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P/N: C11746310 REV. AB

June 2022

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

serious injury

and property damage.

Warning

Indicates an imminently hazardous situation

which, if not avoided,

could result in death

or serious injury

and property damage.

Caution

Indicates a potentially hazardous situation

which, if not avoided,

may result in minor or

moderate injury

and property damage.

Notice

Notifies people of installation, operation or

maintenance information which is important

but not directly hazard-related.

WARNING

Failure to read and comply with any of the limitations noted in this

manual can result in serious bodily injury or death, and/or property

damage.

Содержание SHAW-BOX 800 Series

Страница 1: ...P N C11746310 YK SK Y80 800 Series CRANE KIT ASSEMBLY INSTRUCTION MANUAL B UHSG ASSEMBLY INSTRUCTION MANUAL www columbusmckinnon com P N C11746310 REV AB June 2022 ...

Страница 2: ... 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 STE...

Страница 3: ...ER 44 6 FESTOON SYSTEM INSTALLATION 45 6 A PLAN VIEW 46 STEP 1 CLAMPING CROSS ARM CONTROL BOX SUPPORT RAILS 47 STEP 2 SPACING FOR CROSS ARMS SUPPORT RAILS 47 STEP 3 C RAIL MOUNTING 48 STEP 4 C RAIL JOINT ASSEMBLY 49 STEP 5 MOUNTING BRIDGE PANEL 50 STEP 6 END STOP ASSEMBLY 51 STEP 7 HOIST CABLE ASSEMBLY 52 STEP 8 CONTROL PENDANT CABLE ASSEMBLY 53 YK SK TOW ARM 54 STEP 9 TOW ARM KIT PREPARATION 54 T...

Страница 4: ...3 STEP 17 BRIDGE TRAVEL LIMIT SWITCH INSTALLATION 64 STEP 18 FESTOON RUNWAY CHECKING 65 STEP 19 ADDING CABLE TIES 65 7 RADIO CONTROL HORN INSTALLATION FOR FESTOON SYSTEM 66 STEP 1 CROSS ARM BRACKET INSTALLATION FOR RADIO CONTROL 67 STEP 2 RADIO CONTROL SYSTEM INSTALLATION 68 STEP 3 HORN INSTALLATION INTERNAL EXTERNAL 69 8 WARRANTY 71 TABLE OF CONTENTS ...

Страница 5: ... in death or serious injury and property damage Warning Indicates an imminently hazardous situation which if not avoided could result in death or serious injury and property damage Caution Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury and property damage Notice Notifies people of installation operation or maintenance information which is im...

Страница 6: ... comply with applicable crane design and safety standards The crane designer crane manufacturer or user is responsible for finishing these additional items for compliance Refer to ASME B30 11 Safety Standard for Underhung Cranes If a below the hook lifting device or sling is used with a hoist refer to ASME B30 9 Safety Standard for Slings or ASME B30 20 Safety Standard for Below the Hook Lifting D...

Страница 7: ...control panel nameplate 9 While performing electric repairs maintenance make sure that there is no load on the hook turn off the power supply switch and prevent unauthorized personnel from switching it on 9 Check the loading hook for cracks and deformations Verify the proper operation of the release latch 9 The bridge frame shall not be considered electrically grounded through the end truck wheels...

Страница 8: ...wer source for lifting or lowering persons Never lift and move loads over personnel 9 Use warning signs and barriers on the floor beneath the crane or area where the hoist will be installed WARNING Damage to the hoist a droped load and injury may result if limit switches fail due to improper use Under normal operating conditions stop hoist travel before engaging limit switches Limit switches are s...

Страница 9: ...P N C11746310 REV AB June 2022 9 CHAPTER 2 FABRICATION OF GIRDER S FOR BRIDGE BEAM WITH CAPPING CHANNEL AS REQUIRED ...

Страница 10: ...n to see if a capping channel is required CUT LENGTH TO BE DETERMINED BY SPAN LENGTH STEP 2 CHECK CAMBER 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 ...

Страница 11: ...mbly 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 Structural Welding Code Steel D1 1 2008 and Specification for Welding Industrial and Mill Cranes D14 1 2005...

Страница 12: ...OF GIRDER AT LIVE LOAD 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 Structural Welding Code Steel D1 1 2008 and Specification for Welding Ind...

Страница 13: ...P N C11746310 REV AB June 2022 13 CHAPTER 3 ASSEMBLING BRIDGE GIRDER TO UNDERHUNG END TRUCKS ...

Страница 14: ...P N C11746310 REV AB June 2022 14 3 A PLAN VIEW NOTE CROSS SHAFT IS NOT REQUIRED IF DUAL ENDTRUCK MOTORS ARE PART OF YOUR CONFIGURATION ...

Страница 15: ... 9 17 1 3 8 905368W1 905369W1 9 1 2 10 1 8 1 3 1 4 2 6 3 4 14 7 3 4 17 2 5 8 905368W2 905369W2 10 3 4 1 0 5 8 1 4 1 2 2 9 1 4 14 6 1 2 17 3 7 8 905368PT 905369PT 8 1 4 7 5 8 1 2 2 4 1 4 14 9 17 1 3 8 905368SR 905369SR 8 1 4 7 5 8 1 2 2 4 1 4 14 9 17 1 3 8 905524 905525 9 3 8 8 7 8 1 2 5 8 2 5 1 2 14 9 17 2 5 8 905524W1 905525W1 10 11 16 11 1 2 1 3 15 16 2 8 1 8 14 7 3 4 17 4 905524W2 905525W2 11 1...

Страница 16: ...P N C11746310 REV AB June 2022 16 3 C UNDERHUNG END TRUCK TYPES ...

Страница 17: ...rations 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 DO NOT suspend unattended loads over people ...

Страница 18: ...P N C11746310 REV AB June 2022 18 3 E ROLLED CHANNEL END TRUCK ...

Страница 19: ...IMUM LENGTH OF THE SPAN MINUS 4 0 GIRDER LENGTH TO BE DETERMINED BY SPAN LENGTH STEP 2 MARKING CENTERLINE ON THE GIRDER AS REQUIRED Check your font configuration to see if a capping channel is required RATED LOAD Tons MINIMUM LENGTH OF BEAMS REQUIRED 3 Ton KIT SPAN 1 4 1 2 5 Ton KIT SPAN 1 6 3 4 ...

Страница 20: ... HOLE LOCATIONS ON END TRUCK UHFC MARKING HOLE LOCATION CENTERLINES ON THE GIRDER REFER TO PLAN VIEW PAGE 14 FOR DIMENSIONAL CALCULATIONS FOR GIRDER BRIDGE GIRDER FLANGE WIDTH A 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 7 THRU 7 5 8 4 ...

Страница 21: ...D HOLE LOCATIONS ON END TRUCK UHRC MARKING HOLE LOCATION CENTERLINES ON THE GIRDER REFER TO PLAN VIEW PAGE 14 FOR DIMENSIONAL CALCULATIONS FOR GIRDER BRIDGE GIRDER FLANGE WIDTH A 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 7 THRU 7 5 8 4 ...

Страница 22: ...P N C11746310 REV AB June 2022 22 STEP 4 LOCATE ALIGN END TRUCKS UHFC ...

Страница 23: ...P N C11746310 REV AB June 2022 23 STEP 4A LOCATE ALIGN END TRUCKS UHRC ...

Страница 24: ...CKS FOR SQUARENESS BETWEEN END TRUCKS D1 D2 1 32 D1 D2 DIAGONAL MEASUREMENTS STEP 6 CHECK SPAN CENTER TO CENTER OF END TRUCKS NOTICE The crane builder and user are responsible for marking the crane and also for checking for compliance with all local state and national codes ...

Страница 25: ...P N C11746310 REV AB June 2022 25 STEP 7 DRILLING HOLES ON END TRUCKS AND GIRDER FLANGE UHFC RATED LOAD TONS HOLE DIAMETER ØD BOLT DIAMETER 3 TON KIT 41 64 5 8 5 TON KIT 49 64 3 4 ...

Страница 26: ...P N C11746310 REV AB June 2022 26 STEP 7A DRILLING HOLES ON END TRUCKS AND GIRDER FLANGE UHRC RATED LOAD TONS HOLE DIAMETER ØD BOLT DIAMETER 3 TON KIT 41 64 5 8 5 TON KIT 49 64 3 4 ...

Страница 27: ...URFACES ARE BROUGHT INTO FULL CONTACT WITH EACH OTHER THEN MAKE A FINAL 1 2 TURN ON ALL BOLTS AND NUTS CAUTION DO NOT SUBSTITUTE STANDARD BOLTS AND NUTS FOR THE SPECIAL TRUCK CONNECTING BOLTS AND NUTS FURNISHED WITH KIT ONLY HIGH STRENGTH BOLTS S A E GRADE 5 ANO ELASTIC COLLARARED SELF LOCKING NUTS AS FURNISHED ARE ACCEPTABLE FOR ATTACHING TRUCK FRAMES TO BRIDGE BEAM HIGH STRENGTH BOLTS ARE IDENTI...

Страница 28: ...SURFACES ARE BROUGHT INTO FULL CONTACT WITH EACH OTHER THEN MAKE A FINAL 1 2 TURN ON ALL BOLTS AND NUTS CAUTION DO NOT SUBSTITUTE STANDARD BOLTS AND NUTS FOR THE SPECIAL TRUCK CONNECTING BOLTS AND NUTS FURNISHED WITH KIT ONLY HIGH STRENGTH BOLTS S A E GRADE 5 ANO ELASTIC COLLARARED SELF LOCKING NUTS AS FURNISHED ARE ACCEPTABLE FOR ATTACHING TRUCK FRAMES TO BRIDGE BEAM HIGH STRENGTH BOLTS ARE IDENT...

Страница 29: ...E TO AVOID INJURY AND DAMAGE INSTALL END STOPS ON BOTH ENDS OF BEAMS TO PREVENT HOIST TROLLEY FROM RUNNING OFF END OF BEAM BRIDGE BEAM FLANGE WIDTH A TROLLEY STOP ANGLE SIZE 4 REQ D B C 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 4 x 3 x 3 8 1 1 2 3 5 5 1 2 THRU 6 3 4 3 1 2 5 x 3 x 3 8 1 3 4 3 5 7 THRU 7 5 8 4 6 x 3 x 3 8 1 3 4 4 6 ...

Страница 30: ...P N C11746310 REV AB June 2022 30 STEP 10 ASSEMBLING MOTOR AND GEAR REDUCER WITH END TRUCK ...

Страница 31: ...P N C11746310 REV AB June 2022 31 STEP 10A UHRC END TRUCK A4 DRIVE INSTALLATION ...

Страница 32: ...V AB June 2022 32 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 ...

Страница 33: ...ORT REFER TO PLAN VIEW PAGE 14 FOR NUMBER OF CROSS ARMS AND ITS POSITION DIMENSION DETAILS CROSS ARM SUPPORTS NOT REQUIRED IF YOUR CONFIGURATION INCLUDES DUAL ENDTRUCK MOTORS YOU MAY SKIP TO PAGE 37 RATED LOAD TONS HOLE DIAMETER ØD BOLT DIAMETER 3 TON KIT 41 64 5 8 5 TON KIT 49 64 3 4 ...

Страница 34: ...P N C11746310 REV AB June 2022 34 STEP 13 MOUNTING CROSS SHAFT SUPPORT LOOSELY BOLT THE CROSS SHAFT SUPPORTS TO THE BRIDGE BEAM ...

Страница 35: ...P N C11746310 REV AB June 2022 35 STEP 14 MOUNTING CROSS SHAFT BEARING AND COUPLING ON CROSS SHAFT SUPPORT ...

Страница 36: ...P N C11746310 REV AB June 2022 36 STEP 15 CHECKING HORIZONTAL ALIGNMENT OF THE CROSS SHAFT ...

Страница 37: ...P N C11746310 REV AB June 2022 37 STEP 16 ASSEMBLING COUPLING WITH CROSS SHAFT ...

Страница 38: ...P N C11746310 REV AB June 2022 38 CHAPTER 4 END STOP ASSEMBLY ...

Страница 39: ...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 ...

Страница 40: ...P N C11746310 REV AB June 2022 40 CHAPTER 5 MOUNTING HOIST ON GIRDER ...

Страница 41: ...0 REV AB June 2022 41 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 ...

Страница 42: ...P N C11746310 REV AB June 2022 42 STEP 2 MOUNTING HOIST ON GIRDER ...

Страница 43: ...P N C11746310 REV AB June 2022 43 Y80 800 HOIST INSTALLATION STEP 1 PREPARATION FOR MOUNTING HOIST ON GIRDER ...

Страница 44: ...P N C11746310 REV AB June 2022 44 STEP 2 MOUNTING HOIST ON GIRDER ...

Страница 45: ...P N C11746310 REV AB June 2022 45 CHAPTER 6 FESTOON SYSTEM INSTALLATION ...

Страница 46: ...P N C11746310 REV AB June 2022 46 6 A PLAN VIEW ...

Страница 47: ...une 2022 47 STEP 1 CLAMPING CROSS ARM CONTROL BOX SUPPORT RAILS STEP 2 SPACING FOR CROSS ARMS SUPPORT RAILS WARNING Check for any damage to the crane kit components during shipment DO NOT install damaged crane kit components ...

Страница 48: ...P N C11746310 REV AB June 2022 48 STEP 3 C RAIL MOUNTING ...

Страница 49: ...P N C11746310 REV AB June 2022 49 STEP 4 C RAIL JOINT ASSEMBLY ...

Страница 50: ...P N C11746310 REV AB June 2022 50 STEP 5 MOUNTING BRIDGE PANEL ...

Страница 51: ...P N C11746310 REV AB June 2022 51 STEP 6 END STOP ASSEMBLY ...

Страница 52: ...P N C11746310 REV AB June 2022 52 STEP 7 HOIST CABLE ASSEMBLY ...

Страница 53: ...P N C11746310 REV AB June 2022 53 STEP 8 CONTROL PENDANT CABLE ASSEMBLY ...

Страница 54: ...P N C11746310 REV AB June 2022 54 YK SK TOW ARM STEP 9 TOW ARM KIT PREPARATION TOW ARM ADJUSTMENTS LEFT ISO VIEW RIGHT ISO VIEW ...

Страница 55: ...P N C11746310 REV AB June 2022 55 Y80 800 TOW ARM STEP 9 TOW ARM KIT PREPARATION TOW ARM ADJUSTMENTS LEFT ISO VIEW RIGHT ISO VIEW ...

Страница 56: ...G 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 DO NOT suspend unattended loads over people ...

Страница 57: ...P N C11746310 REV AB June 2022 57 STEP 10 TOW ARM KIT INSTALLATION Y80 800 ...

Страница 58: ...P N C11746310 REV AB June 2022 58 STEP 11 CABLE TRAY INSTALLATION NOTE WIRE TRAY IS ONLY INCLUDED WITH YK SK PRODUCTS ...

Страница 59: ...P N C11746310 REV AB June 2022 59 STEP 12 PLACING FESTOON CABLES ON CABLE TRAY NOTE WIRE TRAY IS ONLY INCLUDED WITH YK SK PRODUCTS ...

Страница 60: ... 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 ...

Страница 61: ...P N C11746310 REV AB June 2022 61 STEP 14 PUSH BUTTON PENDANT ASSEMBLY WARNING DO NOT UNPLUG CONNECTORS WHILE CIRCUIT IS ENERGIZED BEFORE PLUGGING IN CONNECTORS REMOVE POWER FROM SYSTEM ...

Страница 62: ...P N C11746310 REV AB June 2022 62 STEP 15 BRIDGE MOTOR CABLE CONNECTION WARNING DO NOT UNPLUG CONNECTORS WHILE CIRCUIT IS ENERGIZED BEFORE PLUGGING IN CONNECTORS REMOVE POWER FROM SYSTEM ...

Страница 63: ...e trolley frame and bridge frame shall not be considered electrically grounded through the bridge and trolley wheels and its respective tracks A fourth runway conductor and collector shall be provided for grounding WARNING Verify that the crane is furnished for the same voltage frequency and phase as the runway power supply Crane voltage is shown on nameplate on bridge panel Do not operate crane u...

Страница 64: ...G CONNECTORS WHILE CIRCUIT IS ENERGIZED BEFORE PLUGGING IN CONNECTORS REMOVE POWER FROM SYSTEM WARNING 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 Limit switches are safety devices and should not be used as normal operating control ...

Страница 65: ...de 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 ...

Страница 66: ...P N C11746310 REV AB June 2022 66 CHAPTER 7 RADIO CONTROL HORN INSTALLATION FOR FESTOON SYSTEM ...

Страница 67: ...P N C11746310 REV AB June 2022 67 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 ...

Страница 68: ...P N C11746310 REV AB June 2022 68 STEP 2 RADIO CONTROL SYSTEM INSTALLATION WARNING DO NOT UNPLUG CONNECTORS WHILE CIRCUIT IS ENERGIZED BEFORE PLUGGING IN CONNECTORS REMOVE POWER FROM SYSTEM ...

Страница 69: ...P N C11746310 REV AB June 2022 69 STEP 3 HORN INSTALLATION INTERNAL EXTERNAL DANGER Disconnect power and lockout disconnecting means before installing internal or external horn ...

Страница 70: ...P N C11746310 REV AB June 2022 70 NOTES ...

Страница 71: ...S WITH RESPECT TO THE GOODS OR ANY REPLACEMENT PARTS 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 EVENT SHALL SELLER BE LIABLE TO BUYER OR ANY THIRD PARTY WITH RESPECT TO ANY GOOD ...

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