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) ..........
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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 .........................
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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 ........................
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...
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.
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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.
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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.
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)
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)
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)
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...
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.
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:...
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.
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.
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.
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.
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"...
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.
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...
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...
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.
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...
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...
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...
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.
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.
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.
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...
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...
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...
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NOTES: P/N: C11746310 REV. AB June 2022...
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...