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CRANE, RUNWAY AND MONORAIL SYSTEM INSTALLATION
TC/American Monorail
General Installation Manual
TC/A 700-11/06 Page 1 of 28




CRANE, RUNWAY AND MONORAIL SYSTEM
INSTALLATION



GENERAL INFORMATION

The following is general information about the installation of a crane and monorail system. It is
included in the Operation & Maintenance (O&M) Manual as general information and a reference
source, and is to be used in conjunction with the engineering drawings and component
information for the equipment on this project. Note that some of the general information may not
be applicable.

For specific details of the project equipment, refer to the drawings in the project O&M Manual.


New Installations
When a new system is installed into a new building or a new addition to an old building, the
entire system must be re-inspected after 30 to 60 days. As the building settles, alignment of the
monorails may change and may require realignment. All hangers and splice bolts need to be
checked for loose or missing bolts and they may need to be re-torqued. Neglecting to do so can
result in failure of equipment as well as personal injury. TC/American reserves the right to void
all warranty if proper maintenance schedules are not followed.

INDEX

Section Page


A.
Rail Suspension Systems ...................................................................................................... 3
B.
General Runway and Monorail Installation Practice................................................................ 4
C.
Shielded Electrification ........................................................................................................... 5
D. 200
Series Rail ....................................................................................................................... 8
E. 325, 400 and 450 Series Rail.................................................................................................. 9
F. Single
Girder
Hand Pushed Cranes...................................................................................... 11
G. Cranes With Center Motor Drives, Single and Double Girder ............................................... 12
H. Cranes with Motorized Trolley Drives, Single and Double Girder ......................................... 14
I. Crossover
Sections............................................................................................................... 16
J. Spur
Track Supports............................................................................................................. 16
K. General Switch Installation Practice...................................................................................... 17
L. 200 Series Tongue Switches ................................................................................................ 17
TC/American Monorail
General Installation Manual
TC/A 700-11/06 Page 2 of 28

M. 200 and 600 Series Glide Switches ...................................................................................... 17
N. 800 and 2000 Series Glide Switches .................................................................................... 18
O. Electric Actuator Operated Glide and Tongue Switches ....................................................... 18
P. Air Operated Glide and Tongue Switches............................................................................. 19
Q. Trolleys ................................................................................................................................. 19
R. Hoists and Hoist Trolleys ...................................................................................................... 20
S. Drivetractors ......................................................................................................................... 22
T. Double Girder Motor Propelled Hoist Carrier ........................................................................ 24
U. Drive
Tire Adjustment ........................................................................................................... 25
V. Final
Check of System.......................................................................................................... 26
W. Stacker Type Equipment ...................................................................................................... 26

X. Test
Operation...................................................................................................................... 27

Y. Crane Runway Alignment Tolerances................................................................................... 28


TC/American Monorail
General Installation Manual
TC/A 700-11/06 Page 3 of 28

A. RAIL SUSPENSION SYSTEMS

1. Be familiar with all hanger types used for suspension see the O&M manual section
titled Suspension.

2. Each hanger is designed to handle the listed maximum capacity and is utilized in the
system to the designated maximum hanger load.

3. Be certain that each hanger is used at its designated point. Some systems use more
than one hanger variety.

4. There are four types of suspension methods: rigid stools, flexible rod, direct bolt, and
direct 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 a
lesser 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 the
fastener 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 are
seated 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 Monorail
General Installation Manual
TC/A 700-11/06 Page 4 of 28

B. GENERAL RUNWAY AND MONORAIL INSTALLATION PRACTICE

1. 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 in
accordance 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 shall
be installed in accordance with the standards of the American Welding Society, or
equivalent technical publication.

4. Rail joints at splices shall be ground smooth and level. The maximum gap between
adjacent rail ends shall not exceed 1/16", except at switches or other free ends when
3/16" is permitted.

5. Hanger rods and superstructure rods are special steel and should never be welded or
have welding connections applied to them. If any threading is necessary, care must be
taken to prevent undercutting or sharp roots of threads.

6. Bracing of track systems, if required, is the responsibility of the installer and is
determined largely by field conditions to accomplish the following:
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 racking
from stopping and starting of carriers.
c) Crane runway systems normally require one runway to be side braced when runways
are 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