Monorail System

Step 1: Determining Your Total Load

In order to design your system the first thing that must be done is to determine the load
that you will be lifting. This load (expressed in pounds) will be referred to as P.

This load should be the maximum weight of any and all objects you intend to lift
with this system, including any slings, spreader bars, grabs, load tables, or other
devices used to help lift the objects off the ground.

Step 2: Determining Your Length Of Lift

Next you will need to find the length of the lift that will be required. The way to do this is
the measure from the bottom of where the monorail is to be mounted, down to the floor.
Or down to the bottom of the pit, if this system is to lift its load out of a pit or opening in
the floor. From this dimension you can subtract the height of the object that you are
going to be lifting. This will leave you with the maximum life length you will need, this will
be referred to as L.

Step 3: Selecting The Appropriate Hoist

The next thing to do is to select the correct hoist for your application. Determining the
correct hoist will depend on a number of factors, these include: the weight of your load
(P), the length of the lift required (L), the speed(s) required of the hoist, whether a chain
or wire rope is desired, and the method used to power the hoist (manual, electric,
hydraulic, air).
Step 4: Selecting The Correct Trolley

What type of trolley you will need for your system? There are three main types of
trolleys to chose from, a standard push trolley, and hand geared trolley (uses a gear
and chain to move the trolley), and a motorized trolley. There are obviously benefits to
each, but the choice is really based on your application.
One important thing to remember is that you can not have a motorized trolley if you are
planning on having any switches in your system. If switches are required and you still
want motorized movement you will have to use a tractor to pull the trolley, see step 9.

Step 5: Determining Hanger Spacing And Track Selection

Next you need to determine how often you can place hangers for the monorail track.
This will depend on how the building you are installing this system in is designed. The
more frequently you can place the hangers, the greater the load you can support on a
smaller and less expensive track.

Here are links to the load charts for the various rail choices we offer, they go in order
form lightest rail to heaviest to help you find the best option for you.

Hanger Spacing Tables

Step 6: Calculating Hanger Rod Lengths

In order to calculate the length of your hanger rods there is only one piece of
information you need to have, that is the height of any overhead obstructions that are
going to be in the way of the monorail that must be accounted for in the design. Once
you know this you know how far down the track needs to be dropped, and this is your
hanger rod length.
This step is centered around what you need for your facility. Based on how your facility
is laid out, and how you intend to use the system you must decided where the hoist
must be able to travel in order to service your needs.

Any place that you need to have the trolley turn from one section of track on to another
section you will need a switch, the switch must be placed 4 feet before the section of
track you are turning onto in order to complete the switch. Also when planning any
curves or turns in the track, plan on starting the curve 4 feet before you want to finish it.

Step 8: Electrification (optional)

If you have either a motorized trolley or hoist or both, you need to also have a method of
electrification in order to supply power to these items. There are two main options when
it comes to electrification, there is a KANT-SHOCK conductor bar system, or a Festoon
system. The advantage to the Festoon system is that it eliminates mobile collectors
which will prevent sparks, small electrical arcs, and loss of energy. Festoons however
are not good for systems where there will be multiple trolleys or if the extra storage
space that is required by the festooning trolleys (about 5% of the total length of the
system) is not available. The advantages of the conductor bar system is that it can
handle multiple trolley/hoist setups at the same time, can handle a higher ampacity
allowing for larger and more power drawing items, and it requires no extra length. Both
systems can been seen at this page Conductors

Conductor Bar

Shielded Electrification for Cranes and Monorails

KANT-SHOCKTM

Safety type shielded electrification for crane and monorail systems.

Main Features:

 Complete protection
against accidental contact

 Complies with I.E.C.

Finger Test Safety
Standards

 Trouble free operation,

minimal maintenance

 Economical installation
and operation

 Ideal for both indoor and outdoor applications

 Proven reliability

 Two capacities available with 80 amp range designed for curves,

switches,crossover tracks and discontinuous control circuits.

Isometric view of Kant-

Shock showing how the
Top: Cannot make contact
PVC completely encloses
Bottom: Finger will not
the conductor bar except
enter
for the narrow slot provided
for the conductor shoe.
End Caps
To protect the ends of Kant-Shock
Electrification from possible
contact, heavy neoprene caps are
snapped securely over the
shielding at each end of the
system. End stops on monorail
track should be located so that the
collectors do not hit the caps.

Expansion Joint
Used at building expansion joints
and at 300 ft. intervals of each
conductor run for normal
installations. The expansion joint
allows for expansion and
contraction, keeps the separated
conductor bars in alignment, and
guides the collector shoe across
the gap. A length of high tension
insulated cable attached to the end
of each conductor bar forming the
expansion joint, bridges the gap
electrically. The cable is connected
to the standard feed in clamp
screws and fully shrouded by a
polyvinyl snap on cover. Should a
gap be installed at the centre of a
run, power-feeds may be attached
directly to these bridging wires.
Maximum permissible gap at any
one joint is 1". Should more
expansion than this be desirable in
the scheme further joints must be
installed in the system.
Insulating Section
For automatic dispatch control or
other locations where conductor
bars must be isolated, an
insulating section of dielectric
material is furnished to fit securely
inside the Kant-Shock Shielding
and match the adjoining conductor
bars. These insulating sections can
be located at any desired point in
the system.

Collectors have a self cleaning sliding shoe collector, set in a

moulded plastic insulator, which fits on an articulated trolley arm. The
trolley arm is spring loaded to keep the collector in correct alignment
with the conductor at all times.

Power Feeds
Power can be fed to Kant-Shock Electrification at any point,
preferably at a splice. The feed wire is secured to the back of the
Splice Clip by simply placing the cable tag under one of the splice
nuts. A Kant-Shock splice cover with one end plug removed is then
 snapped on to provide complete insulation.

The higher rated requirements are adequately covered by the 200

amp range of the Kant-Shock shielded electrification system. The
system is mechanically stronger and more rigid than others of similar
electrical capacity utilizing copper or similar materials for the
conductor.

Festoon Systems for Flatform & Round Cables

Advantages:

 Elimination of mobile collectors which prevents sparks, small

electrical arcs, loss of energy and dropping of tension when
the current passes from one element to another, trolleys, etc.

 Perfect insulation

 Easy, rapid mounting, maintenance free

Step 9: Selecting A Monotractor (optional)

If your system requires motorized trolley movement, but also requires that you have
track switches, then a monotractor is you solution. A monotractor will run in front of
your hoist and trolley, and will be connected to that trolley by a load bar. The
monotractor uses a rubber drive wheel to pull itself, and your load along the track, its
special design allows it to negotiate the tight curves of monorail curves and switches.

RV101 RV104

RV105

Based on how your facility is laid out,

and how you intend to use the system
it must be decided where the hoist travel will best serve the needs of your facility.
Any place that you need to have the trolley turn from one section of track on to another
section you will need a switch,
the switch must be placed 4 feet before the section of track you are turning onto in order
to complete the switch.
Also when planning any curves or turns in the track, plan on starting the curve 4 feet
before you want to finish it.
Electric Wire Rope Hoists

Heavy Duty Built Up Trolley Hoist

Double Girder Top Running Design

5-Ton thru 75-Ton Capacity
Reliable Type "RS" Hoist Trolleys

STANDARD SPECIFICATIONS

 Horizontally Split Gear Case  One Piece Steel Weldment

Design Trolley Frame

 Five (5) Step Variable Speed  Five (5) Step Variable Speed
Hoist Control Trolley Control

 Mechanical Load Brake  Electric Trolley Motor Brake 100%

Torque Rated
 Electric Hoist Motor Brake 150%
Torque Rated  Precision 4140 Alloy Steel Trolley
Wheels
 Geared Upper and Lower Limit
Switch  True Plumb Hook Lift Reeving

 Weight Operated Upper Limit  Enclosed Lower Hook Block With

Switch Safety Latch

OPTIONAL EQUIPMENT

 Eddy Current Lowering Controls  D.C. Motors and Controls

 AC Static Stepless Control  Dynamic Lowering Controls
 Power Circuit Upper Limit Switch  Spring or Hydraulic Trolley
  Auxiliary Hoists Bumpers

 Special Girder Gages Available  Motorized Rotated Hook

 Special Lifts & Speeds Available

Production Modular Design Trolley Hoist

Double Girder Top Running Design

5-Ton · 7.5-Ton · 10-Ton Capacity
Single Speed, 2 Speed, 3 or 5 Point Variable Speed
Reliable Type "RPM" Monorail Hoists

Lug Suspended Hoists

Optional Features

 Higher Capacities Available Upon Request

 Special Voltages

 Flat Tread Wheels

 2 Speed Hoist
Model SNH
 2 Speed Trolley
  Special LIfts and Speeds

 Pushbutton Stations

 Overload Limit Switches

Automated Pit Scale Hoists

Trolley Suspended Hoists

Motor Driven Hand Push Low Headroom

Model SNHE Model SNHH Model SNHELW
Single Speed or 2 Speed Hoists

STANDARD FEATURES

 Upper and Lower Limit Switch

 250% Torque Hoist Motor Brake

 NEMA Rated Contactors

 No Overhung Gears or Pinions

 Low Headroom Construction

 All Gears Operate In Oil Bath

 Helical Gearing For Quiet Operation

 Trolley Drive on Both Sides of Beam

Model SNHE-S  100% Trolley Brake

 NEMA 3R/12 Control Enclosure

 110 Volt Fused Control Circuit

 230/460-3-60 AC Dual Wound Motors

 TENV Class "F" Insulated Motors

 M.R.O.P. (Motor Running Overcurrent

Protection)

 M.O.P. (Motor Overcurrent Protection)

 All Steel Drum with Machined Grooves

Model SNHE5SLS
 Safety Drop Lugs on Trolley

 Operation on I-Beam or W.F. Beams

Electric Chain Hoists

1. Center Frame

2. Wear-Resistant Durable
Load Sheave

3. Heavy Duty Motor

4. Over-Hoist, Over-Lower
Protection

5. Forged Steel Hooks

6. Ultra Tough Surface

Hardened Load Chain

7. Precision Reduction
Gearings

8. Low Voltage Control

9. Push Button Remote

Control

10. Efficient Brake

11. Silent Gear Case

Single-speed/Two-speed

Model EC-3M Single Speed

Model ECC-3 Single Speed
Model ECT-3M Two Speed
Single Phase Motor
3 Phase 220/440V
Geared/Plain Trolleys

Model MHG-5 Model MHT-5

Geared Trolley Two-speed hoist
Model MHP-5 Model EMTT-MHT-5
Plain Trolley Two-speed hoist, two-speed trolley
MANUAL HOISTS

CHAIN HOISTS

 Patented Safety-Hook with Safety-Latch

 Top Hook has Large Throat Opening

 Chain Guides allow chain to move more freely

 Chain Stop prevents jamming at lowest position of

hook
LEVER HOISTS

 Retaining plate

 Change lever

 Handle

 Grip ring

 Retaining pawl

Features:

 Triple spur geared for easy operation with short

handle.

 Light weight, all steel construction.

 Patented &qout;SURE GRIP" hooks.

 Thumb control up/down with free wheeling grip ring.

 Ratchet and pawl load holding.

 Automatic load brake.

3/4 ton · 1-1/2 ton · 3 ton · 6 ton

Hoist · Pull at angle · Bind · Pull

PULLER

Features:

 Small, light weight.

 Equipped with two safety

devices.

 Fast speed of 10 feet per minute.

 Can be used at any working

angle.

 Equipped with a safety hook.

 Rope release
handle

 Operating lever

 Rope exit

 Rope entry

 Reversing lever

 Carrying handle w/
2 sets of spare
shear pins
 Light, powerful, easy to move, easy to
use. Practical, safe, pulling and lifting
solutions.

AIR HOISTS

Lifting Capacities 1100 LBS. - 2200LBS. (500KG - 1000 KG)

Capacity 500 KG Capacity 1000 KG

1100 lbs. 2200 lbs.

EHL-500 EHR-1000 PENDANT CONTROL SWITCH

Link or Roller Chain

Link and roller chain models available. Link chain models equipped with chain
buckets.

Pendant Control Switch

Excellent control characteristics, minimal setting force required, designed for one-
handed operation. Ergonomic design with standard control hoses (2M length).
Longer hoses available.

Safety Hooks

Drop-forged, heat-treated suspension hook and load hook mounted on swivel steel
balls with safety latches.

Light Duty Air Hoists

EHW-120 EHW-120R AH-250R

Capacity 120 KG Capacity 120 KG Capacity 250 KG
260 lbs. 260 lbs. 550 lbs.
  Safe
 High Speed  Quiet
 Compact  Easy
 Lightweight Handling
RailmasterTM Monorail Systems

RailmasterTM Interlocking Monorail System

The RailmasterTM system is a varied selection of underslung cranes and overhead

runway equipment. The cranes and runway can be interlocked to enable transfer of
loads from crane to runway or crane to crane for maximum flexibility of hoist hook
coverage. Some of its main features are:

 A tough hard wearing alloy steel used

for crane runways and bridges.

 All crane wheels are flangeless, have

hardened treads, are mounted on ball
bearings.

 Trolleys are fitted with ball bearing

mounted side rollers.

 All trolleys are articulated being

mounted on taper roller bearing
spherical seatings.
RailmasterTM Switches

This is a heavy-duty range of manual or power operated glide switches designed,

like the Monorail range, for easy operation and smooth trolley passage through the
curved section of the switch.

The arrangement comprises jig-welded frames, a spring-loaded latch mechanism

and robust safety guards to protect the open track ends. The switch section is
accommodated within the frame and, equipped with needle bearing runners, slides
smoothly on the framework.

As standard, all RailmasterTM switches can be fitted with a combination of one

straight and two curved tracks to give 2-way, 3-way or Y-type operation.

Turntables, 3-way rotary and cross track switches are available to suit individual
requirements.

The RailmasterTM switches are designed to accommodate four Kant ShockTM

insulated conductor bars within the framework of the switch. On automatic
installations two additional bars can be accommodated by increasing the depth of
the switch.
 A standard range of either manually or power operated glide
switches is offered. These are available with the choice of either
electrified or non-electrified track segments, according to specific
requirements.

Intended only for single track installations they enable Monorail

trolleys to be easily transferred from one runway system to
another, as required, without interrupting the work flow.

Lift and Dip Machines

Lifting and dipping operations can be performed on the RailmasterTM Monorail

System without load transfer. Similarly loads can be transferred between high
and low level tracks.

The machines can be operated by air or electric power.

The illustration shows the vertical air cylinder application with twin guides. When
headroom is limited a similar arrangement can be accommodated with operation by
an air cylinder horizontally mounted above the dip section.

End stops on both the dip beam and the adjacent track ends operate automatically
and ensure complete safety when the dip beam is lowered.

We have a broad range of I-Beam monorail components such as:

RailmasterTM Monorail Systems

Monotractors

Monotractor transporters will tow heavy loads under power, with perfect control,
along runways and through monorail switches and bends of minimum radius.

Equipped with a solid rubber-tyred drive wheel they guarantee fast, smooth, quiet
operation. In addition, track wear is practically eliminated and the compact design
enables maximum tractive effort to be achieved from a relatively small motor.

Power feed collectors are attached to the Monotractors trolley yokes and are in
spring loaded contact with the bus bar system. It is an independent power feed
arrangement ensuring positive power pick-up at all times.

RV101

This range of tractors caters for the

twospeed travel demands of heavy loads
on push button controls or under
automatic transfer operations. Maximum
live load capacities are 11,200 lb (5,080
kg).
RV104

This is a general Purpose tractor range

with a maximum live load capacity of
4,480 lb (2,036 kg).

It is designed specifically to power travel

loads with perfect control at all times.

RV105

This range has been developed for

automatic travel installations where the
horsepower and motor frame size
determines a modified design. It is ideal
for particularly arduous site conditions
and its driving characteristics permit its
use on inclined tracks.

The Monotractor can be utilized as an independent drive for hoist or skip

transportation. The unit can also form an integral part of any specially designed
transporter assembly.

The arrangement provides for smooth, gradual acceleration when traveling under
load on either manual or automatic control.

When operated manually, push button controls for all motions are combined in one
pendant box suspended from the Monotractor and enable the operator to remain
clear of the load while effecting accurate spotting of the load.
Applications requiring greater clearances, such as
handling steel sections into and out of racking, can be
accommodated by fitting a swivel assembly. This
arrangement, mounted on the Monotractor extends the
controls further from the load and provides the added
flexibility of 90º rotation at each side of the track centre
line.

On automatic systems the heavy localized wear which

can occur due to continuous starting and stopping at
pre-programmed points is avoided since tractive effort
is applied through the rubber tire drive to the underside
of the track.
Monotractor Transporter

Installation of Erector Monorail System for Paint Booth

Features:

 Floor Supported - complete with Columns and Double

Channel Superstructure

 Superstructure outside of Paint Booth Monorail inside Paint Booth

 1000# Trolleys - total System capacity 20 Tons

 Two Glide Switches

 Flexible Installation with Clamps, Sliding Hangers and Double Channels

 System was complete and installed in 3 weeks from time of order

For the
Veterinary
Medicine

Monorail
System

in
University
For the Construction Industry

Replacing the Facade on a 20

story Cableway
Systems
"MA Bell" Building
Cable Way Track

Drive Corner Unit

Trolleys

Splice Trolleys
Double Suspension Load Bars

Idler Corner Units

90º Idler
180º Idler

Take-up Units

180º Take-up
You will be furnished a Report for each Crane with the following Cover Sheet

Date

Your Company

Street Address

City, State, Zip code

Attention:

Enclosed are our Inspection Reports as mandated by OSHA Regulation 1910.179 for
your

ð Hoists ð Cranes ð Monorails dated . These reports reflect the

conditions at the

time of inspection. Conditions can change drastically with a single misuse!

Therefore,

your operators should be trained to visually inspect the equipment before they
operate it. If your

operators are not properly trained or need to be updated, we would be glad to provide

Overhead Crane Training.

The training will include lecture, enhanced with videos, followed by a test to help you
determine the

level of competence of your operators.

Please be advised that this Inspection made no evaluation of the Design, Engineering
and

Installation of your System.

Please examine the reports carefully and note that items emphasized with color
require your attention and action as follows:
 Red DANGER Indicates an imminently hazardous situation which, if
not corrected, will result in death or serious injury.
This signal word is limited to the most extreme
situations.

WARNING Indicates a potentially hazardous situation which, if

Orange not

corrected, could result in death or serious injury.

Yellow CAUTION Indicates a potentially hazardous situation which, if

not

corrected, may result in minor or moderate injury.

Blue NOTICE Indicates a potential situation which, if not corrected,

could or will result in equipment damage.

Please contact the undersigned with any question or concerns you may have
regarding these reports.

Truly yours,

________________________