Related Manuals for Yale SHAW-BOX YK Series
Summary of Contents for Yale SHAW-BOX YK Series
- Page 1 UHSG ASSEMBLY INSTRUCTION MANUAL P/N: C11746310 , SK , Y80 & ™ ™ 800 Series CRANE KIT ASSEMBLY INSTRUCTION MANUAL P/N: C11746310 REV. AB June 2022 www.columbusmckinnon.com...
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Page 2: Table Of Contents
TABLE OF CONTENTS 1) SAFETY PRECAUTIONS ........................5 IMPORTANT INFORMATION AND WARNINGS ..................6 2) FABRICATION OF GIRDER(S) FOR BRIDGE BEAM WITH CAPPING CHANNEL (AS REQUIRED) .............................9 STEP 1: CUT GIRDER AND C-CHANNEL (AS REQUIRED) ..............STEP 2: CHECK CAMBER (AS REQUIRED) ....................10 STEP 3: GIRDER AND C-CHANNEL WELDING AT END (AS REQUIRED) .......... - Page 3 TABLE OF CONTENTS STEP 14: MOUNTING CROSS SHAFT, BEARING AND COUPLING ON CROSS SHAFT SUPPORT ....................35 STEP 15: CHECKING HORIZONTAL ALIGNMENT OF THE CROSS SHAFT ......... 36 STEP 16: ASSEMBLING COUPLING WITH CROSS SHAFT ..............37 4) END STOP ASSEMBLY ..........................38 4.A) END STOP ASSEMBLY .........................
- Page 4 TABLE OF CONTENTS STEP 14: PUSH-BUTTON PENDANT ASSEMBLY ..................61 STEP 15: BRIDGE MOTOR CABLE CONNECTION .................. 62 STEP 16: BRIDGE TOW ARM INSTALLATION ................... 63 STEP 17: BRIDGE TRAVEL LIMIT SWITCH INSTALLATION ..............64 STEP 18: FESTOON RUNWAY CHECKING ....................65 STEP 19: ADDING CABLE TIES ........................
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Page 5: Safety Precautions
CHAPTER 1 SAFETY PRECAUTIONS Safety Alert Symbols Throughout this manual are steps and procedures that can prevent hazardous situations; the following symbols are used to identify the degree or level of hazard seriousness. DANGER, WARNING, CAUTION AND NOTICE Symbol Description Danger Indicates an imminently hazardous situation which, if not avoided, will result in death or... -
Page 6: Important Information And Warnings
IMPORTANT INFORMATION AND WARNINGS Failure to read and comply with any of the limitations noted herein can result in serious bodily injury or death, and/or property damage. Equipment described in this manual is not designed for and should not be used for lifting, supporting, or transporting humans. - Page 7 Read and observe the instructions and warnings contained in this manual. Read and observe any instructions and warning tags attached to the hoist. Check for any damage to the components during shipment. If any damage has occurred, place a claim with the carrier. DO NOT install a damaged components. Check wire rope for damage and proper spooling on the drum.
- Page 8 If hoist has a trolley, check that the crane bridge beam is level, straight, and clean. Check that trolley stops are installed, or install trolley stops, at the open end or ends of the beam to prevent the trolley from traveling off the beam. Avoid using trolley stops that engage trolley wheels.
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Page 9: Fabrication Of Girder(S) For Bridge Beam With Capping Channel (As Required)
CHAPTER 2 FABRICATION OF GIRDER(S) FOR BRIDGE BEAM WITH CAPPING CHANNEL (AS REQUIRED) P/N: C11746310 REV. AB June 2022... -
Page 10: Step 1: Cut Girder And C-Channel (As Required)
STEP 1: CUT GIRDER AND C-CHANNEL (AS REQUIRED) WARNING Selection of structural steel beams must be verified by qualified engineer. IT IS IMPORTANT THAT ALL INSTRUCTIONS BE FOLLOWED AND THAT COMPONENT APPLICATION LIMITS NOT BE EXCEEDED. Check your configuration to see if a capping channel is required. CUT LENGTH TO BE DETERMINED BY SPAN LENGTH STEP 2: CHECK CAMBER (AS REQUIRED) -
Page 11: Step 3: Girder And C-Channel Welding At End (As Required)
STEP 3: GIRDER AND C-CHANNEL WELDING AT END (AS REQUIRED) NOTICE Assembly of beam and truck requires welding. IT IS EXTREMELY IMPORTANT TO THE SAFETY OF THIS BRIDGE THAT THIS WELDING BE DONE BY A COMPETENT WELL-TRAINED WELDER. It is our strong recommendation that the welder used in this construction be qualified as prescribed by the American Welding Society (AWS) -
Page 12: Step 5: Girder And C-Channel Welding (As Required)
STEP 5: GIRDER AND C-CHANNEL WELDING (AS REQUIRED) NOTICE Assembly of beam and truck requires welding. IT IS EXTREMELY IMPORTANT TO THE SAFETY OF THIS BRIDGE THAT THIS WELDING BE DONE BY A COMPETENT WELL-TRAINED WELDER. It is our strong recommendation that the welder used in this construction be qualified as prescribed by the American Welding Society (AWS) -
Page 13: Assembling Bridge Girder To Underhung End Trucks
CHAPTER 3 ASSEMBLING BRIDGE GIRDER TO UNDERHUNG END TRUCKS P/N: C11746310 REV. AB June 2022... -
Page 14: A) Plan View
3.A) PLAN VIEW P/N: C11746310 REV. AB June 2022... -
Page 15: B) Dimension Details For Girder Length Calculation
3.B) DIMENSION DETAILS FOR GIRDER LENGTH CALCULATION DISTANCE BETWEEN INTERNAL SPACE LENGTH OF DRIVE LENGTH OF CENTER OF END TRUCK LENGTH OF FIRST TRUCKS BETWEEN END SHAFT FROM END SECOND CROSS AND EXTREME END OF CROSS SHAFT CONFIGURATION TRUCK CHANNELS TRUCK CENTER SHAFT ITS TOW PLATE... -
Page 16: C) Underhung End Truck Types
3.C) UNDERHUNG END TRUCK TYPES P/N: C11746310 REV. AB June 2022... -
Page 17: D) Formed Channel End Truck
3.D) FORMED CHANNEL END TRUCK WARNING Alterations or modifications of equipment and use of non-factory repair parts can lead to dangerous operation and injury. TO AVOID INJURY: DO NOT alter or modify equipment. DO NOT use equipment to lift, support or otherwise transport people. -
Page 18: E) Rolled Channel End Truck
3.E) ROLLED CHANNEL END TRUCK P/N: C11746310 REV. AB June 2022... -
Page 19: Step 1: Bridge Girder Length (As Required)
STEP 1: BRIDGE GIRDER LENGTH (AS REQUIRED) * CHANNEL MUST BE A MINIMUM LENGTH OF THE SPAN MINUS 4'-0" * GIRDER LENGTH TO BE DETERMINED BY SPAN LENGTH RATED LOAD MINIMUM LENGTH (Tons) OF BEAMS REQUIRED 3 Ton KIT SPAN + (1' - 4-1/2") 5 Ton KIT SPAN + (1' - 6-3/4") STEP 2:... -
Page 20: Step 3: Marking Centerlines And Hole Locations On End Truck - Uhfc
STEP 3: MARKING CENTERLINES AND HOLE LOCATIONS ON END TRUCK – UHFC MARKING HOLE LOCATION CENTERLINES ON THE GIRDER BRIDGE GIRDER FLANGE WIDTH 3-3/8" 2" 3-5/8" THRU 4" 2-1/4" 4-5/8" THRU 5-1/4" 2-3/4" 5-1/2" THRU 6-3/4" 3-1/2" * REFER TO PLAN VIEW (PAGE 14) FOR DIMENSIONAL CALCULATIONS FOR GIRDER. -
Page 21: Step 3A: Marking Centerlines And Hole Locations On End Truck - Uhrc
STEP 3A: MARKING CENTERLINES AND HOLE LOCATIONS ON END TRUCK – UHRC MARKING HOLE LOCATION CENTERLINES ON THE GIRDER BRIDGE GIRDER FLANGE WIDTH 3-3/8" 2" 3-5/8" THRU 4" 2-1/4" 4-5/8" THRU 5-1/4" 2-3/4" * REFER TO PLAN VIEW (PAGE 14) FOR DIMENSIONAL 5-1/2"... -
Page 22: Step 4: Locate & Align End Trucks - Uhfc
STEP 4: LOCATE & ALIGN END TRUCKS – UHFC P/N: C11746310 REV. AB June 2022... -
Page 23: Step 4A: Locate & Align End Trucks - Uhrc
STEP 4A: LOCATE & ALIGN END TRUCKS – UHRC P/N: C11746310 REV. AB June 2022... -
Page 24: Step 5: Check Squareness Between End Trucks
STEP 5: CHECK SQUARENESS BETWEEN END TRUCKS FOR SQUARENESS BETWEEN END TRUCKS: (D1~D2) ≤ 1/32" NOTICE D1 & D2 - DIAGONAL MEASUREMENTS The crane builder and user are responsible for marking the crane and also for checking for compliance with all local, state and national codes. -
Page 25: Step 7: Drilling Holes On End Trucks And Girder Flange - Uhfc
STEP 7: DRILLING HOLES ON END TRUCKS AND GIRDER FLANGE – UHFC RATED LOAD HOLE DIAMETER BOLT (TONS) “ØD” DIAMETER 3 TON KIT 41/64" 5/8" 5 TON KIT 49/64" 3/4" P/N: C11746310 REV. AB June 2022... -
Page 26: Step 7A: Drilling Holes On End Trucks And Girder Flange - Uhrc
STEP 7A: DRILLING HOLES ON END TRUCKS AND GIRDER FLANGE – UHRC RATED LOAD HOLE DIAMETER BOLT (TONS) “ØD” DIAMETER 3 TON KIT 41/64" 5/8" 5 TON KIT 49/64" 3/4" P/N: C11746310 REV. AB June 2022... -
Page 27: Step 8: Assemble Girder To End Trucks - Uhfc
STEP 8: ASSEMBLE GIRDER TO END TRUCKS – UHFC • IF “X” DISTANCE IS LESS THAN 1", REMOVE FLAT WASHER UNDER THE BOLT HEAD. • IF “X” DISTANCE IS GREATER THAN 1-1/4", ADD A SECOND FLAT WASHER UNDER THE BOLT HEAD. TIGHTEN ALL BOLTS AND NUTS PROVIDED IN KIT USING THE TURN-OF-NUT METHOD. -
Page 28: Step 8A: Assemble Girder To End Trucks - Uhrc
STEP 8A: ASSEMBLE GIRDER TO END TRUCKS – UHRC • IF “X” DISTANCE IS LESS THAN 1", REMOVE FLAT WASHER UNDER THE BOLT HEAD. • IF “X” DISTANCE IS GREATER THAN 1-1/4", ADD A SECOND FLAT WASHER UNDER THE BOLT HEAD. TIGHTEN ALL BOLTS AND NUTS PROVIDED IN KIT USING THE TURN-OF-NUT METHOD. -
Page 29: Step 9: End Stop Installation
STEP 9: END STOP INSTALLATION TROLLEY STOP BRIDGE BEAM ANGLE SIZE* FLANGE WIDTH (4 REQ’D.) 3-3/8" 2" 3 x 3 x 3/8 1" 2" 4" 3-5/8" THRU 4" 2-1/4" 3-1/2 x 3 x 3/8 1" 3" 5" 4-5/8" THRU 5-1/4" 2-3/4"... -
Page 30: Step 10: Assembling Motor And Gear Reducer With End Truck
STEP 10: ASSEMBLING MOTOR AND GEAR REDUCER WITH END TRUCK P/N: C11746310 REV. AB June 2022... -
Page 31: Step 10A: Uhrc End Truck A4 Drive Installation
STEP 10A: UHRC END TRUCK A4 DRIVE INSTALLATION P/N: C11746310 REV. AB June 2022... -
Page 32: Step 11: Assembling Groove Pin With End Truck And Support Bracket
STEP 11: ASSEMBLING GROOVE PIN WITH END TRUCK AND SUPPORT BRACKET IT IS ALLOWABLE TO USE A DRIVE ON EACH TRUCK AND ELIMINATE THE CROSS SHAFT. IN THIS CASE, THE UPCOMING STEPS 12, 13, 14 & 15 ARE NOT REQUIRED. P/N: C11746310 REV. -
Page 33: Step 12: Locate And Drill Holes For Cross Arm Support
STEP 12: LOCATE AND DRILL HOLES FOR CROSS ARM SUPPORT CROSS ARM SUPPORTS NOT REQUIRED IF YOUR CONFIGURATION INCLUDES DUAL ENDTRUCK MOTORS. YOU MAY SKIP TO PAGE 37. RATED LOAD HOLE DIAMETER BOLT (TONS) “ØD” DIAMETER * REFER TO PLAN VIEW (PAGE 14) FOR NUMBER OF 3 TON KIT 41/64"... -
Page 34: Step 13: Mounting Cross Shaft Support
STEP 13: MOUNTING CROSS SHAFT SUPPORT * LOOSELY BOLT THE CROSS SHAFT SUPPORTS TO THE BRIDGE BEAM. P/N: C11746310 REV. AB June 2022... -
Page 35: Step 14: Mounting Cross Shaft, Bearing And Coupling
STEP 14: MOUNTING CROSS SHAFT, BEARING AND COUPLING ON CROSS SHAFT SUPPORT P/N: C11746310 REV. AB June 2022... -
Page 36: Step 15: Checking Horizontal Alignment Of The Cross Shaft
STEP 15: CHECKING HORIZONTAL ALIGNMENT OF THE CROSS SHAFT P/N: C11746310 REV. AB June 2022... -
Page 37: Step 16: Assembling Coupling With Cross Shaft
STEP 16: ASSEMBLING COUPLING WITH CROSS SHAFT P/N: C11746310 REV. AB June 2022... -
Page 38: End Stop Assembly
CHAPTER 4 END STOP ASSEMBLY P/N: C11746310 REV. AB June 2022... -
Page 39: A) End Stop Assembly
4.A) END STOP ASSEMBLY TIGHTEN TO 48 FT-LB WARNING Trolley stops (clip angles) or end stop assemblies must be installed on both ends of the bridge beam to prevent hoist trolley from running off the end of the beam, which could result in injury to the operator and others and damage to the load and other property. -
Page 40: Mounting Hoist On Girder
CHAPTER 5 MOUNTING HOIST GIRDER P/N: C11746310 REV. AB June 2022... -
Page 41: Yk/Sk Hoist Installation
YK/SK HOIST INSTALLATION STEP 1: PREPARATION FOR MOUNTING HOIST ON GIRDER CAUTION Prior to installing the hoist, check for any damage to the hoist during shipment. DO NOT install a damaged hoist. P/N: C11746310 REV. AB June 2022... -
Page 42: Step 2: Mounting Hoist On Girder
STEP 2: MOUNTING HOIST ON GIRDER P/N: C11746310 REV. AB June 2022... -
Page 43: Y80/800 Hoist Installation
Y80/800 HOIST INSTALLATION STEP 1: PREPARATION FOR MOUNTING HOIST ON GIRDER P/N: C11746310 REV. AB June 2022... -
Page 44: Step 2: Mounting Hoist On Girder
STEP 2: MOUNTING HOIST ON GIRDER P/N: C11746310 REV. AB June 2022... -
Page 45: Festoon System Installation
CHAPTER 6 FESTOON SYSTEM INSTALLATION P/N: C11746310 REV. AB June 2022... -
Page 46: A) Plan View
6.A) PLAN VIEW P/N: C11746310 REV. AB June 2022... -
Page 47: Step 1: Clamping Cross Arm & Control Box Support Rails
STEP 1: CLAMPING CROSS ARM & CONTROL BOX SUPPORT RAILS WARNING Check for any damage to the crane kit components during shipment. DO NOT install damaged crane kit components. STEP 2: SPACING FOR CROSS ARMS/SUPPORT RAILS P/N: C11746310 REV. AB June 2022... -
Page 48: Step 3: C-Rail Mounting
STEP 3: C-RAIL MOUNTING P/N: C11746310 REV. AB June 2022... -
Page 49: Step 4: C-Rail Joint Assembly
STEP 4: C-RAIL JOINT ASSEMBLY P/N: C11746310 REV. AB June 2022... -
Page 50: Step 5: Mounting Bridge Panel
STEP 5: MOUNTING BRIDGE PANEL P/N: C11746310 REV. AB June 2022... -
Page 51: Step 6: End Stop Assembly
STEP 6: END STOP ASSEMBLY P/N: C11746310 REV. AB June 2022... -
Page 52: Step 7: Hoist Cable Assembly
STEP 7: HOIST CABLE ASSEMBLY P/N: C11746310 REV. AB June 2022... -
Page 53: Step 8: Control Pendant Cable Assembly
STEP 8: CONTROL PENDANT CABLE ASSEMBLY P/N: C11746310 REV. AB June 2022... -
Page 54: Yk/Sk Tow Arm
YK/SK TOW ARM STEP 9: TOW ARM KIT PREPARATION TOW ARM ADJUSTMENTS RIGHT ISO VIEW LEFT ISO VIEW P/N: C11746310 REV. AB June 2022... -
Page 55: Y80/800 Tow Arm
Y80/800 TOW ARM STEP 9: TOW ARM KIT PREPARATION TOW ARM ADJUSTMENTS RIGHT ISO VIEW LEFT ISO VIEW P/N: C11746310 REV. AB June 2022... -
Page 56: Step 10: Tow Arm Kit Installation - Yk/Sk
STEP 10: TOW ARM KIT INSTALLATION – YK/SK WARNING Alterations or modifications of equipment and use of non-factory repair parts can lead to dangerous operation and injury. TO AVOID INJURY: DO NOT alter or modify equipent. DO NOT use equipment to lift, support or otherwise transport people. -
Page 57: Step 10: Tow Arm Kit Installation - Y80/800
STEP 10: TOW ARM KIT INSTALLATION – Y80/800 P/N: C11746310 REV. AB June 2022... -
Page 58: Step 11: Cable Tray Installation
STEP 11: CABLE TRAY INSTALLATION NOTE: WIRE TRAY IS ONLY INCLUDED WITH YK/SK PRODUCTS P/N: C11746310 REV. AB June 2022... -
Page 59: Step 12: Placing Festoon Cables On Cable Tray
STEP 12: PLACING FESTOON CABLES ON CABLE TRAY NOTE: WIRE TRAY IS ONLY INCLUDED WITH YK/SK PRODUCTS P/N: C11746310 REV. AB June 2022... -
Page 60: Step 13: Festoon Cable Connection
STEP 13: FESTOON CABLE CONNECTION DANGER Disconnect power and lockout disconnecting means before connecting power supply to hoist. WARNING DO NOT UNPLUG CONNECTORS WHILE CIRCUIT IS ENERGIZED. BEFORE PLUGGING IN CONNECTORS REMOVE POWER FROM SYSTEM. P/N: C11746310 REV. AB June 2022... -
Page 61: Step 14: Push-Button Pendant Assembly
STEP 14: PUSH-BUTTON PENDANT ASSEMBLY WARNING DO NOT UNPLUG CONNECTORS WHILE CIRCUIT IS ENERGIZED. BEFORE PLUGGING IN CONNECTORS REMOVE POWER FROM SYSTEM. P/N: C11746310 REV. AB June 2022... -
Page 62: Step 15: Bridge Motor Cable Connection
STEP 15: BRIDGE MOTOR CABLE CONNECTION WARNING DO NOT UNPLUG CONNECTORS WHILE CIRCUIT IS ENERGIZED. BEFORE PLUGGING IN CONNECTORS REMOVE POWER FROM SYSTEM. P/N: C11746310 REV. AB June 2022... -
Page 63: Step 16: Bridge Tow Arm Installation
STEP 16: BRIDGE TOW ARM INSTALLATION WARNING The trolley frame and bridge frame shall not be DANGER considered electrically grounded through the bridge and trolley wheels and its respective Disconnect power and lockout tracks. A fourth runway conductor and disconnecting means before collector shall be provided for grounding. -
Page 64: Step 17: Bridge Travel Limit Switch Installation
STEP 17: BRIDGE TRAVEL LIMIT SWITCH INSTALLATION NOTE: BRIDGE TRAVEL LIMIT SWITCH ONLY WARNING INCLUDED WITH YK/SK PRODUCTS Damage to the hoist, a dropped load, and injury may result if limit switches fail due to improper use. Under normal operating conditions, stop hoist travel before engaging limit switches. -
Page 65: Step 18: Festoon Runway Checking
STEP 18: FESTOON RUNWAY CHECKING WARNING Make sure all INSTALLATIONS AND START-UP INSPECTIONS have been made in accordance with instructions furnished with the HOIST and TROLLEY before turning on the power. WARNING Trolley stops (clip angles) or end stop assemblies must be installed on both ends of the bridge beam to prevent hoist trolley from running off the end of the beam, which could result in injury to the operator and others and damage to the load and other property. -
Page 66: Radio Control & Horn Installation For Festoon System
CHAPTER 7 RADIO CONTROL & HORN INSTALLATION FOR FESTOON SYSTEM P/N: C11746310 REV. AB June 2022... -
Page 67: Step 1: Cross Arm & Bracket Installation For Radio Control
STEP 1: CROSS ARM & BRACKET INSTALLATION FOR RADIO CONTROL NOTE: MOUNTING BRACKET AND CROSS ARM ONLY INCLUDED WITH YK/SK PRODUCTS RADIO CONTROL SYSTEM BRACKET INSTALLATION P/N: C11746310 REV. AB June 2022... -
Page 68: Step 2: Radio Control System Installation
STEP 2: RADIO CONTROL SYSTEM INSTALLATION WARNING DO NOT UNPLUG CONNECTORS WHILE CIRCUIT IS ENERGIZED. BEFORE PLUGGING IN CONNECTORS REMOVE POWER FROM SYSTEM. P/N: C11746310 REV. AB June 2022... -
Page 69: Step 3: Horn Installation (Internal/External)
STEP 3: HORN INSTALLATION (INTERNAL/EXTERNAL) DANGER Disconnect power and lockout disconnecting means before installing internal or external horn. P/N: C11746310 REV. AB June 2022... - Page 70 NOTES: P/N: C11746310 REV. AB June 2022...
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Page 71: Warranty
WARRANTY LIMITATION OF WARRANTIES, REMEDIES, AND DAMAGES INDEMNIFICATION AND SAFE OPERATION Buyer shall comply with and require its employees to comply with directions set C. IN NO EVENT SHALL SELLER BE LIABLE TO BUYER OR ANY THIRD forth in instructions and manuals furnished by Seller and shall use and require its PARTY WITH RESPECT TO ANY GOOD OR REPLACEMENT PART, employees to follow such instructions and manuals and to use reasonable care in WHETHER, IN CONTRACT, TORT OR OTHER THEORY OF LAW, FOR...