Yale SHAW-BOX YK Series, Assembly & Instruction Manual

Page: 2 / 71

P/N: C11746310 REV. AB June 2022
2
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) .....................................................................
10
STEP 2: CHECK CAMBER (AS REQUIRED) ..............................................................................................10
STEP 3: GIRDER AND C-CHANNEL WELDING AT END (AS REQUIRED) .............................................11
STEP 4: CLAMPING GIRDER AND C-CHANNEL (AS REQUIRED) .........................................................11
STEP 5: GIRDER AND C-CHANNEL WELDING (AS REQUIRED) ...........................................................12
STEP 6: CHECK CAMBER AFTER WELDING (AS REQUIRED) ..............................................................12
3) ASSEMBLING BRIDGE GIRDER TO UNDERHUNG END TRUCKS ....................................................13
3.A) PLAN VIEW ............................................................................................................................................14
3.B) DIMENSION DETAILS FOR GIRDER LENGTH CALCULATION ......................................................15
3.C) UNDERHUNG END TRUCK TYPES ....................................................................................................16
3.D) FORMED CHANNEL END TRUCK ......................................................................................................17
3.E) ROLLED CHANNEL END TRUCK ........................................................................................................18
STEP 1: BRIDGE GIRDER LENGTH (AS REQUIRED) .............................................................................19
STEP 2: MARKING CENTERLINE ON THE GIRDER (AS REQUIRED) ..................................................19
STEP 3: MARKING CENTERLINES AND HOLE LOCATIONS ON END TRUCK – UHFC .....................20
STEP 3A: MARKING CENTERLINES AND HOLE LOCATIONS ON END TRUCK – UHRC...................21
STEP 4: LOCATE & ALIGN END TRUCKS – UHFC ...................................................................................22
STEP 4A: LOCATE & ALIGN END TRUCKS – UHRC ................................................................................23
STEP 5: CHECK SQUARENESS BETWEEN END TRUCKS ....................................................................24
STEP 6: CHECK SPAN (CENTER TO CENTER) OF END TRUCKS ........................................................24
STEP 7: DRILLING HOLES ON END TRUCKS AND GIRDER FLANGE – UHFC ...................................25
STEP 7A: DRILLING HOLES ON END TRUCKS AND GIRDER FLANGE – UHRC ................................26
STEP 8: ASSEMBLE GIRDER TO END TRUCKS – UHFC........................................................................27
STEP 8A: ASSEMBLE GIRDER TO END TRUCKS – UHRC .....................................................................28
STEP 9: END STOP INSTALLATION ...........................................................................................................29
STEP 10: ASSEMBLING MOTOR AND GEAR REDUCER WITH END TRUCK ......................................30
STEP 10A: UHRC END TRUCK A4 DRIVE INSTALLATION ......................................................................31
STEP 11: ASSEMBLING GROOVE PIN WITH END TRUCK AND SUPPORT BRACKET ......................32
STEP 12: LOCATE AND DRILL HOLES FOR CROSS ARM SUPPORT ...................................................33
STEP 13: MOUNTING CROSS SHAFT SUPPORT ....................................................................................34