Yale SHAW-BOX

ba-o.2.6.0-us-1.1-y | A11867501 Rev AA
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

Yale SHAW-BOX Specifications

General

Brand	Yale
Model	SHAW-BOX
Category	Other
Language	English

Summary

Wire Rope Hoists Operation & Service Manual

Hoist and Motor Data Plates Information

Hoist and motor data plate information for installation.

General Operating and Safety Instructions

Follow all instructions for inspecting, maintaining, and operating the hoist.

1 General Information

1.1 Information about Safety Messages

Explanation of signal words, symbols, safety instructions, section and embedded messages.

1.2 Spare Parts

Guidance on using original spare parts to avoid damage and malfunctions.

1.3 Target Audience and Responsibilities

Defines owner, trained personnel, qualified person, and electrical qualified person.

1.5 Transport and Storage

Instructions for safe transport and storage of the hoist and its accessories.

1.7 Installation, Commissioning, Maintenance and Repairs

Guidelines for qualified personnel performing installation, commissioning, maintenance, and repairs.

1.9 Periodic Inspections

Requirements for periodic inspections by qualified persons, including frequency.

2 General Safety Notes

2.1 Use for Intended Purpose

Specifies intended use of wire rope hoists and conditions for safe operation.

2.2 Inappropriate Use

Lists forbidden uses and applications of the hoist to prevent hazards.

2.3 Residual Hazards

Identifies residual hazards and preventative measures during operation and maintenance.

2.6 Recommended PPE

Lists personal protective equipment recommended for the owner to provide.

2.9 Fire Safety

Safety warnings and precautions regarding fire fighting and use of extinguishers.

2 General Safety Notes

2.10 Safety-Conscious Operation

Detailed instructions for safe and conscious operation of the hoist to prevent risks.

2.11 Attaching Load

Specific guidelines for safely attaching loads to the hoist hook, ensuring stability.

3 Introduction

3.1 Incorporation

Describes stationary and mobile hoist types and their mounting configurations.

4 Installation

4.1 Stationary Hoist

Instructions for installing stationary hoists, including mounting positions and fleet angles.

4.1.1 Attachment at Bottom

Details the hardware and procedure for attaching the hoist at the bottom.

4.1.2 Attachment at Top

Details the hardware and procedure for attaching the hoist at the top.

4 Installation

4.2 Fleet Angle

Explains fleet angles, preferred installation positions, and provides angle data.

4.2.1 Attachment at Bottom

Provides fleet angle data for various hoist types in bottom attachment configurations.

4.2.2 Attachment at Top

Provides fleet angle data for various hoist types in top attachment configurations.

4.2.3 Attachment at Side

Provides fleet angle data for various hoist types in side attachment configurations.

4.2.5 Angle of Installation

Warnings and guidelines for hoist installation angles to prevent rope damage.

4 Installation

4.3 Monorail Trolleys

Information on monorail trolley construction, installation, and types.

4.3.1 Monorail Trolley (KE-S33 - 76)

Details for installing monorail trolleys KE-S33 to KE-76 with specific hoist types.

4.3.3 Drive Shaft for Trolley Drive (Trolley KE-S76)

Instructions for fitting drive shafts for trolley KE-S76, considering flange widths.

4.3.4 Monorail Trolley (UE-S4)

Details for installing monorail trolley UE-S4 with specific hoists, including installation steps.

4.3.5 Monorail Trolley (UE-S776)

Details for installing monorail trolley UE-S776 with specific hoists, including installation steps.

4.3.6 Articulated Trolley (DKE-S4 DKE-S6)

Instructions for installing articulated trolleys DKE-S4/DKE-S6 with specific hoists.

4 Installation

4.4 End Stops for Monorail Trolleys

Information on end stops for monorail trolleys and associated falling parts hazards.

4.5 Double Rail Trolley (OE-S)

Details for installing double rail trolleys, including runway requirements and checks.

4.6 End Stops for Double Rail Trolleys

Specifications and dimensions for end stops for double rail trolleys.

4.7 Anti-Jump Catch

Description and procedure for installing the anti-jump catch as an anti-derail device.

4 Installation

4.8 Travel Limit Switches

Information on travel limit switches for monorail and double rail trolleys, including functions.

4.9 Electrical Equipment

Overview of electrical equipment, safety precautions, standards, and components.

4.9.1 Supply Cables

Guidelines for selecting and installing supply cables based on operating conditions.

4.9.3 Protection of Equipment

Details protective devices like fuses, overload safety devices, and limit switches.

4 Installation

4.9.4 Emergency Stop

How to disconnect the system using the emergency stop button and main isolator.

4.9.8 Electromagnetic Compatibility

Details on EMC, interference suppression measures, and recommended modules.

4.9.9 Overload Safety Device

Description of the overload safety device, its function, and components.

4 Installation

4.9.10 Connecting to Mains

Safety hazards and procedures for connecting the hoist to the mains supply.

4.9.11 Control and Control Functions

Overview of electronic control devices, safety functions, and non-safety-relevant functions.

4 Installation

4.9.12 Electric Motors and Related Equipment

Information on hoist and travel motors, their specifications, options, and operating conditions.

4.11 Reeving Rope

Instructions for reeving the wire rope, including precautions and potential hazards.

5 Commissioning

Commissioning Safety Hazard

Warning about qualified persons performing commissioning and retesting.

Essential Commissioning Checks

Lists essential checks to be performed during commissioning and retesting.

6 Operating

6.1 Operating Precautions

Detailed list of do's and don'ts for safe hoist operation.

6.2 Duties of Crane Operator

Responsibilities and requirements for crane operators, including PPE and workplace safety.

6.3 Using Control Pendant

Instructions for operating the hoist using the control pendant, including safety warnings.

6.5 Emergency Stop

Procedure for using the emergency stop function and releasing it safely.

7 Inspection and Maintenance

General Information on Inspection and Maintenance

General guidelines, safety, and frequency for inspections and maintenance by qualified persons.

7.1 Inspection Intervals

Table detailing inspection intervals for various hoist components and systems.

7 Inspection and Maintenance

7.2 Maintenance Intervals

Table detailing maintenance intervals for various hoist components and systems.

7.3 Motors

Safety precautions and checks for motors, including insulation resistance testing.

7 Inspection and Maintenance

7.4 Hoist Motor Brake (RSM)

Inspection and replacement procedures for the hoist motor brake (RSM).

7.4.1 Checking Brake

Steps for checking the brake, including measuring air gap.

7.4.2 Replacing Brake Disk (Brake Rotor)

Steps for replacing the brake disk (brake rotor) and related components.

7 Inspection and Maintenance

7.5 Hoist Motor Brake (NM) (Pole-Changing)

Inspection and replacement procedures for NM pole-changing motor brakes.

7.5.1 Checking Brake

Steps for checking the brake, including measuring air gap.

7.5.2 Replacing Brake Disk (Brake Rotor)

Steps for replacing the brake disk (brake rotor) and related components.

7 Inspection and Maintenance

7.6 Hoist Motor Brake (NM) (4-Pole)

Inspection and replacement procedures for NM 4-pole motor brakes.

7.6.1 Checking Brake

Steps for checking the brake, including measuring air gap.

7.6.2 Replacing Brake Disk (Brake Rotor)

Steps for replacing the brake disk (brake rotor) and related components.

7 Inspection and Maintenance

7.7 Hoist Motor Brake (NM) 4 HS.

Inspection and replacement procedures for NM 4HS motor brakes.

7.7.1 Checking Brake

Steps for checking the brake, including measuring air gap.

7.7.2 Replacing Brake Disk (Brake Rotor)

Steps for replacing the brake disk (brake rotor) and related components.

7 Inspection and Maintenance

7.9 Hoist Limit Switch

Information on hoist limit switch layouts, systems, and components.

7.9.1 Hoist Limit Switch (Standard)

Details of the standard hoist limit switch system, including versions.

7 Inspection and Maintenance

7.10 Hoist Limit Switch

Detailed description of hoist limit switch systems and their functions.

7.10.1 Description of Hoist Limit Switch System

Explains the function of emergency and operational limit switches.

7.10.2 Testing Emergency Hoist Limit Switch, Version 1

Procedure for testing the emergency limit switch (version 1).

7.10.3 Testing Operational Hoist Limit Switch, Version 1

Procedure for testing the operational limit switch (version 1).

7 Inspection and Maintenance

7.10.4 Testing Emergency Hoist Limit Switch, Version 2

Procedure for testing the emergency limit switch (version 2).

7.10.5 Testing Operational Hoist Limit Switch, Version 2

Procedure for testing the operational limit switch (version 2).

7 Inspection and Maintenance

7.10.6 Setting Hoist Limit Switch

Detailed steps for setting hoist limit switches, including adjustments and checks.

7 Inspection and Maintenance

7.10.7 Servicing Hoist Limit Switch

Guidance on servicing hoist limit switches, focusing on checking cut-off points.

7.11 Hook Dimensions C for KE-S.. Trolleys

Table of hook dimensions C for top operational hoist limit switch cut-off point.

7 Inspection and Maintenance

7.12 Overload Safety Device

Testing and maintenance procedures for the overload safety device.

7.12.1 Testing Overload Safety Device

Steps for testing the overload safety device, including overload load application.

7.13 Crane Test

Procedure for performing crane tests for commissioning, including dynamic and static tests.

7 Inspection and Maintenance

7.14 Rope Drive

General information on rope drives, rope and rope attachment, and potential hazards.

7.14.1 Rope and Rope Attachment - General Information

Guidelines for inspecting ropes and attachments for damage, twists, and wear.

7 Inspection and Maintenance

7.14.2 Replacement of Wire Rope due to Broken Wires

Procedure for replacing wire rope due to broken wires, based on factory certificates.

7.14.3 Removing Rope Guide

Methods for removing the rope guide, including preferred and alternative procedures.

7 Inspection and Maintenance

7.14.4 Replacing Wire Rope

Detailed steps for replacing the wire rope, including fitting and securing.

7.14.5 Fitting Rope Guide

Instructions for fitting the rope guide, ensuring correct placement and tension.

7.14.6 Checking Rope Drum for Wear

Procedure for checking the rope drum for wear using nominal values and wear limits.

7 Inspection and Maintenance

7.14.7 Inspection and Maintenance of Rope Sheave

How to inspect and maintain rope sheaves for wear, damage, and bearing condition.

7.14.8 Checking Load Hook

Procedure for checking the load hook for wear and damage based on hook size.

7 Inspection and Maintenance

7.15 Trolley

Inspection and maintenance of trolley wheels, drives, and runways for wear.

7 Inspection and Maintenance

7.16 Remaining Service Life

How to determine and manage remaining service life using operating hours and overhaul scheduling.

7.17 General Overhaul

Information regarding general overhaul classification, theoretical lifetime, and manufacturer requirements.

8 Wearing Parts

8.1 Serial Number

Importance of the serial number for ordering original spare parts.

8.2 Hoist

Lists wearing parts for RSM and NM brake rotors, including order numbers.

8 Wearing Parts

Rope Guide

Order numbers for rope guides for different wire rope hoist types and lengths.

9 Troubleshooting

Electric Shock Hazard

Safety warning regarding electrical hazards during troubleshooting and necessary precautions.

Hoist Does NOT Operate

Possible causes and remedies for the hoist not operating, covering power, voltage, and wiring issues.

9 Troubleshooting

Hoist Does NOT Operate, Motor Hums

Possible causes and remedies for motor hum when hoist doesn't operate, e.g., phase issues.

Hoist Does NOT Start After Longer Shutdown, or Starts with Difficulty, Motor Hums

Causes and remedies for difficult starting or motor humming after shutdown.

Hoist Motor Overheats

Causes and remedies for motor overheating, including excessive load and duty cycle.

Hoist Operates Intermittently

Causes and remedies for intermittent hoist operation, related to collectors or contacts.

Braking Distance Is Too Long

Cause and remedy for increased braking distance, typically worn brake lining.

9 Troubleshooting

Loud Clicking Noise When Motor Starts

Cause and remedy for clicking noise when motor starts, often related to brake air gap.

Lifting of Rated Load NOT Possible

Causes and remedies for inability to lift rated load, including voltage and limit switch issues.

Hook Moves in Wrong Direction

Cause and remedy for incorrect hook movement direction, typically due to wiring errors.

Lifting NOT Possible

Causes and remedies for lifting failure, including limit switch defects or control issues.

9 Troubleshooting

Lowering NOT Possible

Causes and remedies for lowering failure, including limit switch faults or control issues.

Hoist Does NOT Follow the Control Commands

Causes and remedies when hoist doesn't follow commands, often related to condition monitoring devices.

Cross Traveling NOT Possible

Causes and remedies for failure in cross traveling, such as excessive load or defective limit switches.

Load Drifts Excessively When Hoist Is Stopped

Cause and remedy for load drift when hoist is stopped, typically due to excessive load.

10 Decommissioning

10.1 Dismantling

Safety warning and steps for dismantling the hoist correctly.

10.2 Scrap Disposal

Guidelines for hazardous waste disposal and recycling of components.

11 Technical Data

11.1 Conditions of Use

Information on intended use environment and special application measures for the hoist.

11 Technical Data

11.2 Hoist

General hoist technical data, motor specifications, and operating conditions.

11.2.1 Pole-Changing Hoist Motors..-MF 50 Hz

Technical data for pole-changing motors at 50Hz, including power and current ratings.

11 Technical Data

11.2.2 Pole-Changing Hoist Motors..-MF 60 Hz

Technical data for pole-changing motors at 60Hz, including power and current ratings.

11.2.3 Pole-Changing Hoist Motors 50 Hz

Technical data for pole-changing hoist motors at 50Hz, covering various power ratings.

11.2.4 Pole-Changing Hoist Motors 60 Hz

Technical data for pole-changing hoist motors at 60Hz, covering various power ratings.

11 Technical Data

11.2.5 Frequency-Controlled Hoist Motors..4 H..-MF 100 Hz

Technical data for frequency-controlled hoist motors at 100 Hz, including voltage and current.

11.2.6 Frequency-Controlled Hoist Motors..4 HS.-MF 120 Hz

Technical data for frequency-controlled hoist motors at 120 Hz, including voltage and current.

11 Technical Data

11.3 Cable Cross Sections and Lengths of Supply Cable

Tables for cable cross sections and lengths of supply cable for pole-changing motors.

11 Technical Data

11.4 Tightening Torques

Table of tightening torques for various screw sizes and grades, including for gear attachment.

11 Technical Data

11.5 Lubricants

Table of lubricants for hoist and travel drives, including factory and alternative options.

11 Technical Data

11.7 Circuit Diagrams

Refers to a separate enclosure for circuit diagrams of the hoist system.

WARRANTY

Limitation of Warranties, Remedies and Damages

Legal limitations on warranties, remedies, and damages, including liability caps.

Indemnification and Safe Operation

Buyer's obligations regarding safe operation and indemnification against claims.

CMCO Warranty (Hoists)

Specific warranty terms for CMCO hoists, covering electrical and mechanical components.