CRANE, RUNWAY AND MONORAIL SYSTEM INSTALLATION

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tcamerican.com sales@tcamerican.com 763-479-700011110 Industrial Circle NW, Suite A, Elk River, MN 55330CRANE, RUNWAY AND MONORAIL SYSTEMINSTALLATIONGENERAL INFORMATIONThe following is general information about the installation of a crane and monorail system. It isincluded in the Operation & Maintenance (O&M) Manual as general information and a referencesource, and is to be used in conjunction with the engineering drawings and componentinformation for the equipment on this project. Note that some of the general information maynot be applicable.For specific details of the project equipment, refer to the drawings in the project O&M Manual.New InstallationsWhen a new system is installed into a new building or a new addition to an old building, theentire system must be re-inspected after 30 to 60 days. As the building settles, alignment ofthe monorails may change and may require realignment. All hangers and splice bolts need tobe checked for loose or missing bolts and they may need to be re-torqued. Neglecting to do socan result in failure of equipment as well as personal injury. TC/American reserves the right tovoid all warranty if proper maintenance schedules are not followed.TC/American Crane CompanyGeneral Installation ManualTC/A 700-2/19Page 1 of 28

INDEXSectionPageA. Rail Suspension Systems . 3B. General Runway and Monorail Installation Practice . 4C. Shielded Electrification . 5D.200 Series Rail . 8E.325, 400 and 450 Series Rail . 9F.Single Girder Hand Pushed Cranes . 11G. Cranes With Center Motor Drives, Single and Double Girder . 12H.Cranes with Motorized Trolley Drives, Single and Double Girder . 14I.Crossover Sections . 16J.Spur Track Supports . 16K.General Switch Installation Practice . 17L.200 Series Tongue Switches . 17M. 200 and 600 Series Glide Switches . 17N.800 and 2000 Series Glide Switches . 18O. Electric Actuator Operated Glide and Tongue Switches. 18P.Air Operated Glide and Tongue Switches . 19Q. Trolleys . 19R.Hoists and Hoist Trolleys . 20S.Drivetractors . 22T.Double Girder Motor Propelled Hoist Carrier . 24U.Drive Tire Adjustment . 25V.Final Check of System . 26W. Stacker Type Equipment . 26X.Test Operation . 27Y.Crane Runway Alignment Tolerances . 28TC/American Crane CompanyGeneral Installation ManualTC/A 700-2/19Page 2 of 28

A. RAIL SUSPENSION SYSTEMS1. Be familiar with all hanger types used for suspension – see the O&M manual sectiontitled “Suspension.”2. Each hanger is designed to handle the listed maximum capacity and is utilized in thesystem to the designated maximum hanger load.3. Be certain that each hanger is used at its designated point. Some systems use morethan one hanger variety.4. There are four types of suspension methods: rigid stools, flexible rod, direct bolt, anddirect bolt to brackets.5. High-strength rods are used on all flexible rod suspension systems.6. Do not, under any circumstances, weld or apply heat to any load carrying rod.7. All load carrying fasteners are minimum grade 5 or A325 grade. Any fasteners of alesser grade will change the hanger or clamp capacity.8. A flat washer must be used if the diameter of the hole is greater than 1/16" above thefastener diameter or has a slotted hole.9. Each fastener must have a lock washer under its nut.10. Shimming at hanger points may be necessary to assure that the rail is installed level.11. After final leveling, at all hanger rod suspension points check that spherical washers areseated properly. Tighten the set screw on each lock nut, then insert the spring pins.12. Be certain that all hanger rods are plumb.13. Recheck fasteners to be certain that all are secured and washers are properly placed.TC/American Crane CompanyGeneral Installation ManualTC/A 700-2/19Page 3 of 28

B. GENERAL RUNWAY AND MONORAIL INSTALLATION PRACTICE1.No holes shall be made in the building structure without permission from the owner.2.All supporting structures to which the track is suspended shall be installed inaccordance with the specifications of the American Institute of Steel Construction,current edition.3.Where supporting steel or equipment is erected by welding operations, such work shallbe installed in accordance with the standards of the American Welding Society, orequivalent technical publication.4.Rail joints at splices shall be ground smooth and level. The maximum gap betweenadjacent rail ends shall not exceed 1/16", except at switches or other free ends when3/16" is permitted.5.Hanger rods and superstructure rods are special steel and should never be welded orhave welding connections applied to them. If any threading is necessary, care must betaken to prevent undercutting or sharp roots of threads.6.Bracing of track systems, if required, is the responsibility of the installer and isdetermined largely by field conditions to accomplish the following:7.a)Monorail tracks must be side braced to prevent excessive swinging, if rod suspended.Normally, this is accomplished at each splice joint.b)Monorail tracks with motor driven carriers must also be end braced to prevent rackingfrom stopping and starting of carriers.c)Crane runway systems normally require one runway to be side braced when runwaysare hung from rods. Both runways must be end braced.d)Switches should be rigidly connected directly to superstructure.e)When switches are supported by hanger rods, the switches must be rigidly braced.f)Curves must be rigidly braced.g)It is best to brace system after leveling and electrifying. If bracing is done beforeconductor bar is installed, be sure clearance is maintained 1" from any portion ofconductor path.Obtaining the final proper elevation of all tracks is the responsibility of the installer.a)Check all hanger fittings provided with hanger schedule and elevations shown on print(see Crane and Suspension drawings). Be sure these fittings will give the dimensionsrequired for the proper elevation before track is hung.b)Elevation of track tread throughout any system is to be held with 1/8" , with elevationreadings at each track splice, switch, etc.TC/American Crane CompanyGeneral Installation ManualTC/A 700-2/19Page 4 of 28

C. SHIELDED ELECTRIFICATION! WARNING! Open the mainline disconnect switch on systems before working onelectrical equipment.Shielded electrification is a highly versatile system of electrification, which when installedaccording to the following instructions, will give many years of trouble-free operation.1. Conductor Bars - All straight conductor bars are furnished in 5, 10, and 20 footlengths with PVC cover in place over the bars. Any odd lengths of bars required for thesystem must be cut to fit at the time of installation. The bar and cover can be cut with ahand hacksaw. All cuts should be square, and the bus bar must be free of burrs,particularly on the inside face of the web of the bus bar channel where the collectorshoe rides. The bars must be accurately gaged from the rail tread and accuratelyaligned with each other horizontally and vertically.2. Gauging of Conductor Bars - In order to assure proper operation of the collectors,the conductor bars must be accurately gaged from the tread of the rail throughout itslength, and there should be an absolute minimum of sag or rise between supportbrackets. The conductor bars are shipped from the factory in a straight condition. Withreasonable care, they can be cut and installed with no change in straightness. Any barthat becomes bent or kinked in shipment or handling must be straightened or replaced.All conductor bar systems in the GEM are “side contact” bars, and the mounting holesare pre-punched in the web of the rails, to assure proper gaging.3. Support Brackets for 200, 400, 325 and 450 Series Rail - The shielded supportbrackets can be mounted while the rail is on the ground or after installation. In eithercase, they should be loosely assembled so that the conductor bar and cover can beslipped lengthwise into the clips. After the splices have been made, the clips must besecurely tightened so that the cover cannot move.4. Support Brackets for 2R3-5T Rail – When mounting the bracket assemblies on 3R35T rail, care must be taken to make sure that the lugs on the spacers are set at rightangles to the bus bars. This is required to stabilize the bracket assembly and tominimize the possibility of the bus bars being cocked when the bracket is tightened.There must be a support bracket on every hanger on 2R3-5T rail.5. End of Runs - At the extreme ends of a run of electrification, the conductor bar andcover are to be cut off square and flush with one another. To prevent accidentalcontact at the end, it is necessary to cover the end of each bar with an end cap. This ismade of flexible neoprene and can be snapped over the end of the bar with little effort.6. Splices - The ends of each 5, 10, and 20 foot lengths of conductor bar are preparedwith holes to accommodate the splice bar. Lengths different from 5, 10, or 20 feetrequired in a system are cut to length in the field. The holes through the conductor barmust be countersunk for #10-24 x 5/8" flat head screws. To provide a smooth surfaceTC/American Crane CompanyGeneral Installation ManualTC/A 700-2/19Page 5 of 28

for the collector shoe, ensure that the countersink is deep enough so that the head ofthe screw is flush or below the face of the conductor bar. Any burrs on the head of thescrews, screw slots, or at the joint between the bars must be removed.7. Electrical Feed-In - Electric feed-in can be accomplished anywhere in the system.However, the most convenient is at any splice. This is done by fastening the lug on thefeed-in wire under a #10-24 nut. When a feed-in is required at a point that is notspliced, drill a 7/32" diameter hole through the bus bar and countersink for a 10-24 x5/8" flat head machine screw. The head of the screw must be flush or below thesurface of the conductor bar to provide a smooth surface for the collector. Any burrson the head of the screw or screw slot must be removed. The back of the cover musthave a 1/2" diameter hole at this point to allow contact with the conductor bar. A splicecover is used to protect the connection. Any splice cover can be used as a feed-incover. The only difference between the feed-in and the splice covers is that the feed-incover is somewhat shorter.8. Standard Line Interlocks - The gaps between bridge rail conductors and spur railconductors at interlocks must be field fabricated. The bars on the spur must be cutsquare and flush and positioned ¼” back from the extreme end of the spur. Theconductor bars on the bridge are positioned ¼” back from the extreme end of thebridge at the factory. The 1/8” gap required between the bridge and spur will leave a5/8” gap between the conductor bars. This 5/8” gap is minimum and 3/4” is themaximum gap. Guides are provided to be used at ends of conductor bar to facilitatesmooth entrance of collector shoes. The bars must be accurately gaged from the railtread and aligned with the bars on the bridge.9. 325 and 400 Series Interlocks – As with standard line interlocks, the gaps betweenthe bridge conductors and spur conductors must be field fabricated. The bars on thespur must be cut square and flush and positioned even with the end of the spur rail.The conductor bars on the bridge are positioned ½” back from the extreme end of thebridge at the factory. The 1/8” gap required between the bridge and spur will leave a5/8” gap between the conductor bars. This 5/8” gap is minimum and 3/4” is themaximum gap. Guides are provided to be used at ends of conductor bar to facilitatesmooth entrance of collector shoes. The bars must be accurately gaged from the railtread and aligned with the bars on the bridge.10. Switches – Conductor bars entering the switches on the straight rail approaches mustbe cut to fit at the time of installation. The conductor bars entering the switches fromthe curved rails are cut to fit at the factory. After the switch has been installed, theapproach conductor bars and covers should be cut square and flush. A gap of 5/8”minimum and 3/4” maximum must be held between the approach bars and those onthe switch. The switches are pre-wired at the factory to provide for electrical continuitythroughout the system. The conductor bars on the rail approaching the switch must beprepared for electric power connection. No splice should be made within two feet of aswitch. All switches are furnished with four conductor bars mounted on the live sectionof the switch. The brackets furnished for mounting the approach conductors are also 4bar brackets. In most instances, only 3 bars are required for the system. It isTC/American Crane CompanyGeneral Installation ManualTC/A 700-2/19Page 6 of 28

necessary, therefore, to convert these brackets to 3-bar brackets. In some instances, itis necessary to convert to 2-bar brackets. Guides are provided to be used at ends ofconductor bars to facilitate smooth entrance of collector shoes. The bars must beaccurately gaged from the rail tread and aligned with the bars on the bridge.11. Curves – The conductor bars and covers for curves are accurately bent at the factoryto match the rail fro which they are intended. The ends are cut to either splice into astraight rail or enter a switch as may be required. Covered conductor bars entering aswitch must be capped as described under “Switches.” It is important that there is aconductor bar support bracket on every hanger in a 2R3-5T rail curve.12. Collectors - The collector head is mounted to the support bracket by means of a nylontrunion and a coil spring support. The nylon trunion provides the necessary flexibilityfor the shoe to track well on the conductor bar, and the spring provides support toassist the shoe to ride centered on the conductor bar. It is important that the feed-inwire has an adequate loop to provide flexibility to the collector head. The loop must betrained parallel to the conductor bar to prevent snagging of the wire when the collectorhas close clearances such as in switches. Remove the rubber grommet from collectorstem after collector shoe has been installed in conductor bar.NOTE: In any conductor system with interlock, switch, and other track deviceswhich create gaps in the conductor system, dual collectors are recommended toprevent loss of continuity when the collector crosses the gap.TC/American Crane CompanyGeneral Installation ManualTC/A 700-2/19Page 7 of 28

D. 200 SERIES RAIL1. Check mark numbers on each track length and curve, identify with location on print.2. Assemble upper hanger, rod, and track hanger by hand to approximate length requiredto obtain elevation shown on print. If system is electrified, be sure insulator supports orbrackets are in place on rods. It is the responsibility of the mechanical installer tocoordinate this work with the electrical contractor. Insulators cannot be installed aftertrack and hangers are installed.3. Install hanger assemblies in proper location by securing upper fitting.4. Raise track section in place and secure clamp at track hanger.5. Install Grade 5 splice bolts and Class 2 nuts (provided with rail) at rail joints.a) Seat splice nuts with air or electric impact wrench.b) If splice bolt is seated by hand, the end of bolts must be center punched to preventlooseningc) A track hanger point must not exceed 1/8 of the span.6. Adjust each hanger to exact elevation by using a vise grips pliers on the hanger rod andadjust the hanger nuts with an open end wrench.7. Tighten all nuts on hanger rods.NOTE: Allow enough thread on hanger rod for future leveling.TC/American Crane CompanyGeneral Installation ManualTC/A 700-2/19Page 8 of 28

E. 325, 400 and 450 SERIES RAIL1. Check mark numbers on each track length (see system layout drawings), identify withlocation on print.2. Check all hanger fittings provided with hanger schedule and elevation shown on print.Be sure these fittings will give the dimensions required for the proper elevation beforetrack is hung.3. Lay out system location from print, establishing each hanger location on supportingsteel. This can be done by a chalk layout on floor and plumbing up; a line stretchedunder steel above; or using a transit marking each location. Be sure layoutmeasurements are from proper building reference.4. When installing a monorail system, it is recommended to start at a switch and curvelocated in the system. For a single run of rail, start at one end and work sequentiallytoward the other end.5. When installing crane systems, it is recommended to start with the runway that has theelectrification, or if a spur track or crossover is incorporated, start at that point. Afterinstalling this runway, proceed to align, level and brace. Align the rail both parallel andperpendicular to the web. Always level the rail from the riding tread, never from the topflange. The riding tread elevation should be 1/8” . Refer to Crane Runway AlignmentTolerances. This rail becomes the benchmark and reference point to install the cranesystem.6. For multiple crane runways, the procedure is the same except that all crane runwayspans are measured to the first crane runway installed as a benchmark. The spantolerances should not exceed 1/8” . Refer to Crane Runway Alignment Tolerances.7. Before track sections are raised into position, electrification, track hangers, etc. shouldbe assembled on track. Bolts should be snug, capable of slight movement for finaladjustment.8. Make splices between rail sections as each track is hung. Splice bolts can be started,but left loose, or make-up bolts can be used. A hanger must be centered over eachtrack splice. If top of rails are not flush at splices when treads are aligned, shims are tobe inserted under the low sid

spliced, drill a 7/32" diameter hole through the bus bar and countersink for a 10-24 x 5/8" flat head machine screw. The head of the screw must be flush or below the surface of the conductor bar to provide a smooth surface for the collector. Any burrs on the head of the screw or screw slot must be removed. The back of the cover must

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