Yale SHAW-BOX YK Series Installation guide

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

P/N: C11746310 REV. AB June 2022
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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

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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.........................................................................................................................39
5) MOUNTING HOIST ON GIRDER............................................................................................................40
YK/SK HOIST INSTALLATION .....................................................................................................................41
STEP 1: PREPARATION FOR MOUNTING HOIST ON GIRDER .............................................................41
STEP 2: MOUNTING HOIST ON GIRDER ..................................................................................................42
Y80/800 HOIST INSTALLATION...................................................................................................................43
STEP 1: PREPARATION FOR MOUNTING HOIST ON GIRDER .............................................................43
STEP 2: MOUNTING HOIST ON GIRDER ..................................................................................................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
TOW ARM ADJUSTMENTS..........................................................................................................................54
Y80/800 TOW ARM ........................................................................................................................................55
STEP 9: TOW ARM KIT PREPARATION ..................................................................................................... 55
TOW ARM ADJUSTMENTS..........................................................................................................................55
STEP 10: TOW ARM KIT INSTALLATION – YK/SK ....................................................................................56
STEP 10: TOW ARM KIT INSTALLATION – Y80/800.................................................................................. 57
STEP 11: CABLE TRAY INSTALLATION ..................................................................................................... 58
STEP 12: PLACING FESTOON CABLES ON CABLE TRAY.....................................................................59
STEP 13: FESTOON CABLE CONNECTION ............................................................................................. 60
TABLE OF CONTENTS

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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 ..................................................................................................................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

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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
Noties 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.

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IMPORTANT INFORMATION AND WARNINGS
9Failure to read and comply with any of the limitations noted herein can result in serious
bodily injury or death, and/or property damage.
9Equipment described in this manual is not designed for and should not be used for lifting,
supporting, or transporting humans.
9To ensure the good working order and reliable operation of your hoist, strictly adhere to the
requirements of the installation provided in this manual.
9Strictly adhere to the requirements for safe operation to prevent dangers to personnel and
damages to the electric hoist.
9When making repairs, only use parts supplied by the manufacturer.
9The connection of the bridge panel power cable with the crane runway power supply shall
only be performed by a qualied electrician.
9Assembly and commissioning of the crane system shall only be done by qualied persons
authorized by CMCO.
9Modications to upgrade, re-rate, or otherwise alter this equipment shall be authorized only
by the original equipment manufacturer or qualied professional engineer.
9Equipment described in this manual may be used in the design and manufacture of cranes.
Additional equipment or devices may be required for the crane to comply with applicable
crane design and safety standards. The crane designer, crane manufacturer, or user is
responsible for nishing 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 Devices.
9Hoists and cranes used to handle hot molten material may require additional equipment or
devices. Refer to ANSI Z241.2, Safety Requirements for Melting and Pouring of Metals in
the Metal Casting Industry.
9The hoists are not designed to operate in a chemically aggressive and explosive
environment.
Working in or near exposed energized electrical equipment presents the danger of electric shock.
WARNING
Before installing, removing inspecting, or performing any maintenance on a hoist, the main switch
shall be de-energized. Lock and tag the main switch in the de-energized position in accordance
with ANSI Z244.1.
Follow other maintenance procedures outlined in this manual and applicable ASME B30 volumes.
Additional WARNINGS are listed in various portions of this manual. Personnel shall read and
follow these WARNINGS. Failure to read and comply with these WARNINGS as well as other
instructions or any limitations noted in this manual and applicable ASME B30 volumes could result
in serious bodily injury or death, and/or property damage.

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9Read and observe the instructions and warnings contained in this manual. Read and
observe any instructions and warning tags attached to the hoist.
9Check 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.
9Check wire rope for damage and proper spooling on the drum. Be sure rope is properly
seated in drum grooves and sheaves. Tightly secure both of the rope ends.
9After each rope replacement as well as after repair and reassembling of the electric hoist,
check the phasing and direction of operation. Verify the hook position of all limit switches
per the hoist manual.
9Be certain that power supply to the bridge control panel has the same voltage, frequency,
and phase specied on the bridge control panel nameplate.
9While performing electric repairs/maintenance, make sure that there is no load on the hook;
turn o󰀨 the power supply switch and prevent unauthorized personnel from switching it on.
9Check the loading hook for cracks and deformations. Verify the proper operation of the
release latch.
9The bridge frame shall not be considered electrically grounded through the end truck
wheels and its respective tracks. A separate runway bonding conductor must be provided.
WARNING
Hazardous voltages are present in the control enclosure, other electrical components, and
connections between these components.
Before performing any mechanical or electrical maintenance on the equipment, disconnect the
main switch supplying power to the equipment and implement lockout/tagout procedure. Refer to
ANSI Z244.1, personnel protection - lockout/tagout of energy sources.
DO NOT operate the equipment without control enclosure cover or covers in place.
Only trained and competent personnel should inspect and repair this equipment.

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9If 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 o󰀨 the beam. Avoid using trolley stops that engage
trolley wheels. Check that trolley stops will prevent overhanging parts of the hoist and
trolley from interfering with other equipment beyond the ends of the beam.
9Daily, before starting work, check the operation of the brake and the limit switch.
9Never use a limit switch as an operational switches.
9Do not leave the lifted load out of sight.
9Do not exceed the rated capacity.
9Do not lift loads at an angle and do not drag them.
9Do not try to detach rmly xed loads (for example, loads frozen to the ground).
9Do not change or modify the electric diagram. Do not use the pushbuttons and limit
switches for other purposes other than those mentioned in this manual.
9Equipment covered herein is not designed or suitable as a power source for lifting or
lowering persons. Never lift and move loads over personnel.
9Use warning signs and barriers on the oor 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 safety devices and should not be used as normal opertating control.
WARNING
Only qualied personnel with proper supervision shall install the hoist on the monorail and
perform the nal pre-operation inspection.
Before installing, removing, inspecting, or performing any maintenance on a hoist, the main switch
shall be de-energized. Lock and tag the main switch in the de-energized position in accordance
with ANSI Z244.1.
Follow other maintenance procedures outlined in the manual and applicable ASME B30 volumes.
Additional WARNINGS are listed in various portions of this manual. Personnel shall read and
follow these WARNINGS. Failure to read and comply with these WARNINGS as well as other
instructions or any limitations noted in this manual and applicable ASME B30 volumes could
result in serious bodily injury or death, and/or property damage.

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CHAPTER 2
FABRICATION OF GIRDER(S)
FOR BRIDGE BEAM WITH
CAPPING CHANNEL
(AS REQUIRED)

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STEP 1: CUT GIRDER AND C-CHANNEL (AS REQUIRED)
Check your conguration 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 veried
by qualied engineer. IT IS IMPORTANT THAT
ALL INSTRUCTIONS BE FOLLOWED AND THAT
COMPONENT APPLICATION LIMITS NOT BE
EXCEEDED.

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STEP 3: GIRDER AND C-CHANNEL WELDING AT END (AS REQUIRED)
ALL WELD IS TO BE AWS CLASS E-70XX OR EQUIVALENT
STEP 4: CLAMPING GIRDER AND C-CHANNEL (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 qualied as prescribed
by the American Welding Society (AWS)
Structural Welding Code-Steel D1.1-2008
and Specication for Welding Industrial
and Mill Cranes D14.1-2005.

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STEP 5: GIRDER AND C-CHANNEL WELDING (AS REQUIRED)
ALL WELD IS TO BE AWS CLASS E-70XX OR EQUIVALENT
STEP 6: CHECK CAMBER AFTER WELDING (AS REQUIRED)
CAMBER ≤{DEFLECTION OF GIRDER AT DEAD LOAD
+ 1/2 * DEFLECTION 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 qualied as prescribed
by the American Welding Society (AWS)
Structural Welding Code-Steel D1.1-2008
and Specication for Welding Industrial
and Mill Cranes D14.1-2005.

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CHAPTER 3
ASSEMBLING BRIDGE GIRDER TO
UNDERHUNG END TRUCKS

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3.A) PLAN VIEW
NOTE: CROSS SHAFT IS NOT REQUIRED IF DUAL ENDTRUCK MOTORS ARE PART OF YOUR CONFIGURATION

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3.B) DIMENSION DETAILS FOR GIRDER LENGTH CALCULATION
TRUCKS
CONFIGURATION
NUMBERS
DISTANCE BETWEEN
CENTER OF END TRUCK
AND EXTREME END OF
ITS TOW PLATE
INTERNAL SPACE
BETWEEN END
TRUCK CHANNELS
LENGTH OF DRIVE
SHAFT FROM END
TRUCK CENTER
LENGTH OF FIRST
CROSS SHAFT
LENGTH OF
SECOND CROSS
SHAFT
E G H I J K
905368, 905369 8-1/4" 7-5/8" 1' - 2" 2' - 4-1/4" 14' - 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 11-15/16" 1' - 2" 1' - 5-3/16" 2' - 10-5/8" 14' - 6-1/2" 17' - 5-1/4"
905524PT, 905525PT 9-3/8" 8-7/8" 1' - 2-5/8" 2' - 5-1/2" 14' - 9" 17' - 2-5/8"
905524SR, 905525SR 9-3/8" 8-7/8" 1' - 2-5/8" 2' - 5-1/2" 14' - 9" 17 - 2-5/8"
C5 TON KIT: 7-9/16"

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3.C) UNDERHUNG END TRUCK TYPES

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3.D) FORMED CHANNEL END TRUCK
WARNING
Alterations or modications 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.

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3.E) ROLLED CHANNEL END TRUCK

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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
STEP 2: MARKING CENTERLINE ON THE GIRDER (AS REQUIRED)
Check your font conguration 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")

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STEP 3: MARKING CENTERLINES AND 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"