the respective motor Hoist motor type Brake fastening screws 1 Shoulder screws 5 lbf ft 12 2H3...

Page 108: ...h switching points A and A for the highest and lowest hook position Additionally the geared limit switch is equipped with an operational hoist limit switch for switching off in the highest hook position in normal operation switching point B At switching point B switching takes place from the fastest to the slowest speed or vice versa If overtravel of the operational hoist limit switch takes place ...

Page 109: ...r vice versa If overtravel of the operational hoist limit switch takes place with a fault B or B the emergency hoist limit switch A or A switches off the hoisting movement Only once the error has been eliminated is it possible to drive out of the area again Adjustment screw Switching point Function Remark S0 S1 S8 Adjustment screw for the block adjustment of all switching points S1 A Emergency hoi...

Page 110: ... YKB SKB 2 YKC SKC YKE SKE 3 9 YKD SKD 5 9 Actuate the UP button in the control pendant with caution Observe the hoisting movement until the operational hoist limit switch switches off in the top hook position B Prior to reaching the switch off point B make sure that a reduction to the slow speed takes place B The minimum distance a c between the hook block and the next obstacle or hook aperture C...

Page 111: ...ion B Actuate the override button S260 in the control box and the UP button at the same time until the emergency hoist limit switch switches off A When using the optional hook operated hoist limit switch see chapter 4 11 this must be overridden If the wire rope hoist does not travel further the emergency hoist limit switch has already switched off during step 2 and the operational hoist limit swit...

Page 112: ... between the rope guide ring 1 and the clamping claws 2 for the rope anchorage With emergency hoist limit switching the load hook must not be lowered onto the ground Measure the distance from the rope guide ring to the clamping claws The minimum distance f between the rope guide ring 1 and the clamping claws 2 for the rope anchorage f 0 79 in With deviations adjust the geared limit switch again se...

Page 113: ... the operational hoist limit switch switches off in the top hook position B Prior to reaching the switch off point B make sure that a reduction to the slow speed takes place B The minimum distance a c between the hook block and the next obstacle see table or hook aperture C see section 7 15 must be maintained as a minimum depending on the dimension at which the hook hangs lower With deviations adj...

Page 114: ... 3 9 YKD SKD 5 9 Check with precision hoist Actuate the UP button in the control pendant with caution Observe the hoisting movement until the operational hoist limit switch switches off in the top hook position B Actuate the override button S260 in the control box and the UP button at the same time until the emergency hoist limit switch switches off A When using the optional hook operated hoist li...

Page 115: ...ches off A If the wire rope hoist does not travel further the emergency hoist limit switch has already switched off during step 9 and the operational hoist limit switch is not working Do not undershoot the minimum distance f of f 0 79 in between the rope guide ring 1 and the clamping claws 2 for the rope anchorage With emergency hoist limit switching the load hook must not be lowered onto the grou...

Page 116: ...unction and correct setting WARNING Danger due to falling load Perform all checks and settings without load only Cordon off and secure the danger zone NOTICE Danger of material damage Never remove dust accumulations with the enclosure open using compressed air because the dust can significantly penetrate the contacts as a result of this and impair the switching capacity Never use benzine or other ...

Page 117: ...ment screws S1 to S4 Turning clockwise Switching point is shifted upwards Turning anticlockwise Switching point is shifted downwards The switching points must be set in the following order Adjustment screw Switching point Function S3 B Operational hoist limit switching top S1 A Emergency hoist limit switching top S4 B Fast slow switching top S2 A Emergency hoist limit switching bottom ...

Page 118: ...y 3 9 in dimension c increases in accordance with the table Type Dimension c enlargement in YKA SKA YKB SKB 2 YKC SKC YKE SKE 3 9 YKD SKD 5 9 Adjusting operational hoist limit switching top B 1st Actuate the UP button in the control pendant with caution Hoist the load hook to 0 39 in in front of the switch off point B Observe the minimum distance a c between the hook block and the next obstacle or...

Page 119: ...the option hook operated hoist limit switch see section 4 12 this must be overridden keep the connecting rope under tension Observe the minimum distance a between the hook block and the next obstacle see table or hook aperture C c see section 7 15 depending on the dimension at which the hook hangs lower If the emergency hoist limit switch should switch off beforehand turn the adjustment screw S1 c...

Page 120: ...KB 2 YKC SKC YKE SKE 3 9 YKD SKD 5 9 Adjusting the fast slow switching top B Hoist the load hook to 0 39 in in front of the desired switch off point observe the minimum distance b If the load hook should become slower beforehand turn the adjustment screw S4 clockwise 1 revolution and repeat step 1 Turn the adjustment screw S4 anticlockwise until the switch contact latches audibly Actuate the DOWN ...

Page 121: ... bottom emergency hoist limit switching position has been set Checking the switching points After setting the switching points check these at a slow lifting and lowering speed and readjust the switching points if necessary 7 14 2 Geared limit switch version 2 The individual switching points are set in the factory with the adjustment screws S1 to S6 Turning clockwise Switching point is shifted upwa...

Page 122: ...4 b YK SK with frequency inverter b V t 0 023 ft V Hoist speed fpm t Brake ramp s Factory setting 1 5 s Example YKC SKC L05 S264 V b 64 1 5 0 023 2 2 ft c 1 2 4 d 4 7 e Effective hook path 1 With the option hook operated hoist limit switch see section 4 12 dimension a increases by 3 9 in dimension c increases in accordance with the table Type Dimension c enlargement in YKA SKA YKB SKB 2 YKC SKC YK...

Page 123: ... has been set Dim in a 1 50 Hz 60 Hz Reeving 1PS 1PD 5 1 5 9 1 2PS 2PD 2 8 3 1 2 4PS 4PD 1 6 2 4 b YK SK with frequency inverter b V t 0 023 ft V Hoist speed fpm t Brake ramp s Factory setting 1 5 s Example YKC SKC L05 S264 V b 64 1 5 0 023 2 2 ft c 1 2 4 d 4 7 e Effective hook path 1 With the option hook operated hoist limit switch see section 4 11 dimension a increases by 3 9 in dimension c incr...

Page 124: ...ontrol box and the UP button at the same time to exit the switching area The bottom emergency hoist limit switching position has been set Adjusting the fast slow switching bottom B Hoist the load hook to 0 39 in in front of the desired switch off point observe the minimum distance b Turn the adjustment screw S5 clockwise until the switch contact latches audibly Checking the switching points After ...

Page 125: ...m line for the wire rope hoist Draw a vertical line for the corresponding flange width Draw a horizontal line though the point of intersection and read off the hook dimension C 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 Hook dimensions C in Flange width in YKA SKA 2PS L2 L3 YKA SKA 2PS L2 L3 PLS YKA SKA 2PS L2 L3 BLS ...

Page 126: ...ok dimensions C in Flange width in YKA SKA 4PS L2 L3 YKA SKA 4PS L2 L3 PLS YKA SKA 4PS L2 L3 BLS YKA SKA 2PD L2 L3 YKA SKA 2PD L2 L3 BLS 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 Hook dimensions C in Flange width in YKB SKB 2PS L2 L3 YKB SKB 2PS L2 L3 PLS YKB SKB 2PS L2 L3 BLS YKB SKB 2PS L4 YKB SKB 2PS L4 PLS YKB SKB 2PS L4 BLS ...

Page 127: ...width in YKB SKB 4PS L2 L4 YKB SKB 4PS L2 L4 PLS YKB SKB 4PS L2 L4 BLS YKB SKB 2PD L2 L3 YKB SKB 2PD L2 L3 BLS 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 Hook dimensions C in Flange width in YKC SKC 2500daN 2PS L2 L3 YKC SKC 2500daN 2PS L2 L3 PLS YKC SKC 2500daN 2PS L2 L3 BLS YKC SKC 2500daN 2PS L4 YKC SKC 2500daN 2PS L4 PLS YKC SKC 2500daN 2PS L4 BLS...

Page 128: ...nsions C in Flange width in YKC SKC 2500daN 4PS L2 L4 YKC SKC 2500daN 4PS L2 L4 PLS YKC SKC 2500daN 4PS L2 L4 BLS YKC SKC 2500daN 2PD L2 L4 YKC SKC 2500daN 2PD L2 L4 BLS 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 Hook dimensions C in Flange width in YKC SKC 2500daN 2PS L2 L3 YKC SKC 2500daN 2PS L2 L3 PLS YKC SKC 2500daN 2PS L2 L3 BLS ...

Page 129: ...ange width in YKC SKC 2500daN 4PS L2 L3 YKC SKC 2500daN 4PS L2 L3 PLS YKC SKC 2500daN 4PS L2 L3 BLS YKC SKC 2500daN 2PD L2 L3 YKC SKC 2500daN 2PD L2 L3 BLS 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 Hook dimensions C in Flange width in YKD SKD 2PS L2 YKD SKD 2PS L2 PLS YKD SKD 2PS L2 BLS YKD SKD 2PS L3 L4 YKD SKD 2PS L3 L4 PLS YKD SKD 2PS L3 L4 BLS ...

Page 130: ...0 22 24 26 28 30 32 Hook dimensions C in Flange width in YKD SKD 4PS L2 L4 YKD SKD 4PS L2 L4 PLS YKD SKD 4PS L2 L4 BLS 33 35 37 39 41 43 45 47 49 51 53 55 57 59 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 Hook dimensions C in Flange width in YKE SKE 2PS L2 L4 YKE SKE 2PS L2 L4 PLS YKE SKE 2PS L2 L4 BLS YKE SKE 2PD L2 L4 YKE SKE 2PD L2 L4 BLS ...

Page 131: ...e wedge 4 Bottom hook block Fig 76 Feed the rope end through the bottom hook block 4 see figure Lay rope 1 around the rope wedge 3 and draw together in the rope bag 1 The rope end must protrude out of the bottom hook block 4 by dimension L see table as a minimum Secure rope end with rope clamp 2 dimension a away from the bottom hook block 4 The rope clamp must not be mounted at the rope binding Fo...

Page 132: ...vement 2 Clean without dismantling and grease from the outside with a thin bodied lubricant 7 17 3 Maintenance of overload safety device with shear force sensor 1 Check plate thickness min 0 059 in 2 If necessary replace plate after removing screw D 7 18 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 cr...

Page 133: ...ut can lead to the rope breaking and a load crash resulting in serious injuries or even death Check the wire rope regularly If a wire rope is worn out it must be replaced immediately Use only original spare parts Wire ropes must be checked in accordance with the periods listed in the risk assessment although at least once yearly Depending on the operating conditions and the operational situation a...

Page 134: ...t necessary with 100 Internal corrosion Clear visible signs of internal corrosion e g corrosion particles emerging Replacement necessary with 100 Fretting corrosion Reddish brown dust between the strands which almost covers the entire outer surface Replacement necessary with 100 or with uncertainty regarding the degree of severity Reduction in rope diameter Replace wire ropes with the following ev...

Page 135: ... rope loops Bends Replace wire ropes with severe bends Damage due to the effects of heat or arcs Replace wire ropes with bluish discolouration or broken or melted wires Wire breakages Relieve the rope tension and bend the rope roughly by hand to the radius of the rope pulley Compare visible wire breakages with the number of wire breakages permitted see rope certificate and replace if necessary Twi...

Page 136: ...spring washer DIN 6796 This protection must be correctly reinstalled YKA SKA YKC SKC YKE SKE Fig 79 Fig 80 Unscrew the protective plate 1 beneath the rope drum at the points a The rope guide ring now turns freely Do not unscrew the stop with bearing 2 Loosen screws 5 Loosen the rope guide ring lock 7 on one side if present Remove the ring halves 1 and 4 Detach the rope tension spring ...

Page 137: ... groove of the rope guide ring half 1 and hook the spring ends together Place second rope guide ring half with large opening 4 on the rope drum Run the wire rope straight and free of bends from the drum groove through the opening Make sure that the two rope guide ring halves 1 and 4 meet each other with no offset Connect both rope guide ring halves 1 and 4 together with screw spring 5 Make sure th...

Page 138: ...torques see table Type Thread size Tightening torque lbf ft YKA SKA YKB SKB M8 1 15 YKC SKC M10 1 30 YKE SKE M16 1 118 Install the grease pan again Observe the minimum distance f 0 79 in between the rope guide ring 1 and clamping plates 2 for the rope anchorage With wire rope hoist type YKE SKE 2PS with drum lengths L4 L5 Assemble the rope guide ring lock 7 ...

Page 139: ...ing the rope guide The rope guide ring has 2 pre drilled holes 10 and 30 Rope guide rings for other angles must be drilled according to the order Remove the rope guide see section 7 19 3 Screw bearing into the new rope guide ring at the same point Assemble on the half of the rope guide ring with the opening for the rope 30 for stationary wire rope hoist underslung trolley nBh and double rail crab ...

Page 140: ...m with right hand groove R WARNING Danger of falling parts Cordon off and secure the danger zone Discarding a wire rope Travel with the hook block until shortly before the lowest hook position and set down on a firm surface Undo the rope end in the rope fastening point rope lock with rope wedge Set down the rope end Do not allow the rope to drop to the ground uncontrolled Remove the rope guide see...

Page 141: ...evel surface When unrolling make sure no loops bends or twists arise and that no foreign objects penetrate the wire rope Fig 83 Mount the rope 6 on the rope drum with all clamping plates 9 do not forget the safety washers Leave the rope end projecting approx 1 18 1 57 in Wind the rope 5 10 windings taut with the motorized drive When doing so allow the rope to run through a greasy cloth for grease ...

Page 142: ...e with a rope clamp see section 4 13 2 Rope fastening point Tighten the screws 8 for the clamping plates 9 once more for tightening torques see table Type Thread size Tightening torque lbf ft YKA SKA M6 7 M10 30 YKB SKB M10 37 YKC SKC M10 37 M12 64 YKE SKE M12 M16 64 155 Tab 31 Run the rope in with a partial load Check the geared limit switch and adjust if necessary see section 7 14 Adjusting the ...

Page 143: ...0 236 4 91 4 72 0 094 4 88 4 69 0 106 0 256 0 276 4 91 4 69 0 11 4 88 4 65 0 126 YKB SKB 0 276 6 51 6 29 0 11 6 48 6 26 0 126 0 335 0 354 6 51 6 22 0 144 6 48 6 19 0 161 YKC SKC 0 335 0 354 8 52 8 24 0 144 8 49 8 2 0 161 0 394 8 54 8 23 0 157 8 5 8 19 0 177 0 472 0 492 8 52 8 13 0 197 8 48 8 08 0 22 YKE SKE 0 472 0 492 13 86 13 46 0 197 13 81 13 42 0 22 0 551 13 86 13 43 0 217 13 8 13 37 0 244 0 6...

Page 144: ... with a special caliper Measure groove base depth h with a depth gauge If the measured values exceed or fall short of the values in the table Replace the rope sheave Ordering no New rope sheave Max base height h Min wall thickness t Ø D Base height h in in in in A0143001530 3 86 0 433 0 512 0 157 A0143004530 3 94 0 394 0 512 0 157 A0143000530 4 92 0 472 0 551 0 157 A2233000530 5 51 0 551 0 63 0 15...

Page 145: ...rands have dug into the base of the groove Impressions of single wires are acceptable A rope sheave must also be replaced if the radius of the base of the groove R has become too small for the new rope due to reduction in diameter of the old rope or wear N B The negative profile of the rope in the base of the groove may provide optimum contact to the wire rope currently fitted Rope sheaves should ...

Page 146: ...hook for damage corrosion and wear Check function of the hook safety latch With visible damage corrosion or wear replace the load hook Measure the dimensions y and h Compare the measured values with the permissible values see table If y max is exceeded or h min is undershot replace the load hook RSN RS Hook size 025 04 05 08 1 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...

Page 147: ...0 22 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 37 1 Perform visual inspection of runw...

Page 148: ...on 1 5 7 21 2 Multicontroller SMC optional Fig 91 The Multicontroller SMC has a load spectrum recorder The load specific operating hours of the hoisting mechanism are stored in the load spectrum recorder The SMC uses this load spectrum data to calculate the full load operating hours of the hoisting mechanism The remaining service life is calculated from the full load operating hours determined wit...

Page 149: ...e wire rope hoist must be overhauled by the manufacturer NOTICE Danger of material damage Components which are in the power flux may only be overhauled by the manufacturer The rope drive is classified according to FEM 9 661 see factory certificate As the service life of components such as gears is limited in accordance with the classification it must be ensured that this is not exceeded After the ...

Page 150: ...rder no lbf ft 12 2H73 100 822 RSM150 A0443075650 16 12 2H73 1PC3052 A70017594 24 4H92 RSM500 A0543011650 33 Tab 39 NM brake rotor Hoist motor Hoist motor brake A Tightening torque Order no lbf ft 12 2H33 MF NM 38722 A5674770 7 4H33 MF NM 38720 A5674770 12 2H42 MF NM 38732 A5674750 4H42 MF NM 38730 A5674750 4HS3 MF NM 38730 A5676320 12 2H62 MF NM 38732 A5678050 16 4H62 MF NM 38740 A5674790 12 2H71...

Page 151: ...er 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 41 Fig 95 Wire rope E See factory certificate or rope certificate for length and number of wire rope ...

Page 152: ...erheating 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 ...

Page 153: ...l 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 wir...

Page 154: ...isposal 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 w...

Page 155: ... conditions usual in industry in non hazardous areas Special measures are necessary for particular applications such as e g high degree of chemical pollution outdoor use offshore application etc The 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 156: ... 20 1 20 40 240 120 24 0 56 0 14 0 32 0 12 2H91 MF 1 6 7 40 2 20 40 240 120 45 0 101 0 78 3 435 0 26 0 58 0 45 0 250 0 0 60 0 70 100 60 50 Hz Motor 3 Power Duration factor Switching hour Nominal current Starting current Nominal current Starting current cos phi k Main fuse CC J 2 420 460 V 500 525 V 420 460 V 500 525 V HP CDF c h IN A IK A IN A IK A A 12 2H33 MF 0 5 3 2 20 60 480 240 3 4 5 5 6 9 35...

Page 157: ... current Starting current cos phi k Main fuse CC J 2 440 480 V 575 600 V 440 480 V 575 600 V HP CDF c h IN A IK A IN A IK A A 12 2H33 MF 0 7 4 7 20 50 360 180 3 9 7 3 7 3 43 0 3 1 5 8 5 8 34 4 0 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 24...

Page 158: ... 2 220 240 V 380 415 V 220 240 V 380 415 V HP CDF c h IN A IK A IN A IK A A 12 2H73 100 822 1 5 30 6 20 50 360 180 44 0 72 0 88 0 486 25 3 41 4 50 6 279 0 59 0 63 125 80 6 38 6 20 40 240 120 44 0 96 0 25 3 55 2 12 2H73 1PC3052 1 5 30 8 20 50 360 180 41 0 90 0 80 0 576 24 0 52 0 46 0 331 0 52 0 60 125 80 6 38 9 20 40 240 120 42 0 108 24 0 62 0 24 4H92 1 9 1 61 7 13 27 160 80 61 0 84 0 87 4 542 0 51...

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

Page 160: ... Duration factor Nominal current Main fuse CC J 1 440 480 V 575 600 V 440 480 V 575 600 V HP CDF IN A A 4HS3 4 7 80 8 1 6 5 15 10 5 8 70 9 3 7 4 7 2 60 10 8 8 6 4HS5 9 7 70 17 0 13 6 25 15 12 1 60 19 0 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 49 1 Protect...

Page 161: ...t AWG ft AWG ft AWG ft AWG AWG AWG ft AWG ft AWG ft AWG ft 50 Hz 380 415 V 500 525 V 380 415 V 500 525 V 380 415 V 500 525 V 400 V 500 V 380 415 V 500 525 V 380 415 V 500 525 V 12 2H33 12 167 14 157 10 52 12 49 12 108 14 102 10 12 8 66 10 69 10 128 12 125 12 2H42 10 233 12 230 8 66 10 69 10 154 12 151 8 10 8 66 10 69 10 108 12 108 12 2H62 8 203 10 210 6 66 8 62 8 138 10 141 6 8 6 66 8 59 8 98 10 1...

Page 162: ...ains along crane runway to crane control Power supply along crane bridge to hoist U 5 U 1 U 4 4 5 U 2 5 U 1 5 5 6 S L1 S L1 S L2 S L2 S L3 S L3 S S S L4 S L4 S L5 S L5 AWG ft AWG ft AWG ft AWG ft AWG ft AWG ft AWG AWG AWG ft AWG ft AWG ft AWG ft 50 Hz 380 415 V 500 525 V 380 415 V 500 525 V 380 415 V 500 525 V 400 V 500 V 380 415 V 500 525 V 380 415 V 500 525 V 12 2H73 100 822 4 226 6 220 2 69 4 6...

Page 163: ...ply for the attachment of the mounting plate to the gear WARNING Safety hazard Unsuitable installation material and incorrect tightening torques may lead to damage and accidents Use only original spare parts Tighten screw connection with a torque spanner to the prescribed tightening torque Thread Screw grade 8 8 10 9 100 Standard Y lbf ft M6 8 11 M8 18 26 M10 36 51 55 M12 63 90 64 M16 155 221 184 ...

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

Page 165: ...chs 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 ...

Page 166: ...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...

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