OPERATION, SERVICE

AND
PARTS MANUAL
SINGLE AND DOUBLE GIRDER
TOP RUNNING BRIDGES
WITH
INDIVIDUAL MOTOR DRIVEN TRUCKS

June, 2009 Copyright 2009, Yale Lift-Tech, division of Columbus McKinnon Corporation Part No. 115326-19
 FOREWORD should be securely fastened to the runway beam.
This manual contains important information to help you install, INSTALLING BRIDGE CRANE
operate, maintain and service your new top running single or
double girder bridge crane. We recommend that you study The installation of the crane on the runway shall be performed
its contents thoroughly before putting the bridge crane into only by a qualified crane installer.
use. With proper installation, application of correct operating
For information regarding attaching, lifting and moving the loads
procedures, and practicing the recommended maintenance
during installation, refer to ANSI B30.2-latest edition, Chapter
suggestions you will be assured of the maximum service from
2-3 Overhead and Gantry Cranes (Top Running Bridge, Single
your bridge crane.
or Multiple Girder, Top Running Trolley Hoist; ANSI B30.17-latest
edition, Chapter 17-3 Overhead and Gantry Cranes (Top Running
The bridge cranes described in this manual are intended for
Bridge, Single Girder, Underhung Hoist) and other applicable
indoor service. Bridge cranes to be used for outdoor service
codes.
require special considerations.

IMPORTANT WARNING
When ordering replacement parts be sure to include Catalog,
Part and Serial Numbers of the endtrucks and or drive gearmotor Before installing the crane on the runway, lock the
along with individual part numbers of components needed as runway conductor disconnect switch in the open (off)
identified elsewhere in this manual. position.

Information given in this manual is subject to change without

notice. Prior to the start of any crane erection the building should be
measured to confirm span and clearances. These measurements
should be checked against the corresponding crane
GENERAL DESCRIPTION measurements to insure correctness of “fit”. After assuring that
the crane fits the building, determine orientation of crane position
GENERAL with respect to the runway. In addition, verify building and runway
power supply to ensure it matches the power requirements of
These top running bridge cranes are designed to operate
the crane.
on parallel crane runway beams with ASCE Rail from 25# to
105# rail or square bar. Specific rail range is wheel diameter
These types of cranes are usually lifted into position on the runway
dependant. Motors are designed for operation on three phase
in one piece. Total weight of this crane should be checked against
power supplies from 190 to 415 V-50 Hz and 200 to 575 V-60 Hz.
lifting equipment selected for erection of this crane.
Bridge motors and brakes are designed and intended strictly for
variable frequency control operated by pushbutton pendant or
Immediately after the crane is placed on the runway rails check the
radio control. Pendant may be located and suspended from an
wheel flange clearances to the rail. Clearance between the side
independent festoon or attached directly to the hoist and trolley.
of rail head and inside flange of wheel should be between a total
Top running single girder cranes described herein are built to 1
of 3/4” and 1-1/8”, depending on the wheel and rail combination
through 15 tonne capacities with spans to 60 feet (18.2 meter).
and whether or not the truck is centered on the rail. Total wheel
Top running double girder cranes described herein are built to 1
float should not be less than the 3/4" as recommended by CMAA
through 20 tonne with spans to 50 feet (15.2 meter). Cranes are
Specifications #70 and #74.
designed per CMAA Specifications 70 and 74 to meet Class C
Moderate Duty Service classification.
Note: It is suggested that the trolley and hoist be
installed on the bridge crane at this time so that all
BASIC CONSTRUCTION wiring connections can be completed.
The basic construction of single and double girder top running
bridges consist of American Standard S, W Section or fabricated
box girder(s) rigidly connected to the top and side of each endtruck. TYPICAL CONNECTION OF BRIDGE TO ELECTRICAL
Each endtruck has a drive and trailer wheel which run on the SERVICE
runway rails. The wheels are double flanged, flat tread with an
The crane inter-connection diagram is shown in Figure 10.
integral rotating axle supported by anti-friction bearings. Each
endtruck is driven by a helical gearmotor and brake. This drive
engages the drive wheel by a splined connection.
CAUTION
INSTALLATION 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
GENERAL not operate crane until "Start Up and Pre-Operational
The runways on which these cranes will operate must be Inspection" are made.
sufficiently strong enough to support bridge crane, hoisting
equipment and rated load. Runway rails must be level and
parallel with +/- 1/8”. Rail joints must be smooth and held firmly
in alignment either by bolted splice bars or by welding. Rails

Page 2
 motor) in accordance with the appropriate crane interconnection
WARNING wiring diagram as shown in Figure 10. If bridge motors quick
connection plugs are not pre-wired, connect leads on motor
Before attempting any electrical connections the main cables from the bridge control panel per Figure 1.
power switch feeding the runway conductors must be
LOCKED IN THE OPEN (OFF) POSITION.

NOTICE
A fused disconnect switch or circuit breaker must be
installed and electrically positioned between building
power supply and crane runway conductor system. This
disconnect must be lockable in the open position, in-sight
and in-reach for the crane operator, and clearly labeled.
A second lockable disconnect is required on the bridge
crane, electrically positioned between the runway conductor
system and bridge controls. Refer to Article 610 of NFPA
No. 70 National Electric Code, OSHA Regulation 1910.179,
ANSI/ASME B30.2 and B30.17, local, state and provincial
standards and regulations for specific requirements.

CAUTION Figure 1. Bridge Gear Motor Quick Connection Plug

In accordance with Article 610 of NFPA No. 70 National
Electric Code a separate bonding conductor must be run
for ground. Grounding through the wheels to girders and
runway steel is not permitted.
CAUTION
Gearmotors provided with this crane kit are intended for
RUNWAY CONDUCTORS variable frequency control only. The brake used on the
Motorized bridge cranes and bridge cranes equipped with a gearmotor is a holding brake with no provision for torque
motorized trolley or hoist require runway conductors. Install adjustment. Severe load swing will result without the
conductors according to manufacturer’s instructions and in controlled deceleration when stopping provided by the
accordance with National, State and Local codes. variable frequency control. The use of contactor, across
the line starting, controls is not permitted, will result in
damage and premature failure of these units and void any
RUNWAY COLLECTORS warranty.
Install, adjust and align collectors with runway conductors.
Connect collectors to appropriate crane wiring as shown in
Crane Inter-Connection Diagram Figure 10.
NOTICE
Prior to placing the crane into service, the crane shall
NOTICE receive an initial inspection. This inspection should be
performed by a qualified person in accordance with ANSI/
A minimum of two collector shoes for each conductor bar ASME B30.2 or B30.17, local, state and provincial standards
is required when using variable frequency drives (inverters) and regulations.
on bridge and/or hoist controls, per Section 5.14.7 of CMAA
Specifications #70 and #74. Yale•Shaw-Box standard bridge
controls utilize variable frequency drive. START-UP AND PRE-OPERATIONAL INSPECTION
After the crane has been installed on the runway and the crane,
hoist and trolley has been connected to electrical service but prior
CROSS CONDUCTORS & PUSHBUTTON FESTOON to placing into service, as a minimum the following inspections
should be made by a qualified person.
In most cases, the cross conductors and pushbutton festoon, if
provided, will be installed on your crane as received; however, if 1. Check the main collector system for proper adjustment to
the conductors have been separately shipped, be certain that the maintain proper contact with conductors. Check along runway
instructions covering installation of these conductors are carefully for possible interference if power is supplied by a cable reel or
followed. Connect all wiring on the crane (main collectors to bridge festooned cable.
panel, bridge panel to cross conductors, bridge panel to bridge

Page 3
 3. who has not been properly instructed.
WARNING
4. who has not been informed and does not have a thorough
Lock main runway disconnect switch in open position knowledge of all applicable safe operating practices, including
before attempting to adjust main collectors or those in this book as well as of rigging equipment and
conductors. practices.

2. Check the cross and pushbutton festoon conductors for

adjustment, including cable loop depth, and tracking. NOTICE
3. Check oil level in both drive gearcases and axle bearing grease See applicable National, State and Local Safety Codes
fittings (if provided) for proper lubrication. If lubrication is required and regulations for additional requirements relating to
refer to the LUBRICATION SECTION of this manual. Safe Operating Practices, including ANSI B30.2 or ANSI
B30.17 - latest edition.
4. Inspect crane to make certain that all bolted connections
and attachments are properly tightened and that all electrical
connections are secure. OPERATING RULES

5. Inspect and adjust the motor brake air gap. Refer to the Operating rules listed below are an earnest effort to encourage
MAINTENANCE SECTION of this manual. SAFETY and are not intended to take precedence over individual
plant safety rules and regulations or rules set forth by various
6. The hoist/trolley should be inspected as instructed in the hoist/ applicable codes.
trolley manufacturers instruction manual. For a single girder
crane inspect the clearance between the trolley wheels and toe A good operator operates his crane as smoothly as possible and
of flange on bridge girder beam per manufacturers requirements. knows and follows the suggested rules below for safe, efficient
For a double girder crane inspect the clearance between wheel crane handling.
flanges and the girder rail per manufacturers requirements. If
hoist is equipped with adjustable limit switches, confirm settings
meet the applications requirements. OPERATING PRECAUTIONS

7. Inspect the alignment of the trolley end stops to the trolley

and the runway end stops to the bridge endtrucks. WARNING
8. Turn power on at both disconnects and mainline. Inspect hoist These bridge cranes are not designed nor intended
for reverse phase condition by ensuring push button operation to be used for support or transport of people or for
corresponds to intended direction of travel and correct if necessary transporting loads over people.
per manufacturer’s instructions.

9. Operate the crane to verify both motors operate in the same Safe operation of an overhead hoist is the operator’s responsibility.
direction, in both bridge directions. Listed below are some basic rules that can make an operator
aware of dangerous practices to avoid and precautions to take
10. With no load operate hoist/trolley back and forth the full for his own safety and the safety of others. Observance of
length of bridge girder and operate the crane the full length these rules in addition to frequent examinations and periodic
of the runway. During the operation ensure and verify proper inspection of the equipment may save injury to personnel and
clearances from obstructions per CMAA, ASME B30.2, ASME damage to the equipment.
B30.17 and OSHA requirements.
DO NOT load bridge beyond rated capacity.
11. Load testing the crane should be performed in accordance
with ANSI/ASME B30.2 or B30.17, local, state and/or provincial DO NOT subject bridge crane to side loads. Always center
codes and regulations. A written report should be prepared during trolley over load when hoisting.
the performance of this test and placed on file.
DO NOT stand and DO NOT cause or allow others to stand
or get under any load the bridge crane is supporting.
OPERATION
DO keep clear, and make sure others keep clear, of any load
the bridge crane is supporting.
OPERATOR QUALIFICATIONS
Safe and efficient crane operation requires skill, extreme care, DO NOT attempt to operate bridge crane before completing
good judgment, alertness, concentration and knowledge of and tests and adjustments.
rigid adherence to proven safety rules and practices. No person
should be permitted to operate a crane or hoist: DO NOT run bridge crane into end stops, other bridge cranes,
or any obstruction on beam. Improper and careless operation
1. who does not possess the above characteristics. can result in a hazardous condition for operator and load.

2. who is not qualified or has handicaps that could adversely ALWAYS be sure load is clear of obstruction before traversing
affect such operation. load.

Page 4
 LEARNING THE CONTROLS WHILE OPERATING CRANE
CAUTION WITH NO LOAD
If bridge crane is mounted on an open-end runway rail, Having inspected and tried the control, the crane operator is
then end stops must be installed to prevent bridge crane now ready to try the crane under power.
from running off the end of the runway rail resulting in
injury to the operator and others and damages to the
load and other property. End stops for the trolley must
also be installed. CAUTION
ALWAYS ALLOW THE BRIDGE CRANE TO COME TO
A COMPLETE STOP BEFORE CHANGING DIRECTION.
Refer to hoist and trolley instruction manuals for safety ABRUPT CHANGE OF BRIDGE DIRECTION WHILE
warnings on hoists and trolleys. IN MOTION MAY CAUSE ADVERSE OPERATING
CHARACTERISTICS OR DAMAGE TO BRIDGE AND DRIVE
Read and comply with ANSI B30.2 or B30.17-latest edition. COMPONENTS.
Read and comply with all local, state and national safety
codes.
STEP 1.
Close the crane runway disconnect switch.
GENERAL
Motor driven cranes are usually operated from a pendant push STEP 2.
button station or radio control, which controls the bridge electri- Close the crane disconnect switch mounted on the crane. The
cally. The push button may be suspended from the bridge, trolley crane main disconnect switch is located in the bridge panel and
or hoist. Push button control stations, supported by a strain is operable from the front of the panel without opening the panel.
cable, have a built-in interlock to prevent energizing opposing The switch is operated by rotating the handle. The “OFF” and “ON”
motions at the same time. positions of the switch are marked on the switch assembly.

The bridge control panel also contains a 3-pole mainline contactor.

CAUTION This contactor is connected in the electrical system on the load
side of the crane main disconnect switch, so that all the crane
Make sure all INSTALLATION AND START-UP INSPECTION power flows through this contactor. The mainline contactor is
have been made in accordance with instructions furnished opened and closed (turned off and on) by means of the stop-
with the HOIST and TROLLEY before turning on the start buttons on the pendant push button station. This stop-start
power. circuit, as well as other control circuits, typically operate at 115
volts. This 115 volt control circuit voltage is obtained from a
transformer mounted in the bridge control panel.
LEARNING THE CONTROLS
After making certain the crane is completely and properly installed, STEP 3.
with the crane connected to the electrical service and all the Press the start or green push button which will close the mainline
installation and start-up inspections made, the crane operator(s) contactor, applying power to all control devices. The crane is
should learn and become acquainted with the controls. now ready for use.

On cranes having any or all motions electrically operated, the STEP 4.

operator should locate the runway disconnect and make sure The drive motors on the endtrucks of this crane are controlled
this switch is locked open (POWER OFF). The operator should by inverters, programmable variable frequency control. Standard
now operate the various push buttons to get the “feel” and programming on Yale•Shaw-Box provided controls is two step
determine that they do not bind or stick in any position. The infinitely variable. The motion buttons on the pushbutton for the
operator should become familiar with push button location for crane, typically labeled “FWD” and “REV” are two step buttons,
their respective motions as well as “start” and “stop” buttons for this programming. The first step is the initial starting speed of
(normally the top two green and red buttons), which operate the the crane and it also performs a speed hold function. The second
crane main line contactor. The mainline contactor will shut off step of the button performs an acceleration function.
power to all motions.
To operate the crane, press the button for desired direction,
FWD or REV, to the first step. The crane will start moving and
WARNING accelerate to its programmed starting speed. Press the same
button further to the second step and the crane will accelerate
If any push button binds or sticks in any position - Do up to full speed. If the crane reaches a desired speed during this
not turn the power on - Determine the cause of the acceleration, back the button off to the first step to hold that
malfunction and correct it before operating the crane. speed. If the crane is traveling too fast and you wish to slow it
down, release the motion button completely and the crane will
start to decelerate. Once the desired slower speed is obtained,
press button to the first step to hold that speed. To bring the
crane to a stop release the motion button completely, the crane
will decelerate to a stop and the holding brakes will set.

Page 5
Practice operating the crane in both directions, accelerating to
intermediate and full speeds, decelerating to a slower speed, WARNING
and bringing it to a stop. Get acquainted with the operating
characteristics of this crane, acceleration, deceleration and Do not contact or strike the hoist frame with the hook
stopping distances, to ensure smooth load movement, accurate block. If the hoist motion is not interrupted by the limit
load positioning, and to minimize load swing. switch, stop the hoist by removing your finger from
the button and/or depressing the STOP button. Do not
attempt further operation until the limit switch is operable.
Consult the Hoist Manufacturer's Instructions.
NOTICE
If default settings for the bridge’s variable frequency control,
inverter, does not meet your specific requirements it can
be re-programmed. Programming of the inverter shall be
NOTICE
done by a qualified crane technician per the manufacturer’s Jogging is the rapid and repeated pressing of a motion
instruction manual. Each crane has a maximum speed pushbutton (hoist, trolley or bridge) to get the equipment
setting based on its capacity, span, duty classification, etc. to move in short increments or “inching”. Although jogging
Do NOT exceed maximum speed for which the crane may be necessary to position a load, excessive jogging will
was specified when ordered. cause premature wear and failure of motors, brakes and
controls. It will also cause the motors to quickly overheat,
resulting in their thermal protection to disable bridge motion
STEP 5. until cooled.
The trolley motion buttons are typically labeled “Left” and “Right”.
The hoist motion buttons are typically labeled “Up” and “Down”.
Practice and become acquainted with these controls.
WARNING
THIS EQUIPMENT IS NOT DESIGNED OR SUITABLE
NOTICE AS A POWER SOURCE FOR LIFTING, LOWERING, OR
TRANSPORT OF PERSONS.
Since a variety of hoist/trolley combinations may be used
with this type of bridge crane, refer to the manufacturer’s
instruction manual for this equipment and the specific
OPERATING THE CRANE
details on its operation.
Once the crane has successfully passed its Start-up and Pre-
Operational (Initial) inspection, and all the crane operators have
STEP 6. been successfully trained and/or licensed, it is now ready to be
Once the operator(s) are acquainted and comfortable operating placed into service.
the crane and the hoist/trolley, they shall learn the Pre-Shift
inspection procedure. Refer to the INSPECTION section of this
manual. WARNING
Do not operate a crane, hoist or trolley having unusual
vibrations, sounds, warnings or with anything wrong
WARNING or apparently wrong. Danger may be present that the
crane operator cannot see. Determine and correct the
If, when depressing the hoist "Up" button, the hook cause of the unusual conditions and make certain that
should lower - STOP AT ONCE - Do not attempt to operate the crane can be operated SAFELY.
again. Report this condition to the proper supervisor
for correction with the instructions furnished with your
hoist manual by a qualified crane technician. STEP 1.
Turn power on to the crane, disconnects and mainline. If not
already done so, perform Pre-Shift Inspection, refer to the
Set lower limit switches of the hoist and insure proper functioning Inspection Section of this manual.
per the Hoist Manufacturer's Manual.
STEP 2.
When operating the hoist in the up direction CAREFULLY Move the crane to the load making certain the load hook is high
OBSERVE the relationship of the hook block and the bottom enough to clear any obstruction in its path. Position the hoist and
of the hoist frame. The hoist upper limit switch, when working trolley so that the load hook is centered over the load. Lower the
properly, should cause the hoist up motion to stop and/or reverse load hook for load attachment. For larger sized loads, the use of
direction. a rigging or load director may need to be used to direct the lift
and movement of the load. This person should use the proper
hand signals as shown in this manual. The crane operator should
respond only the signals of the designated person directing the
load, except for emergency stop as shown in Figure 2.

Page 6
 can be increased and maintained until the load is clear of all
WARNING obstructions or the floor man gives the signal to stop.

Prior to attaching or lifting a load, know the weight of STEP 4.

the load and the below the hook lifting devices (spreader Starting slowly and increasing speed as distance permits, move
or lifting beams, magnets, grabs, slings, etc.). The total the bridge toward the point where the load is to be lowered.
weight of the load and lifting devices shall not exceed Decelerate and stop by releasing the push button. Final spotting
the rated capacity of the hoist and/or crane. is accomplished by pressing the button to the first step to creep
into position.
STEP 3.
Attach load to load hook. Slowly raise the hook until the slack STEP 5.
has been taken out of the below the hook devices. When the Learn to judge the stopping distance of the bridge and trolley, both
floor man signals and the operator is satisfied the load is secure with light and full loads. This will enable you to “spot” loads with
in the sling, lift the load slowly until clear. Now, hoisting speed the minimum amount of jogging and excessive load swing.

Figure 2. Operator Hand Signals

Page 7
 equipment and all safety devices. Crane is to be operated
WARNING without a load to check for any unusual sounds, vibrations, or
anything that may be apparently wrong. Any discrepancies or
Never leave an unattended load hanging from the crane. suspected discrepancies shall be immediately reported to crane
Load must be safely placed on floor prior to the crane operator’s supervisor. Below is a check list which can be used
operator leaving the controls. for this inspection.

PRE-OPERATION INSPECTION CHECKLIST

When crane is not in use, during the work period, it should be
parked in a safe location, such as the end of the bay or a location
that will not interfere with the movement of people, materials and  Tagged Crane Check that crane or hoist is not tagged with an
or Hoist out-of-order sign.
equipment. Turn power off to the mainline contactor of the crane.
Store the pendant against a wall or column to prevent damage  Control Devices Test run that all motions agree with control
device markings.
from traffic. At the end of the work period or day, park crane as
described herein and turn power off at both disconnects.  Brakes Check that all motions do not excessive drift
and that stopping distance is normal.
 Hook Check for damage, cracks, nicks, gouges,
RESPONSIBILITY FOR SAFE OPERATION deformations of the throat opening, wear on
saddle or load bearing point, and twist. Refer
Each crane operator should be held directly responsible for the to the manual furnished by the original crane
safe operation of his crane. The crane operator should STOP manufacturer.
the crane and refuse to handle loads when:
 Hook Latch If a hook latch is required, check for proper
operation.
1. there is any doubt as to SAFETY.
 Wire Rope Check for broken wires, broken strands, kinks,
and any deformation or damage to the rope
2. any unusual vibrations or sounds are noticed before or when structure.
starting the lift or traverse motions.  Hoist Chain Check for cracks, nicks, gouges, wear and
stretch-check that the chain is in the upper and
3. there are arguments or disagreements with the floor man or lower sprockets and in the chain guide.
hitchers.  Reeving Check that the wire rope is properly reeved
and that rope parts are not twisted about each
4. the operator feels ill or is not alert. other.
 Limit Switches Check that the upper limit device stops the
lifting motion of the hoist load block before
INSPECTION striking any part of the hoist or crane.
 Oil Leakage Check for any sign of oil leakage on the crane
Overhead cranes are subject to four levels of inspection; Initial, and on the floor beneath the crane.
Pre-Shift, Frequent and Periodical in accordance with the latest  Unusual Sounds Check for any unusual sounds from the crane
editions of ANSI/ASME B30.2, B30.17 and CMAA 78. These or hoist mechanism while operating the crane
inspections are necessary to ensure the equipment is safe for use or hoist.
and operating at its required performance level. Inspection criteria  Warning and Check that warning and other safety labels are
described herein are general requirements. Specific inspection Safety Labels not missing and are legible.
criteria will be based on the options and accessories provided  Housekeeping Check area for accumulation of material to
with your crane. Refer to the manufacturer’s maintenance manual and Lighting prevent tripping or slipping. Also check area for
for the hoist/trolley and its specific inspection criteria. poor lighting.

INITIAL INSPECTION
New, re-installed, altered, repaired and modified cranes shall be FREQUENT INSPECTION
inspected prior to initial use. Inspection of all altered, repaired
or modified cranes may be limited to the provisions affected Frequent inspections are to be performed by a qualified designated
by the work as determined by a qualified crane technician. person. Inspection intervals vary by class of service, for Class C
Inspections shall include, but not limited to, clearances, operating Service cranes they are to be performed monthly at a minimum.
speeds, lubrication, control settings, safety devices, etc. Refer Hooks and wire rope or load chain are to be inspected in monthly
to START UP and PRE-OPERATIONAL INSPECTION elsewhere intervals as a minimum and recorded including date, serial/trace
in this manual. numbers and a signature. Frequent inspections also include a
thorough operational inspection. Items to be inspected include
limit switches, lubrication levels in all gearcases, wheels, bearings,
PRE-SHIFT INSPECTION etc., brakes, electrical equipment and all safety devices. Crane
is to be operated without a load to check for any unusual
A pre-shift inspection shall be performed by the crane operator or sounds, vibrations, or anything that may be apparently wrong.
designated person at the beginning of each shift, or the first time The designated person shall determine if conditions found are
the crane is used during each shift. This is a visual and operational a hazard and a more detailed inspection is necessary. Refer to
inspection to ensure the equipment is in good working order. the typical Inspection Schedule and Maintenance Report found
Items to be checked include limit switches, brakes, electrical on page 12 in this manual.

Page 8
 LUBRICATION
NOTICE
Cranes that have been sitting idle for a period between AXLE BEARINGS
one to six months shall receive the frequent inspection
Axle bearings on the 4.5" (115 mm) and 6.3" (160 mm) diameter
prior to its use.
wheels are permanently lubricated, with no additional lubrication
requirements. Axle bearings on the 7.9" (200 mm) and 10.2" (260
mm) diameter wheels require periodical lubrication. To access
PERIODIC INSPECTION grease fittings, remove the rail sweep. Fitting is located on the
pilot diameter of each bearing cage, four total per endtruck as
Periodic inspections are to be performed by a qualified designated shown in figures 3 & 4. Lubricate with NLGI #2 General Purpose
person. Inspection intervals vary by class of service. For Class C Grease, every three months. Replace rail sweep upon completion.
Service crane, they are to be performed annually at a minimum. Using a torque wrench, tighten all bolts to 72 ft. lbs. torque for all
Frequency of this inspection may have to be increased based on size end trucks. Frequency of and type of lubrication used may
the severity of the duty cycle and environmental conditions the be adjusted based the severity of the duty cycle and operating
crane is subjected to. A written, dated and signed inspection report environment.
shall be provided and maintained on file. All worn, damaged or
malfunctioning parts are to be repaired or replaced to maintain a
SAFE operational crane. Refer to the typical Inspection Schedule
and Maintenance Report found elsewhere in this manual.
Items to be inspected include but are not limited to:

1. All functional operating mechanisms for misadjustment

interfering with crane operation.
2. Operating parts for excessive wear.
3. All safety devices for malfunction.
4. All connections and mountings for loose bolts, nuts and other
fasteners for tightness.
5. All structural members and welds for deformation, cracks or
corrosion.
6. All electrical apparatus, including control contactors, limit
switches, push button stations for signs of pitted contact points,
wear or deterioration.
7. All hoists and trolleys installed on the crane in accordance
with the manufacturer’s recommendation.

Figure 3. Trailer Wheel

WARNING
Always lock main switch in the open position (off)
before inspection.

NOTICE
Cranes that have been sitting idle for six months or
greater shall receive a complete periodic inspection
prior to its use.

MAINTENANCE
GENERAL
Maintenance services required on top running cranes are, for
the most part, simple periodic inspections and adjustments.
Procedures for lubrication, routine adjustments and replacement
of parts, if required, are described in the following paragraphs. Figure 4. Drive Wheel

Page 9
GEARMOTOR (Endtruck) WHEEL AND BEARING REMOVAL & REPLACEMENT
The gearcase lubricant should be changed after 10,000 hours of Refer to parts illustration Figure 7.
use, based on moderate (Class C) service. Lubrication frequency
will need to be increased dependant on the severity of service. To remove the wheels follow the steps below:
Oil required is Aral Degol BG 220 gear oil (suitable substitutes 1. Remove load and below the hook devices from hook. Move
are Texaco Pinnacle 220 & Shell Omala 220). Do not mix lubricant hoist and trolley to opposite end of crane from end work is
types (this applies in particular to mineral and synthetic lubricants). being done.
Too much lubricant can lead to overheating. Gearcase is not
provided with, nor requires a vent plug.
WARNING
Motor Gearcase oil capacity Make sure that truck is adequately supported so that it
horsepower KW (liters) cannot drop when wheel is removed. Due to the weight
0.75 .55 .18 of the wheels and bearing cages, make sure that the
1.0 .75 .18 proper equipment is in place to safely remove the wheels
and bearing cages from the end truck. Also lock main
1.5 1.2 .40 runway disconnect switch in the open position (off) when
2.0 1.5 .55 working on wheels adjacent to runway conductors.
3.0 2.2 .55
2. Disconnect power and lock out.
To change gearcase oil:
1. Disconnect and lock out power supply. NOTICE
2. Unplug motor connection.
MAKE SURE ALL JACKING OR LIFTING OF END TRUCK
3. Unbolt complete gearmotor from endtruck. Gearmotors weigh FOR WHEEL REMOVAL IS DONE NEAR THE BRIDGE
up to approximately 75 lbs. GIRDER(S) OR SIMULTANEOUSLY AT EACH END OF
4. Remove drain/filler plug on top of gearcase as shown in THE TRUCK BETWEEN THE WHEEL AND THE GIRDER(S).
figure 5. Tip motor to drain oil in to proper container. Properly JACKING OR LIFTING ONLY ONE END OF THE TRUCK
dispose of used oil. MAY PERMANENTLY DAMAGE THE CRANE.
5. Fill gearcase with correct amount of oil per chart above and
replace drain/filler plug. 3. Remove load from wheel axle. This can be accomplished by
jacking or lifting at the girder(s). Jacking or lifting only one end
6. Mount complete gearmotor back on endtruck and bolt back
of the truck may permanently damage the crane.
into place. Using a torque wrench, tighten all bolts to 7.5 ft.
lbs. torque for 115 mm (4.5") and 160 mm (6.3") end trucks 4. If working on driver wheel, unplug motor leads from gearmotor
and 18 ft. lbs. torque for 200 mm (7.9") and 260 mm (10.2") and remove gearmotor from bearing cage. Remove rail sweep
end trucks. from endtruck and bolts from bearing cages.
7. Re-install motor plug
5. Jack endtruck to height that will allow bearing cage to roll out
8. Turn power back on to crane and test run, checking for any from end of endtruck.
signs of leaks.
6. Roll wheel, bearings and bearing caps assembly from under
endtruck and remove from runway. Be careful not to drop bearing
caps, bearings and wheel from runway height.

7. Remove bearing caps, bearings should stay on wheel axle.

8. Remove bearings from axle. Depending on the condition of

the bearings and axles, a bearing puller may be required. Be
careful not to damage bearing fits on axle.

9. Inspect axle bearing diameter and wheel tread diameter and

flange for excessive wear, spalling and work hardening on the
tread and flange, nicks and gouges on bearing diameters, etc.
Replace wheel if necessary.

10. Prior to re-assembling bearings to axle, pack the roller

bearings with grease. Use NLGI #2 general purpose grease
unless the severity of the duty cycle and/or operating environment
warrants otherwise. Press bearings onto wheel axle, ensure
Figure 5. Gearcase Drain/Filler Plug they are fully seated.

11. Assemble both bearing caps onto bearings

HOIST & TROLLEY 12. Place wheel assembly onto runway rail and roll it into place
For hoist and trolley lubrication instructions refer to the in the endtruck. Orient the grease fitting (if provided) on bearing
manufacturer’s manuals. cap, pointing towards the rail sweep.

Page 10
13. Carefully lower endtruck, ensuring bearing caps and the BRAKE REMOVAL AND REPLACEMENT
endtruck pilot diameters align properly. Install and tighten bearing If brake air gap exceeds the maximum allowed, or is not
cap bolts. Using a torque wrench, tighten all bolts to 36 ft. lbs. functioning properly, the brake may need to be replaced. Follow
torque for 115 mm (4.5"), 160 mm (6.3") and 200 mm (7.9") end these instructions.
trucks and 72 ft. lbs. torque for 260 mm (10.2") end trucks.
1. Turn power off to crane and lock out
14. Lower endtruck onto runway rail. 2. Unplug motor leads, open motor conduit box and disconnect
15. Re-install rail sweep and gearmotor. Connect motor power brake leads from rectifier
plug. Refer to page 10 for torque specifications. 3. Remove brake cover

16. Turn power back on to crane and inspect crane for proper 4. Remove retaining ring and fan (if applicable).
operation. 5. Remove (3) mounting bolts holding brake magnet body in
place. Pull brake leads from motor, remove magnet, brake coil
and rotor.
BRIDGE MOTOR BRAKES 6. Re-assemble in reverse order, and tighten mounting bolts to
specified torque.
Motor brakes are DC rectified solenoid activated, spring set disc
type brakes. Brake is intended to be used strictly as a holding 7. Turn power back on to crane and test brakes for proper
brake and does NOT have any torque adjustment for decelerating operation.
and stopping the crane. Deceleration and stopping is to be
provided by the variable frequency (inverter) motor control.

Air Gap
Brake Air Gap Inspection Motor End Bell Brake Mounting Bolts

To inspect brake air gap refer to figure 6: Shroud

1. Disconnect and lock out power supply

2. Remove brake cover
3. Carefully roll the o-ring back towards the magnet body exposing
the air gap between the armature plate and magnet. Use feeler
gauge and measure the gap between the armature plate and
magnet. If gap exceeds maximum allowed, replace the brake.

Motor Normal Maximum Brake Mounting Retaining Rings

horsepower KW Air Gap Air Gap Bolt Torque (where applicable)

0.75 .55
0.3 mm
1.0 .75
(.012 in.)
0.2 mm 3 Nm Shroud Bolt
1.5 1.2
(.008 in.) (2.2 ft. lbs.) Plastic Fan
Brake Disc (where applicable)
2.0 1.5 0.4 mm
O-Ring Magnet
3.0 2.2 (.016 in.) Body

4. Roll o-ring back into place and re-install brake cover. Figure 6. Motor Brake

5. Turn power back on to crane and test brakes for proper

operation.

ELECTRICAL
BRAKE RECTIFIER REMOVAL AND REPLACEMENT
Rectifier is located inside the motor conduit box cover. To replace 1. Gearmotors
follow these steps:
a. The bridge gearmotors are inverter duty. If gearmotor
1. Disconnect and lock out power supply. requires any service or repairs, other than what is described
2. Unplug motor leads and open conduit box. in this manual, the complete gearmotor must be replaced.
3. Remove rectifier and unplug wires. b. For hoist and trolley motors, consult the hoist and trolley
4. Plug wires into replacement rectifier. literature.
a. Connect brake leads to DC side of rectifier, terminals 2. Bridge Control Panel.
marked “+” & “–”.
a. All connections should be checked frequently for
b. Connect leads from the plug to the AC side, two terminals
tightness.
marked “~”.
5. Re-assemble in reverse order disassembly. 3. Hoist and Trolley. Panel, brakes, limit switches, etc. Consult
hoist and trolley literature for maintenance and spare parts
6. Turn power onto crane and test for proper operation.
information.

Page 11
 INSPECTION SCHEDULE AND MAINTENANCE REPORT
CRANE SERIAL NO. (MFGRS) CUSTOMER CRANE IDENTITY NO.
CAPACITY LOCATION IN PLANT
THIS INSPECTION IS MONTHLY  ANNUAL 
TYPE SEMI-ANNUAL 
VOLTAGE INSPECTED BY DATE

CONDITION
*Recommended
COMPONENT, UNIT OR PART (Check column best indicating condition when part
Inspection CORRECTIVE ACTION NOTES
and location or unit is inspected. Use note column to the right if
Interval
condition is not listed below.)
(Indicate corrective action taken during inspection and note

LUBRICATION REQ.
(Loose Parts or Wires)
REPAIR REQUIRED

REPLACEMENT

(Worn or Damaged)
date. For corrective action to be done after inspection, a

(Low Oil or Grease

SEMI-ANNUAL

Rust or Corrosion)

CLEANING OR
ADJUSTMENT
LOCATION

REQUIRED

REQUIRED

REQUIRED
MONTHLY

PAINTING
designated person must determine that the existing deficiency

ANNUAL

GOOD
COMPONENT, UNIT does not constitute a safety hazard before allowing unit to
OR PART operate. When corrective action is completed, describe and
note date in this column.)
DATE
Motor ¡
Gears & Bearings ¡
BRIDGE

Wheels ¡
Trucks ¡
Girders & Connections ¡
Footwalk & Handrail
Motor ¡
Motor Brake ¡
Mechanical Load Brake ¡
Overload Clutch ¡
Couplings ¡
Gears, Shafts & Bearings ¡
HOIST

Upper Block ¡
Lower Block ¡
Hook & Throat Opening l X Record Hook Throat Opening
Hoist Rope l
Rope Drum ¡
Guards ¡
Limit Switch ¡
Bridge Panel ¡
PUSHBUTTON
PANELS AND
CONTROL

Trolley Panel ¡
Hoist Panel ¡
Pushbutton ¡
Wiring ¡
Motor ¡
Brake (When so Equip.) ¡
Couplings ¡
Gears, Shafts & Bearings ¡
TROLLEY

Frame ¡
Wheels ¡
Bumpers ¡
Guards ¡
Conductors ¡
Collectors ¡
Monorail Joints ¡
RUNWAYS

Monorail ¡
Main Conductors ¡
Main Collectors ¡
General Condition ¡
Load Attach. Chains l
MISC.

Rope Slings & Connect. l

Change Gearcase Lub. ¡
Grounding Faults ¡
* See text for DAILY & WEEKLY REQUIREMENTS  SIGNED & DATED REPORT REQUIRED - OSHA
 INSPECTION INTERVAL X MAGNETIC PARTICLE OR EQUIVALENT EXAMINATION REQUIRED.

Typical Inspection Schedule and Maintenance Report form.

User must adjust inspection interval and components to suit his individual conditions and usage. 12382

Page 12
 REPLACEMENT PARTS
WARNING
The following parts lists and illustrations cover standard model
NON-FACTORY AUTHORIZATIONS OR MODIFICATION
cranes. Typical units are used as the basis for the exploded parts
OF EQUIPMENT AND USE OF NON-FACTORY REPAIR
illustrations; therefore, certain variations may occur from the
PARTS CAN LEAD TO DANGEROUS OPERATION AND
parts information given. For this reason always give the catalog
INJURY.
number, sales order number, model number, motor horsepower,
voltage, phase and frequency when ordering replacement parts. TO AVOID INJURY:
For motors, gear cases and electrical components, give complete Do not alter or modify equipment without factory
nameplate data. authorization.
Do use only factory provided replacement parts.

The numbers assigned to the parts of the various

assemblies in the parts lists, may not be the part
numbers used in manufacturing the part. They are
identification numbers, that when given with the
catalog number permits us to identify, select or
manufacture, and ship the correct part needed.

NOTES

Page 13
 45150901-exp

Figure 7. End Truck Assembly

115 mm Truck 160 mm Truck 200 mm Truck 260 mm Truck

Ref. Part Quantity Part Quantity Part Quantity Part Quantity
No. Description No. S.G. D.G. No. S.G. D.G. No. S.G. D.G. No. S.G. D.G.
Driver Wheel (65 mm tread) 23487501 1 1 23487601 1 1 23487701 1 1 23487801 1 1
1
Driver Wheel (88 mm tread) - - - 23487603 1 1 23487703 1 1 23487803 1 1
Trailer Wheel (65 mm tread) 23487502 1 1 23487602 1 1 23487702 1 1 23487802 1 1
2
Trailer Wheel (88 mm tread) - - - 23487604 1 1 23487704 1 1 23487804 1 1
3 Bearing Cage, Open (Driver) 23487901 1 1 23488001 1 1 23488101 1 1 23488201 1 1
4 Bearing Cage, Closed (Trailer) 23487902 3 3 23488002 3 3 23488102 3 3 23488202 3 3
5 SHCS 11802705 12 12 11802705 12 12 11802728 12 12 11802718 12 12
6 Hi-Collar Lock Washer 11803202 12 12 11803202 12 12 11803202 12 12 11803203 12 12
7 Bearing 10378011 4 4 10378016 4 4 10380106 4 4 10380106 4 4
8 Grease Fitting - - - - - - NO6099 5 5 NO6099 5 5
Rail Sweep (65 mm tread) 23488701 2 2 23488805 2 2 23488901 2 2 23489001 2 2
9
Rail Sweep (88 mm tread) - - - 23488806 2 2 23488902 2 2 23489002 2 2
10 M10-1.50 SHCS 11802729 4 4 11802729 4 4 11802729 4 4 11802729 8 8
11 M10 Flat Washer 11803101 4 4 11803101 4 4 11803101 4 4 11803101 8 8
12 M10 Hi-Collar Lock Washer 11803203 4 4 11803203 4 4 11803203 4 4 11803203 8 8
Bumper - R1 11680704 2 2 11680704 2 - - - - - - -
Bumper - R2 11680701 2 2 11680701 2 2 11680701 2 - - - -
13 Bumper - R3 - - - 11680703 2 2 11680703 2 2 11680703 2 2
Bumper - R4 - - - - - - 11680702 2 2 11680702 2 2
Bumper - R5 - - - - - - 11680705 - 2 11680705 - 2
Flat Washer - R1 11803102 2 2 11803102 2 - - - - - - -
Flat Washer - R2 11803101 2 2 11803101 2 2 11803101 2 - - - -
14 Flat Washer - R3 - - - 11803101 2 2 11803101 2 2 11803101 2 2
Flat Washer - R4 - - - - - - 11803103 2 2 11803103 2 2
Flat Washer - R5 - - - - - - 11803103 - 2 11803103 - 2
15 H.S. Hex Head Bolt Cl. 8.8 11802609 12 24 11802609 12 24 11802509 12 24 11802509 14 28
16 Hex Nut 10399109 12 24 10399109 12 24 10399110 12 24 10399110 14 28
17 Washer 11803501 12 24 11803501 12 24 11803502 12 24 11803502 14 28
18 Slotted Roll Pin 11807001 2 4 11807001 2 4 11807001 2 4 11807001 2 4
19 Hand Hole Cap Plug 10849811 4 8 10849811 4 8 10849811 4 8 10849811 4 8

Page 14
 Figure 8. Gearmotor

Gearmotor Repair Parts

115 mm Truck 160 mm Truck 200 mm Truck 260 mm Truck 260 mm Truck
Ref. (0.55 kW, ¾ hp) (0.75 kW, 1 hp) (1.2 kW, 1½ hp) (1.55 kW, 2 hp) (2.2 kW, 3 hp)
No. Description Qty Part Number Part Number Part Number Part Number Part Number
1 Mounting Hardware Kit 1 45152050 45152051 45152052 45152053
Brake Rectifier, (380/460V & 575V) 1 45152065
2
Brake Rectifier, (190/200-230V) 1 45152066
Complete Brake Kit 180VDC, (190/200-230V &
1 45152055 45152059 45152061
3 380/460V)
Complete Brake Kit 250VDC, (575V) 1 45152056 45152060 45152062
4 Fan Kit (where applicable) 1 45152075 45152077 45152078
5 Shroud Kit 1 45152080 45152082 45152083
6 Mating Easy Connect Plug (where applicable) 1 11829301
Complete Gearmotor Assembly
190volt-3phase-50Hz, 208/230volt-3phase-60Hz 45152001 45152011 45152021 45152031 45152041
7 380volt-3phase-50Hz, 460volt-3phase-60Hz 1 45152003 45152013 45152023 45152033 45152043
575volt-3phase-60Hz 45152004 45152014 45152024 45152034 45152044

Page 15
     


Figure 9. Electrical Enclosure.

Reference Quantity
Number Part Number Required Description
1 1 Fused Disconnect Switch
33190201 30A Switch
33190202 60A Switch
3 Replacement Fuses - 600V
11695215 15 AMP
11695230 30 AMP
11695260 60 AMP
2 1 Mainline Contactor
33311033 30A
33311036 60A

Page 16
 Figure 9. Electrical Enclosure (Continued)

Reference Quantity
Number Part Number Required Description
3 11695303 1 Fuse Base (30 amp)
11695313 Fuse Base (60 amp)

3 Fuses - 600V
11695202 2 AMP
11695203 3 AMP
11695204 4 AMP
11695205 5 AMP
11695206 6 AMP
11695208 8 AMP
11695210 10 AMP
11695212 12 AMP
11695215 15 AMP
11695220 20 AMP
11695225 25 AMP
11695230 30 AMP
11695240 40 AMP

4 1 Variable Frequency Drive

44849123 2 HP, 230V
44849124 3 HP, 230V
44849125 5 HP, 230V
44849126 7.5 HP, 230V
44849142 2 HP, 460V
44849143 3 HP, 460V
44849144 5 HP, 460V
44849145 7.5 HP, 460V
44494651 2 HP, 575V
44494652 3 HP, 575V
44494653 5 HP, 575V
44494654 7.5 HP, 575V

5 33310931 & 1 Brake Relay (For V.F.C. Control)

33311996
6 1 Fused Transformer
22946771 75VA, 230/460V
22946772 75VA, 208/277V
22946773 75VA, 575V
22946711 100VA, 230/460V
22946712 100VA, 208/277V
22946713 100VA, 575V
3 Fuses - 600V
11696305 .6 AMP
11696307 .8 AMP
11696308 1 AMP
11696310 1.4 AMP
11696312 2 AMP

7 11741010 3 Terminal Boards

8 11785601 1 Ground Lug

Page 17
Page 18
FIGURE 10 - INTERCONNECTION WIRING DIAGRAM
Notes
 Recommended Spare Parts for Your Yale Crane

Certain parts of your crane will, in time, require replacement under normal wear conditions. It is suggested that the following
parts be purchased for your crane as spares for future use.

1 Set of Wheel Bearings

1 Set of Fuses

Note: When ordering parts always furnish the part number and the manufacturer's serial number.

IN USA

YaleLift-Tech
P.O. Box 769
Muskegon, MI 49443-0769
www.yaleshawbox.com
Phone: 800 742-9269
Fax: 800 742-9270

WARRANTY
WARRANTY AND LIMITATION OF REMEDY AND LIABILITY

A. Seller warrants that its products and parts, when shipped, and its B. Upon Buyer’s submission of a claim as provided above and its
work (including installation, construction and start-up), when performed, substantiation, Seller shall at its option either (i) repair or replace its
will meet applicable specifications, will be of good quality and will be product, part or work at either the original f.o.b. point of delivery or
free from defects in material and workmanship. All claims for defective at Seller’s authorized service station nearest Buyer or (ii) refund an
products or parts under this warranty must be made in writing immedi- equitable portion of the purchase price.
ately upon discovery and in any event, within one (1) year from shipment C. This warranty is contingent upon Buyer’s proper maintenance and
of the applicable item unless Seller specifically assumes installation, care of Seller’s products, and does not extend to normal wear and
construction or start-up responsibility. All claims for defective products tear. Seller reserves the right to void warranty in event of Buyer’s use
or parts when Seller specifically assumes installation, construction or of inappropriate materials in the course of repair or maintenance, or if
start-up responsibility and all claims for defective work must be made Seller’s products have been dismantled prior to submission to Seller
in writing immediately upon discovery and in any event, within one for warranty inspection.
(1) year from completion of the applicable work by Seller, provided;
D. The foregoing is Seller’s only obligation and Buyer’s exclusive remedy
however, all claims for defective products and parts must be made in
for breach of warranty and is Buyer’s exclusive remedy hereunder by
writing no later than eighteen (18) months after shipment. Defective
way of breach of contract, tort, strict liability or otherwise. In no event
items must be held for Seller’s inspection and returned to the original
shall Buyer be entitled to or Seller liable for incidental or consequential
f.o.b. point upon request. THE ‘FOREGOING IS EXPRESSLY IN LIEU
damages. Any action for breach of this warranty must be commenced
OF ALL OTHER WARRANTIES WHATSOEVER, EXPRESS, IMPLIED
within one (1) year after the cause of action has accrued.
AND STATUTORY, INCLUDING, WITHOUT LIMITATION, THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS.