OPERATION, SERVICE

& PARTS MANUAL

SINGLE & DOUBLE GIRDER

TOP RUNNING BRIDGES
WITH INDIVIDUAL MOTOR DRIVEN

END TRUCKS
SINGLE GIRDER RATED LOADS:
115 mm (4.5”) thru 305 mm (12.01”)

DOUBLE GIRDER RATED LOADS:

160 mm (6.3”) thru 305 mm (12.01”)

P/N: 11532619 REV. AD August 2022

 YALE HOIST PARTS AND SERVICES ARE AVAILABLE
IN THE UNITED STATES AND IN CANADA
As a YALE Hoist and Trolley user you are assured of reliable repair and parts services through a network of Master Parts Depots and Service
Centers that are strategically located in the United States and Canada. These facilities have been selected on the basis of their demonstrated
ability to handle all parts and repair requirements promptly and efficiently. To quickly obtain the name of the Master Parts Depot or Service
Center located nearest you, call (800) 888-0985. Fax: (716) 689-5644.

LAS PIEZAS Y REPARACIONES DE LOS POLIPASTOS

DE YALE ESTÁN ASEGURADAS EN ESTADOS UNIDOS Y CANADÁ
Como usuario de un polipasto y carro de YALE le aseguramos cualquier reparación o la disponibilidad de cualquier pieza de repuesto a
través de una red de almacenes de piezas de repuesto y centros de servicio situados estratégicamente en Estados Unidos y Canadá. Estas
instalaciones se han seleccionado en base a su capacidad demostrada en la reparación de equipos y suminstro de piezas de repuesto de forma
rápida y eficaz. Para obtener la dirección del almacén de piezas de repuesto o del centro de servicio más cercano, llame al teléfono
(800) 888-0985. Fax: (716) 689-5644 (sólo en Estados Unidos y Canadá).

LE SERVICE DE RÉPARATION ET DE PIÈCES POUR PALANS

YALE EST DISPONIBLE AUX ÉTATS-UNIS ET AU CANADA
Soyez assurés qu'en temps d'utilisateur de palan et treuil YALE, d'un service de réparation et de pièces fiable par l'entremise d'un réseau de
Centres de service et de Dépôts de pièces maîtresses qui sont stratégiquement situés aux États-Unis et au Canada. Ces établissements ont été
sélectionnés sur une base de leur habileté démontrée à s'occuper promptement et efficacement des besoins de réparation de pièces. Appelez le
(800) 888-0985, Fax: (716) 689-5644 pour obtenir rapidement le nom du dépôt de pièces maîtresses ou du centre de service situé le plus près.

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

WITH INDIVIDUAL MOTOR DRIVEN 2 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
 FOREWORD BASIC CONSTRUCTION
The basic construction of single and double girder bridges consist
This manual contains important information to help you install,
of American Standard S, W Section or fabricated box girder(s)
operate, maintain and service your new top running single or
rigidly connected to the top and side of each end truck. Each
double girder bridge crane. We recommend that you study its
end truck has a drive and trailer wheel which run on the runway
contents thoroughly before putting the bridge crane into use.
rails. The wheels are double flanged, flat tread with an integral
With proper installation, application of correct operating procedures,
rotating axle supported by anti-friction bearings. Each end truck
and practicing the recommended maintenance suggestions you
is driven by a helical gearmotor and brake. This drive engages
will be assured of the maximum service from your bridge crane.
the drive wheel by a splined connection.
The bridge cranes described in this manual are intended for indoor
service. Bridge cranes to be used for outdoor service require INSTALLATION
special considerations.
GENERAL
IMPORTANT The runways on which these cranes will operate must be
sufficiently strong enough to support bridge crane, hoisting
When ordering replacement parts be sure to include Catalog, Part
equipment and rated load. Runway rails must be level and
and Serial Numbers of the end trucks and or drive gearmotor along
parallel with +/- 1/8”. Rail joints must be smooth and held firmly
with individual part numbers of components needed as identified
in alignment either by bolted splice bars or by welding. Rails
elsewhere in this manual.
should be securely fastened to the runway beam.
Information given in this manual is subject to change without notice.
INSTALLING BRIDGE CRANE
The installation of the crane on the runway shall be performed
GENERAL DESCRIPTION only by a qualified crane installer.

GENERAL For information regarding attaching, lifting and moving the loads
during installation, refer to ANSI B30.2-latest edition, Chapter
These top running bridge cranes are designed to operate on
2-3 Overhead and Gantry Cranes (Top Running Bridge, Single
parallel crane runway beams with ASCE Rail from 25# to 105# rail
or Multiple Girder, Top Running Trolley Hoist); ANSI B30.17-
or square bar. Specific rail range is wheel diameter dependant.
latest edition, Chapter 17-3 Overhead and Gantry Cranes (Top
Motors are designed for operation on three phase power supplies
Running Bridge, Single Girder, Underhung Hoist) and other
from 190 to 415 V-50 Hz and 200 to 575 V-60 Hz. Bridge motors
applicable codes.
and brakes are designed and intended strictly for variable frequency
control operated by push-button pendant or radio control. Pendant
may be located and suspended from an independent festoon or
attached directly to the hoist and trolley. Standard under running
WARNING
single girder plug & play crane kits described herein are built Before installing the crane on the runway, lock the
to 1 through 15 tonne capacities with spans to 60 feet (18.2 runway conductor disconnect switch in the open (OFF)
meter). Standard top running double girder plug & play crane kits position.
described herein are built to 1 through 20 tonne with spans to
60 feet (18.2 meter). Higher capacities & spans are available and Prior to the start of any crane erection the building should be
reviewed upon individual application. Cranes are designed per measured to confirm span and clearances. These measurements
CMAA Specifications 70 and 74 to meet Class C Moderate Duty should be checked against the corresponding crane
Service classification. measurements to insure correctness of “fit.” After assuring that
the crane fits the building, determine orientation of crane position
with respect to the runway. In addition, verify building and runway
WARNING power supply to ensure it matches the power requirements of
To prevent traverse motors from coming loose, Loctite the crane.
must be applied to mounting bolts and bolts must be
torqued properly. These types of cranes are usually lifted into position on the runway
in one piece. Total weight of this crane should be checked against
Bolt torque should be checked on a regular maintenance lifting equipment selected for erection of this crane.
schedule.
Immediately after the crane is placed on the runway rails check the
Truck Bolt Size Required Torque wheel flange clearances to the rail. Clearance between the side
of rail head and inside flange of wheel should be between a total
115 mm M6 x 1.0 x 20
7.5 to 8 ft-lbs of 3/4” and 1-1/8”, depending on the wheel and rail combination
160 mm M6 x 1.0 x 25 and whether or not the truck is centered on the rail. Total wheel
200 mm M8 x 1.25 x 30 float should not be less than the 3/4" as recommended by CMAA
18 to 20 ft-lbs Specifications #70 and #74.
260 mm M8 x 1.25 x 40
305 mm M12 x 1.75 x 45 62 to 68 ft-lbs Note: It is suggested that the trolley and hoist be
installed on the bridge crane at this time so that all
wiring connections can be completed.

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

WITH INDIVIDUAL MOTOR DRIVEN 3 P/N: 11532619 REV. AD August 2022
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OPERATION, SERVICE & PARTS MANUAL
TYPICAL CONNECTION OF BRIDGE TO ELECTRICAL CROSS CONDUCTORS & PUSH-BUTTON FESTOON
SERVICE In most cases, the cross conductors and push-button festoon, if
The crane inter-connection diagram is shown in Figure 10. provided, will be installed on your crane as received; however, if
the conductors have been separately shipped, be certain that the
instructions covering installation of these conductors are carefully
CAUTION followed. Connect all wiring on the crane (main collectors to bridge
Verify that the crane is furnished for the same voltage, panel, bridge panel to cross conductors, bridge panel to bridge
frequency and phase as the runway power supply. Crane motor) in accordance with the appropriate crane interconnection
voltage is shown on nameplate on bridge panel. Do wiring diagram as shown in Figure 10. If bridge motors quick
not operate crane until "Start Up and Pre-Operational connection plugs are not pre-wired, connect leads on motor
Inspection" are made. cables from the bridge control panel per Figure 1.

WARNING
Before attempting any electrical connections, the main
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 Figure 1. Bridge Gear Motor Quick Connection Plug
standards and regulations for specific requirements.

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

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

WITH INDIVIDUAL MOTOR DRIVEN 4 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
 • Who has not been informed and does not have a thorough
WARNING knowledge of all applicable safe operating practices,
including those in this book as well as of rigging equipment
Lock main runway disconnect switch in open position and practices
before attempting to adjust main collectors or
conductors.
NOTICE
2. Check the cross and push-button festoon conductors for
adjustment, including cable loop depth and tracking. See applicable National, State and Local Safety Codes
and regulations for additional requirements relating to
3. Check oil level in both drive gearcases and axle bearing grease Safe Operating Practices, including ANSI B30.2 or ANSI
fittings (if provided) for proper lubrication. If lubrication is B30.17 - latest edition.
required, refer to the LUBRICATION SECTION of this manual.

4. Inspect crane to make certain that all bolted connections

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

7. Inspect the alignment of the trolley end stops to the trolley WARNING
and the runway end stops to the bridge end trucks. These bridge cranes are not designed nor intended
8. Turn power on at both disconnects and mainline. Inspect to be used for support or transport of people or for
hoist for reverse phase condition by ensuring push button transporting loads over people.
operation corresponds to intended direction of travel and
correct if necessary per manufacturer’s instructions. Safe operation of an overhead hoist is the operator’s responsibility.
Listed below are some basic rules that can make an operator
9. Operate the crane to verify both motors operate in the same aware of dangerous practices to avoid and precautions to take
direction, in both bridge directions. for his own safety and the safety of others. Observance of these
rules in addition to frequent examinations and periodic inspection
10. With no load, operate hoist/trolley back and forth the full
of the equipment may save injury to personnel and damage to
length of bridge girder and operate the crane the full length
the equipment.
of the runway. During the operation, ensure and verify proper
clearances from obstructions per CMAA, ASME B30.2, ASME
DO NOT load bridge beyond rated capacity.
B30.17 and OSHA requirements.

11. Load testing the crane should be performed in accordance DO NOT subject bridge crane to side loads. Always center
with ANSI/ASME B30.2 or B30.17, local, state and/or provincial trolley over load when hoisting.
codes and regulations. A written report should be prepared
during 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
DO NOT attempt to operate bridge crane before completing
Safe and efficient crane operation requires skill, extreme care, tests and adjustments.
good judgment, alertness, concentration and knowledge of and
rigid adherence to proven safety rules and practices. No person DO NOT run bridge crane into end stops, other bridge cranes,
should be permitted to operate a crane or hoist: or any obstruction on beam. Improper and careless operation
can result in a hazardous condition for operator and load.
• Who does not possess the above characteristics

• Who is not qualified or has handicaps that could adversely ALWAYS be sure load is clear of obstruction before travers-
affect such operation ing load.

• Who has not been properly instructed

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

WITH INDIVIDUAL MOTOR DRIVEN 5 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
 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 or others, as well as damages to
the load and other property. End stops for the trolley CAUTION
must also be installed. ALWAYS ALLOW THE BRIDGE CRANE TO COME TO
A COMPLETE STOP BEFORE CHANGING DIRECTION.
Refer to hoist and trolley instruction manuals for safety warn- ABRUPT CHANGE OF BRIDGE DIRECTION WHILE
ings 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 electrically. Close the crane disconnect switch mounted on the crane. The
The push button may be suspended from the bridge, trolley or crane main disconnect switch is located in the bridge panel and
hoist. Push-button control stations, supported by a strain cable, is operable from the front of the panel without opening the panel.
have a built-in interlock to prevent energizing opposing motions The switch is operated by rotating the handle. The “OFF” and
at the same time. “ON” 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 power.
start buttons on the pendant push-button station. This stop-start
circuit, as well as other control circuits, typically operate at 115
LEARNING THE CONTROLS volts. This 115 volt control circuit voltage is obtained from a
transformer mounted in the bridge control panel.
After making certain the crane is completely and properly installed,
with the crane connected to the electrical service and all the STEP 3.
installation and start-up inspections made, the crane operator(s) Press the start or green push button which will close the mainline
should learn and become acquainted with the controls. contactor, applying power to all control devices. The crane is
now ready for use.
On cranes having any or all motions electrically operated, the
operator should locate the runway disconnect and make sure this STEP 4.
switch is locked open (POWER OFF). The operator should now The drive motors on the end trucks of this crane are controlled
operate the various push buttons to get the “feel” and determine by inverters, programmable variable frequency control. Standard
that they do not bind or stick in any position. The operator should programming on Yale•Shaw-Box provided controls is two-step
become familiar with push-button location for their respective infinitely variable. The motion buttons on the push button for the
motions as well as “start” and “stop” buttons (normally the top crane, typically labeled “FWD” and “REV” are two-step buttons,
two green and red buttons), which operate the crane main line for this programming. The first step is the initial starting speed
contactor. The mainline contactor will shut off power to all motions. of the crane and it also performs a speed hold function. The
second step of the button performs an acceleration function.

WARNING To operate the crane, press the button for desired direction,
FWD or REV, to the first step. The crane will start moving and
If any push button binds or sticks in any position - Do
accelerate to its programmed starting speed. Press the same
not turn the power on - Determine the cause of the
button further to the second step and the crane will accelerate
malfunction and correct it before operating the crane.
up to full speed. If the crane reaches a desired speed during this
acceleration, back the button off to the first step to hold that
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.

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

WITH INDIVIDUAL MOTOR DRIVEN 6 P/N: 11532619 REV. AD August 2022
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OPERATION, SERVICE & PARTS MANUAL
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 in order to ensure smooth load movement, block. If the hoist motion is not interrupted by the limit
accurate 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
NOTICE operable. Consult the Hoist Manufacturer's Instructions.

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
done by a qualified crane technician per the manufacturer’s
NOTICE
instruction manual. Each crane has a maximum speed Jogging is the rapid and repeated pressing of a motion
setting based on its capacity, span, duty classification, etc. pushbutton (hoist, trolley or bridge) to get the equipment
Do NOT exceed maximum speed for which the crane to move in short increments or “inching.” Although jogging
was specified when ordered. may be necessary to position a load, excessive jogging will
cause premature wear and failure of motors, brakes and
controls. It will also cause the motors to quickly overheat,
STEP 5. resulting in their thermal protection to disable bridge motion
The trolley motion buttons are typically labeled “Left” and “Right.” until cooled.
The hoist motion buttons are typically labeled “Up” and “Down.”
Practice and become acquainted with these controls.

WARNING
NOTICE
THIS EQUIPMENT IS NOT DESIGNED OR SUITABLE
Since a variety of hoist/trolley combinations may be used AS A POWER SOURCE FOR LIFTING, LOWERING, OR
with this type of bridge crane, refer to the manufacturer’s TRANSPORT OF PERSONS.
instruction manual for this equipment and the specific
details on its operation.
OPERATING THE CRANE
STEP 6. Once the crane has successfully passed its Start-up and Pre-
Once the operator(s) are acquainted and comfortable operating the Operational (Initial) inspection, and all the crane operators have
crane and the hoist/trolley, they shall learn the Pre-Shift inspection been successfully trained and/or licensed, it is now ready to be
procedure. Refer to the INSPECTION section of this manual. placed into service.

WARNING WARNING
If, when depressing the hoist "Up" button, the hook Do not operate a crane, hoist or trolley having unusual
should lower - STOP AT ONCE - Do not attempt to vibrations, sounds, warnings or with anything wrong
operate again. Report this condition to the proper or apparently wrong. Danger may be present that the
supervisor for correction with the instructions furnished crane operator cannot see. Determine and correct the
with your hoist manual by a qualified crane technician. cause of the unusual conditions and make certain that
the crane can be operated SAFELY.

Set lower limit switches of the hoist and insure proper functioning
per the Hoist Manufacturer's Manual. STEP 1.
Turn power on to the crane, disconnects, and mainline. If
When operating the hoist in the up direction CAREFULLY OBSERVE not already done, perform Pre-Shift Inspection. Refer to the
the relationship of the hook block and the bottom of the hoist frame. Inspection Section of this manual.
The hoist upper limit switch, when working properly, should cause
the hoist up motion to stop and/or reverse direction. STEP 2.
Move the crane to the load, making certain the load hook is high
enough to clear any obstruction in its path. Position the hoist and
trolley so that the load hook is centered over the load. Lower the
load hook for load attachment. For larger sized loads, the use of
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 to the signals of the designated person directing
the load, except for emergency stop as shown in Figure 2.

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

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OPERATION, SERVICE & PARTS MANUAL
 STEP 4.
WARNING Starting slowly and increasing speed as distance permits, move
the bridge toward the point where the load is to be lowered.
Prior to attaching or lifting a load, know the weight of the Decelerate and stop by releasing the push button. Final spotting
load and the below-the-hook lifting devices (spreader is accomplished by pressing the button to the first step to creep
or lifting beams, magnets, grabs, slings, etc.). The total into position.
weight of the load and lifting devices shall not exceed
the rated capacity of the hoist and/or crane. STEP 5.
Learn to judge the stopping distance of the bridge and trolley,
STEP 3. both with light and full loads. This will enable you to “spot” loads
Attach load to load hook. Slowly raise the hook until the slack has with the minimum amount of jogging and excessive load swing.
been taken out of the below-the-hook devices. When the floor man
signals and the operator is satisfied that the load is secure in the
sling, lift the load slowly until clear. Now hoisting speed can be
increased and maintained until the load is clear of all obstructions
or the floor man gives the signal to stop.

Figure 2. Operator Hand Signals

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

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OPERATION, SERVICE & PARTS MANUAL
 apparently wrong. Any discrepancies or suspected discrepancies
WARNING shall be immediately reported to crane operator’s supervisor.
Below is a check list which can be used for this inspection.
Never leave an unattended load hanging from the crane.
Load must be safely placed on floor prior to the crane PRE-OPERATION INSPECTION CHECKLIST
operator leaving the controls.
 Tagged Crane Check that crane or hoist is not tagged with an
When crane is not in use during the work period, it should be or Hoist out-of-order sign.
parked in a safe location, such as the end of the bay or a location  Control Devices Test run that all motions agree with control
that will not interfere with the movement of people, materials and device markings.
equipment. Turn power off to the mainline contactor of the crane.  Brakes Check that all motions do not have excessive
Store the pendant against a wall or column to prevent damage drift and that stopping distance is normal.
from traffic. At the end of the work period or day, park crane as  Hook Check for damage, cracks, nicks, gouges,
described herein and turn power off at both disconnects. deformations of the throat opening, wear on
saddle or load bearing point, and twist. Refer
to the manual furnished by the original crane
RESPONSIBILITY FOR SAFE OPERATION manufacturer.
Each crane operator should be held directly responsible for the  Hook Latch If a hook latch is required, check for proper
safe operation of their crane. The crane operator should STOP operation.
the crane and refuse to handle loads when:  Wire Rope Check for broken wires, broken strands, kinks,
and any deformation or damage to the rope
• There is any doubt as to SAFETY structure.
 Hoist Chain Check for cracks, nicks, gouges, wear and
• Any unusual vibrations or sounds are noticed before or when stretch-check that the chain is in the upper and
starting the lift or traverse motions lower sprockets and in the chain guide.

• There are arguments or disagreements with the floor man  Reeving Check that the wire rope is properly reeved
and that rope parts are not twisted about each
or hitchers other.

• The operator feels ill or is not alert  Limit Switches Check that the upper limit device stops the
lifting motion of the hoist load block before
striking any part of the hoist or crane.

INSPECTION  Oil Leakage Check for any sign of oil leakage on the crane
and on the floor beneath the crane.
Overhead cranes are subject to four levels of inspection: Initial,  Unusual Sounds Check for any unusual sounds from the crane
Pre-Shift, Frequent, and Periodical in accordance with the latest or hoist mechanism while operating the crane
or hoist.
editions of ANSI/ASME B30.2, B30.17 and CMAA 78. These
inspections are necessary to ensure the equipment is safe for use  Warning and Check that warning and other safety labels are
Safety Labels not missing and are legible.
and operating at its required performance level. Inspection criteria
described herein are general requirements. Specific inspection  Housekeeping Check area for accumulation of material to
and Lighting prevent tripping or slipping. Also check area for
criteria will be based on the options and accessories provided
poor lighting.
with your crane. Refer to the manufacturer’s maintenance manual
for the hoist/trolley and its specific inspection criteria.

FREQUENT INSPECTION
INITIAL INSPECTION
Frequent inspections are to be performed by a qualified designated
New, re-installed, altered, repaired and modified cranes shall be person. Inspection intervals vary by class of service, for Class C
inspected prior to initial use. Inspection of all altered, repaired or Service cranes they are to be performed monthly at a minimum.
modified cranes may be limited to the provisions affected by the Hooks and wire rope or load chain are to be inspected in monthly
work as determined by a qualified crane technician. Inspections intervals as a minimum and recorded including date, serial/trace
shall include, but not limited to, clearances, operating speeds, numbers and a signature. Frequent inspections also include a
lubrication, control settings, safety devices, etc. Refer to START UP thorough operational inspection. Items to be inspected include
and PRE-OPERATIONAL INSPECTION elsewhere in this manual. traverse motor mounting bolt torque (see page 3 for bolt torque
specifications), limit switches, lubrication levels in all gearcases,
wheels, bearings, etc., brakes, electrical equipment and all safety
PRE-SHIFT INSPECTION devices. Crane is to be operated without a load to check for any
unusual sounds, vibrations, or anything that may be apparently
A pre-shift inspection shall be performed by the crane operator or wrong. The designated person shall determine if conditions found
designated person at the beginning of each shift, or the first time are a hazard and a more detailed inspection is necessary. Refer
the crane is used during each shift. This is a visual and operational to the typical Inspection Schedule and Maintenance Report
inspection to ensure the equipment is in good working order. Items found on page 15 in this manual.
to be checked include limit switches, brakes, electrical equipment
and all safety devices. Crane is to be operated without a load to
check for any unusual sounds, vibrations, or anything that may be

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

WITH INDIVIDUAL MOTOR DRIVEN 9 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
 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) , 10.2" (260
mm) and 12.01” (305 mm) diameter wheels require periodical
PERIODIC INSPECTION lubrication. To access grease fittings, remove the rail sweep.
Fitting is located on the pilot diameter of each bearing cage,
Periodic inspections are to be performed by a qualified designated four total per end truck as shown in figures 3 & 4. Lubricate with
person. Inspection intervals vary by class of service. For Class C NLGI #2 General Purpose Grease, every three months. Replace
Service crane, they are to be performed annually at a minimum. rail sweep upon completion. Using a torque wrench, tighten all
Frequency of this inspection may have to be increased based on bolts to 72 ft. lbs. torque for all size end trucks. Frequency of
the severity of the duty cycle and environmental conditions the and type of lubrication used may be adjusted based the severity
crane is subjected to. A written, dated and signed inspection report of the duty cycle and operating 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:

• All functional operating mechanisms for misadjustment

interfering with crane operation.

• Operating parts for excessive wear.

• All safety devices for malfunction.

• All connections and mountings for loose bolts, nuts and other
fasteners for tightness.

• All structural members and welds for deformation, cracks

or corrosion.

• All electrical apparatus, including control contactors, limit

switches, push-button stations for signs of pitted contact
points, wear or deterioration.
• 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

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

WITH INDIVIDUAL MOTOR DRIVEN 10 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
GEARMOTOR (End Truck)
The gearcase lubricant should be changed after 10,000 hours of
use, based on moderate (Class C) service. Lubrication frequency
will need to be increased dependant on the severity of service.
Oil required is Aral Degol BG 220 gear oil (suitable substitutes are
Texaco Pinnacle 220 & Shell Omala 220). Do not mix lubricant types
(this applies in particular to mineral and synthetic lubricants). Too
much lubricant can lead to overheating. Gearcase is not provided
with, nor requires a vent plug.

Motor Gearcase oil capacity

horsepower KW (liters)
0.75 .55 .18
1.0 .75 .18
1.5 1.2 .40
2.0 1.5 .55 Figure 5. Gearcase Drain/Filler Plug
3.0 2.2 .55
5.0 3.7 1.2 HOIST & TROLLEY
For hoist and trolley lubrication instructions, refer to the
To change gearcase oil: manufacturer’s manuals.
1. Disconnect and lock out power supply. WHEEL AND BEARING REMOVAL & REPLACEMENT
2. Unplug motor connection. Refer to parts illustration Figure 7.
3. Unbolt complete gearmotor from end truck. Gearmotors weigh To remove the wheels follow the steps below:
up to approximately 170 lbs.
1.  emove load and below the hook devices from hook. Move
R
4.  emove drain/filler plug on top of gearcase as shown in
R hoist and trolley to opposite end of crane from end work
figure 5. Tip motor to drain oil in to proper container. Properly is being done.
dispose of used oil.

5.  ill gearcase with correct amount of oil per chart above and
F WARNING
replace drain/filler plug.
Make sure that truck is adequately supported so that
6.  ount complete gearmotor back on end truck and bolt back
M it cannot drop when wheel is removed. Due to the
into place. Using a torque wrench, tighten all bolts to the weight of the wheels and bearing cages, make sure
specifications listed below: that the proper equipment is in place to safely remove
the wheels and bearing cages from the end truck.
Truck Bolt Size Required Torque Also lock main runway disconnect switch in the open
115 mm M6 x 1.0 x 20 position (OFF) when working on wheels adjacent to
7.5 to 8 ft-lbs runway conductors.
160 mm M6 x 1.0 x 25
200 mm M8 x 1.25 x 30 2. Disconnect power and lock out.
18 to 20 ft-lbs
260 mm M8 x 1.25 x 40
305 mm M12 x 1.75 x 45 62 to 68 ft-lbs NOTICE
7. Re-install motor plug. MAKE SURE ALL JACKING OR LIFTING OF END TRUCK
FOR WHEEL REMOVAL IS DONE NEAR THE BRIDGE
8.  urn power back on to crane and test run, checking for any
T
GIRDER(S) OR SIMULTANEOUSLY AT EACH END OF
signs of leaks.
THE TRUCK BETWEEN THE WHEEL AND THE GIRDER(S).
JACKING OR LIFTING ONLY ONE END OF THE TRUCK
MAY PERMANENTLY DAMAGE THE CRANE.

3. Remove load from wheel axle. This can be accomplished

by jacking or lifting at the girder(s). Jacking or lifting only
one end of the truck may permanently damage the crane.

4. I f working on driver wheel, unplug motor leads from gearmotor

and remove gearmotor from bearing cage. Remove rail sweep
from end truck and bolts from bearing cages.

5.  ack end truck to height that will allow bearing cage to roll
J
out from end of end truck.

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WITH INDIVIDUAL MOTOR DRIVEN 11 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
6.  oll wheel, bearings and bearing caps assembly from under
R AMB Gearmotors
end truck and remove from runway. Be careful not to drop
Motor Normal Maximum Brake Mounting
bearing caps, bearings and wheel from runway height.
horsepower KW Air Gap Air Gap Bolt Torque
7. Remove bearing caps, bearings should stay on wheel axle. 0.75 .55
0.3 mm
8.  emove bearings from axle. Depending on the condition of
R 1.0 .75
(.012 in.)
0.2 mm 3 Nm
the bearings and axles, a bearing puller may be required. Be 1.5 1.2
(.008 in.) (2.2 ft. lbs.)
careful not to damage bearing fits on axle. 2.0 1.5 0.4 mm
9. Inspect axle bearing diameter and wheel tread diameter and 3.0 2.2 (.016 in.)
flange for excessive wear, spalling and work hardening on the 0.3 mm 0.9 mm 10 Nm
5.0 3.7
tread and flange, nicks and gouges on bearing diameters, etc. (.012 in.) (.035 in.) (7.5 ft. lbs.)
Replace wheel if necessary.

10. P
 rior to re-assembling bearings to axle, pack the roller bearings 4. Roll o-ring back into place and re-install brake cover.
with grease. Use NLGI #2 general purpose grease unless 5. Turn power back on to crane and test brakes for proper
the severity of the duty cycle and/or operating environment operation.
warrants otherwise. Press bearings onto wheel axle, ensure
they are fully seated.
Brake Air Gap Inspection for Nord Gearmotors
11. Assemble both bearing caps onto bearings.
The brake air gap is checked by placing a feeler gage between
12. P
 lace wheel assembly onto runway rail and roll it into place in metal anchor plate and the brake coil housing. This procedure
the end truck. Orient the grease fitting (if provided) on bearing is identical even for the larger twin rotor brakes.
cap, pointing towards the rail sweep.
Procedure
13. C
 arefully lower end truck, ensuring bearing caps and the end 1.  oosen the fixing screws that attach the brake to the motor’s
L
truck pilot diameters align properly. Install and tighten bearing end-shield by approximately half a turn.
cap bolts. Using a torque wrench, tighten all bolts to 36 ft. lbs.
torque for 115 mm (4.5"), 160 mm (6.3") and 200 mm (7.9") 2. If required, the brake assembly may be loosened slightly
end trucks, 72 ft. lbs. torque for 260 mm (10.2") and 305 mm from the motor’s end shield by turning the threaded setting
(12.01") end trucks. bolts (hollow screws) that surround the fixing screws, counter
clockwise, into the brake coil housing.
14. Lower end truck onto runway rail.

15. R
 e-install rail sweep and gearmotor. Connect motor power Air Gap
Motor End Bell Brake Mounting Bolts
plug. Refer to page 10 for torque specifications.
Shroud
16. T
 urn power back on to crane and inspect crane for proper
operation.

BRIDGE MOTOR BRAKES

Motor brakes are DC rectified solenoid activated, spring set disc
type brakes. Brake is intended to be used strictly as a holding brake
and does NOT have any torque adjustment for decelerating and
stopping the crane. Deceleration and stopping is to be provided
by the variable frequency (inverter) motor control. Retaining Rings
(where applicable)

Brake Air Gap Inspection for ABM Gearmotors

To inspect brake air gap refer to figure 6: Shroud Bolt

Brake Disc Plastic Fan

1. Disconnect and lock out power supply. (where applicable)
O-Ring Magnet
2. Remove brake cover. Body

3. Carefully roll the o-ring back towards the magnet body exposing
the air gap between the armature plate and magnet. Use feeler Figure 6. Motor Brake
gauge and measure the gap between the armature plate and 3.  epending upon whether or not the air gap needs to be
D
magnet. If gap exceeds maximum allowed, replace the brake. decreased or increased, turn the fixing screws accordingly
until the desired nominal air gap is reached, as measured
using the appropriate feeler gauge. Turning the fixing screws
clockwise allows the brake coil housing to be moved towards
the anchor plate and reduces the air gap. Turning the fixing
screws counter-clockwise allows the brake coil housing to be
moved away from the anchor plate and increases the air gap.

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

WITH INDIVIDUAL MOTOR DRIVEN 12 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
4. I f the setting bolts (hollow screws) were adjusted as suggested 9. Put the rubber bearing holder in touch with the brake cover.
in Step 2, re-secure the brake coil housing firmly against the
motor’s end shield by turning the setting bolts (hollow screws) 10. P
 ut the ball bearing in touch with the rubber bearing holder
clockwise, out of the brake coil housing. and lock with the retaining ring.

5. Tighten the fixing screws to the appropriate torque. 11. Put the fan and screw the two (2) screws of the clamp.

6. Re-check and measure the air gap in multiple locations to 12. Put the fan cover and tighten with four (4) M4 screws.
check for appropriate spacing. Repeat the steps as needed
until the desired air gap spacing is uniform and consistent all
the way around the brake. Fir Gearmotor
Motor Normal Maximum Brake Mounting
Nord Gearmotor horsepower KW Air Gap Air Gap Bolt Torque
Motor Normal Maximum Brake Mounting 0.75 0.55 0.3 0.4 Not Defined
horsepower KW Air Gap Air Gap Bolt Torque 1.0 0.75 0.4 0.5 Not Defined
0.75 - - - - 1.5 1.2 0.4 0.5 Not Defined
1.0 0.75 0.2 0.6 4.4 lb-ft 2.0 1.5 0.4 0.5 Not Defined
1.5 1.2 0.2 0.7 7.4 lb-ft 3.0 2.2 0.4 0.5 Not Defined
2.0 1.5 0.2 0.7 7.4 lb-ft 5.0 3.6 - - -
3.0 - - - -
5.0 - - - - BRAKE RECTIFIER REMOVAL AND REPLACEMENT
Rectifier is located inside the motor conduit box cover. To replace
Brake Air Gap Inspection for FIR Gearmotors
follow these steps:
Procedure
1. Disconnect and lock out power supply.
1. Remove the fan cover
2. Unplug motor leads and open conduit box.
2. Unscrew the (2) screws of the clamp and remove the fan.
3. Remove rectifier and unplug wires.
3. Remove the retaining ring.
4. Plug wires into replacement rectifier.
4. Unscrew the (4) M4 screws.
a. Connect brake leads to DC side of rectifier, terminals
5.  emove the brake cover, with rubber bearing holder and the
R marked “+” & “–”.
ball bearing.
b. Connect leads from the plug to the AC side, two
6.  heck the air gap (0,4÷0,5 mm) in different positions, using
C terminals marked “~”.
the feeler gauge. 5. Re-assemble in reverse order disassembly.
7. If the air gap is different than the adjustment range: 6. Turn power onto crane and test for proper operation.
a.  aintain locked the first nut (and the rotor shaft) with the
M
adjustable spanner.
BRAKE REMOVAL AND REPLACEMENT
b.  sing a second adjustable spanner, completely unscrew
U
the second nut. If brake air gap exceeds the maximum allowed, or is not
functioning properly, the brake may need to be replaced. Follow
c. Clean the shaft thread from the old thread-lock. these instructions.
d.  sing the first adjustable spanner, adjust the air gap
U 1. Turn power off to crane and lock out.
(maintain locked the rotor shaft):
CW rotation = air gap (DECREASE) 2.  nplug motor leads, open motor conduit box and disconnect
U
CCW rotation = air gap (INCREASE) brake leads from rectifier.
e. Check using the feeler gauge in different positions. 3. Remove brake cover.
f.  ut a drop of LOCTITE 270 thread-lock on the shaft thread
P 4. Remove retaining ring and fan (if applicable).
and tighten the second nut without touching the first nut.
g.  o not move/rotate the first adjustable spanner (first nut)
D 5.  emove three (3) mounting bolts holding brake magnet body
R
to the brake disk lining, otherwise the air gap changes. in place. Pull brake leads from motor, remove magnet, brake
Tighten the second nut. coil and rotor.
h. Check the air gap again to confirm the right adjustment. 6.  e-assemble in reverse order, and tighten mounting bolts
R
If adjustments are needed, lightly unscrew the second to specified torque.
nut and follow points d – e. Then, finish by following
points g – h. 7. Turn power back on to crane and test brakes for proper
operation.
8.  osition the brake cover using a bit of grease and tighten the
P
four (4) M4 screws.

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

WITH INDIVIDUAL MOTOR DRIVEN 13 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
ELECTRICAL
1. Gearmotors

a.  he bridge gearmotors are inverter duty. If gearmotor

T
requires any service or repairs, other than what is
described in this manual, the complete gearmotor must
be replaced.
b. For hoist and trolley motors, consult the hoist and trolley
literature.
2. Bridge Control Panel.

a. All connections should be checked frequently for

tightness.
3.  oist and Trolley. Panel, brakes, limit switches, etc. Consult
H
hoist and trolley literature for maintenance and spare parts
information.

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

WITH INDIVIDUAL MOTOR DRIVEN 14 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
 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  X Record Hook Throat Opening
Hoist Rope 
Rope Drum 
Guards 
Limit Switch 
Bridge Panel 
PUSH BUTTON
PANELS AND
CONTROL

Trolley Panel 
Hoist Panel 
Push Button 
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 
MISC.

Rope Slings & Connect. 

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

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

WITH INDIVIDUAL MOTOR DRIVEN 15 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
 REPLACEMENT PARTS
The following parts lists and illustrations cover standard model
WARNING
cranes. Typical units are used as the basis for the exploded parts NON-FACTORY AUTHORIZATIONS OR MODIFICATION
illustrations; therefore, certain variations may occur from the OF EQUIPMENT AND USE OF NON-FACTORY REPAIR
parts information given. For this reason always give the catalog PARTS CAN LEAD TO DANGEROUS OPERATION AND
number, sales order number, model number, motor horsepower, INJURY.
voltage, phase and frequency when ordering replacement parts.
For motors, gear cases and electrical components, give complete TO AVOID INJURY:
nameplate data. Do not alter or modify equipment without factory
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

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WITH INDIVIDUAL MOTOR DRIVEN 16 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
 45150901-exp

Figure 7. End Truck Assembly

115 mm Truck 160 mm Truck 200 mm Truck 260 mm Truck 305 mm Truck
Ref. Part Quantity 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. 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 45483903 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 45483904 1 1
3 Bearing Cage, Open (Driver) 23487901 1 1 23488001 1 1 23488101 1 1 23488201 1 1 45483801 1 1
4 Bearing Cage, Closed (Trailer) 23487902 3 3 23488002 3 3 23488102 3 3 23488202 3 3 45483802 3 3
5 SHCS 11802705 12 12 11802705 12 12 11802728 12 12 11802718 12 12 11802718 12 12
6 Hi-Collar Lock Washer 11803202 12 12 11803202 12 12 11803202 12 12 11803203 12 12 11803203 12 12
7 Bearing 10378011 4 4 10378016 4 4 10380106 4 4 10380106 4 4 10380108 4 4
8 Grease Fitting - - - - - - NO6099 5 5 NO6099 5 5 NO6099 4 4
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 45492701 2 2
10 M10-1.50 SHCS 11802729 4 4 11802729 4 4 11802729 4 4 11802729 8 8 11802729 8 8
11 M10 Flat Washer 11803101 4 4 11803101 4 4 11803101 4 4 11803101 8 8 11803101 8 8
12 M10 Hi-Collar Lock Washer 11803203 4 4 11803203 4 4 11803203 4 4 11803203 8 8 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 11680702 2 2
Bumper - R5 - - - - - - 11680705 - 2 11680705 - 2 11680705 2 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 11803103 2 2
Flat Washer - R5 - - - - - - 11803103 - 2 11803103 - 2 11803103 2 2
15 H.S. Hex Head Bolt Cl. 8.8 11802609 12 24 11802609 12 24 11802509 12 24 11802509 14 28 11802509 14 28
16 Hex Nut 12 24 10399109 12 24 10399110 12 24 10399110 14 28 10399110 14 28
17 Washer 11803501 12 24 11803501 12 24 11803502 12 24 11803502 14 28 11803502 14 28
18 Slotted Roll Pin 11807001 2 4 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 10849811 2 4

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WITH INDIVIDUAL MOTOR DRIVEN 17 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
 Figure 8. Gearmotor

ABM Gearmotor Repair Parts

115 mm 160 mm 200 mm 260 mm 260 mm 305 mm
Truck Truck Truck Truck Truck Truck
(0.55 kW, ¾ (0.75 kW, 1 (1.2 kW, 1½ (1.55 kW, 2 (2.2 kW, 3 (3.7 kW, 5
Ref. hp) hp) hp) hp) hp) hp)
No. Description Qty Part Number Part Number Part Number Part Number Part Number Part Number
1 Mounting Hardware Kit 1 45152050 45152051 45152052 45152053 45152054
Brake Rectifier, (380/460V & 575V) 1 45152066 45152066
2
Brake Rectifier, (190/200-230V) 1 45152065 45152065
Complete Brake Kit 180VDC, (190/200-230V
1 45152055 45152059 45152061 45152063
3 & 380/460V)
Complete Brake Kit 250VDC, (575V) 1 45152056 45152060 45152062 45152064
4 Fan Kit (where applicable) 1 45152075 45152077 45152078 33295051
5 Shroud Kit 1 45152080 45152082 45152083 33295055
6 Mating Easy Connect Plug (where applicable) 1 11829301
ABM Complete Gearmotor Assembly
190volt-3phase-50Hz, 208/230volt-3phase-
45152001 45152011 45152021 45152031 45152041 451520100
60Hz
7 1
380volt-3phase-50Hz, 460volt-3phase-60Hz 45152003 45152013 45152023 45152033 45152043 451520101
575volt-3phase-60Hz 45152004 45152014 45152014 45152034 45152044 451520102

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WITH INDIVIDUAL MOTOR DRIVEN 18 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
 Nord Gearmotor Repair Parts
115 mm 160 mm 200 mm 260 mm 260 mm 305 mm
Truck Truck Truck Truck Truck Truck
(0.55 kW, ¾ (0.75 kW, 1 (1.2 kW, 1½ (1.55 kW, 2 (2.2 kW, 3 (3.7 kW, 5
Ref. hp) hp) hp) hp) hp) hp)
No. Description Qty Part Number Part Number Part Number Part Number Part Number Part Number
1 Mounting Hardware Kit 1 45328550 45328551 45328552 45328553 N/A
2 Rectifier Repair Part, (208V) 1 45328565 N/A
Rectifier Repair Part, (190/230 280/460V) 45328566 N/A
Rectifier Repair Part, (575V) 1 45328567 N/A
3 Brake Repair Kit, (208V) 1 45328553 45328555 45328557 N/A
Brake Repair Kit, (190/230 280/460V) 45328553 45328555 45328557 N/A
Brake Repair Kit, (575V) 1 45328554 45328556 N/A
N/A Brake Release Handle 1 45328560 45328561 N/A
4 Fan Kit (where applicable) 1 45328575 45328577 45328578 N/A
5 Shroud Kit 1 45328580 45328582 45328583 N/A N/A
6 Mating Easy Connect Plug (where applicable) 1 11829301
Nord Complete Gearmotor Assembly
208-3phase-60Hz 45328502 45328512 45328522 45328532 45328542 N/A
190volt-3phase-50Hz, 230volt-3phase-60Hz
7 1 45328503 45328513 45328523 45328533 45328543 N/A
380volt-3phase-50Hz, 460volt-3phase-60Hz
575volt-3phase-60Hz 45328504 45328514 45328524 45328534 45328544 N/A

FIR Gearmotor Repair Parts

115 mm 160 mm 200 mm 260 mm 260 mm 305 mm
Truck Truck Truck Truck Truck Truck
(0.55 kW, ¾ (0.75 kW, 1 (1.2 kW, 1½ (1.55 kW, 2 (2.2 kW, 3 (3.7 kW, 5
Ref. hp) hp) hp) hp) hp) hp)
No. Description Qty Part Number Part Number Part Number Part Number Part Number Part Number
1 Mounting Hardware Kit 1 45319150 45319151 45319152 45319153 45319153 N/A
2 Rectifier Repair Part, (190V) 1 45319165 45319167 45319165 N/A
Rectifier Repair Part, (208/230V) 1 45319165 45319167 45319165 N/A
Rectifier Repair Part, (380V) 1 45319165 N/A
Rectifier Repair Part, (460V) 1 45319165 N/A
Rectifier Repair Part, (575V) 1 45319166 N/A N/A N/A
3 Brake Repair Kit, (190V) 1 45319156 43519159 45319161 N/A
Brake Repair Kit, (208/230V) 1 45319156 43519159 45319161 N/A
Brake Repair Kit, (380V) 1 45319155 43519159 45319158 N/A
Brake Repair Kit, (460V) 1 45319155 43519159 45319158 N/A
Brake Repair Kit, (575V) 1 45319157 43519160 45319158 N/A
N/A Brake Release Handle 1 N/A N/A N/A N/A N/A N/A
4 Fan Kit (where applicable) 1 N/A
45319175 45319177 45319178
5 Shroud Kit 1 N/A
6 Mating Easy Connect Plug (where applicable) 1 11829301
FIR Complete Gearmotor Assembly
190volt-3phase-50Hz 45319101 45319111 45319121 45319131 45319141 N/A
208/230volt-3phase-60Hz 45319101 45319111 45319121 45319131 45319141 N/A
7 380volt-3phase-50Hz 1 45319103 45319113 45319123 45319133 45319143 N/A
460volt-3phase-60Hz 45319103 45319113 45319123 45319133 45319143 N/A
575volt-3phase-60Hz 45319104 45319114 45319124 45319134 45319144 N/A

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

WITH INDIVIDUAL MOTOR DRIVEN 19 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
    





Figure 9. Electrical Enclosure

Reference Quantity
Number Part Number Required Description
1 1 Fused Disconnect Switch

33353201 30 AMP Switch

33353202 60 AMP Switch

3 Replacement Fuses - 600V

11692515 15 AMP

11695230 30 AMP

11695260 60 AMP

2 1 Mainline Contactor

33311033 30 AMP

33311036 60 AMP

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

WITH INDIVIDUAL MOTOR DRIVEN 20 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
 Figure 9. Electrical Enclosure (Continued)

Reference Quantity
Number Part Number Required Description
3 1 Fuse Base
11695303 30 AMP
11695313 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
45199723 2 HP, 230V
45199724 3 HP, 230V
45199725 5 HP, 230V
45199726 7.5 HP, 230V
45199727 10 HP, 230V
45199742 2 HP, 460V
45199743 3 HP, 460V
45199744 5 HP, 460V
45199745 7.5 HP, 460V
45199746 10 HP, 460V
45334652 2 HP, 575V
45334653 3 HP, 575V
45334654 5 HP, 575V
45334655 7.5 HP, 575V
45334656 10 HP, 575V
5 33310931 1 Brake Relay (For VFC Control)
33311996 Surge Surpressor
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

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

WITH INDIVIDUAL MOTOR DRIVEN 21 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
 FIGURE 10 - INTERCONNECTION WIRING DIAGRAM

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

WITH INDIVIDUAL MOTOR DRIVEN 22 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
 RECOMMENDED SPARE PARTS
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 Hoist Serial Number, Catalog Number, Motor Horsepower, Voltage, Phase, Frequency
and Rated Load of Hoist on which the parts are to be used.
PARTS AND SERVICES ARE AVAILABLE IN THE UNITED STATES AND IN CANADA
Parts for your hoist or trolley are available from your local authorized repair station. For the name of the nearest parts or service center,
visit our website www.columbusmckinnon.com or call the Columbus McKinnon customer service department at (800) 888-0985.

Notes

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

WITH INDIVIDUAL MOTOR DRIVEN 23 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
 WARRANTY
LIMITATION OF WARRANTIES, REMEDIES AND DAMAGES

THE WARRANTY STATED BELOW IS GIVEN IN PLACE OF ALL OTHER GOODS THAT SELLER DETERMINES TO HAVE BEEN DEFECTIVE OR, IF SELLER
WARRANTIES, EXPRESS OR IMPLIED, OF MERCHANTABILITY, FITNESS FOR DETERMINES THAT SUCH REPAIR OR REPLACEMENT IS NOT FEASIBLE, TO
A PARTICULAR PURPOSE, OR OTHERWISE, NO PROMISE OR AFFIRMATION A REFUND OF THE PURCHASE PRICE UPON RETURN OF THE GOODS TO
OF FACT MADE BY ANY AGENT OR REPRESENTATIVE OF SELLER SHALL SELLER. NO CLAIM AGAINST SELLER FOR ANY BREACH OF
CONSTITUTE AWARRANTY BY SELLER OR GIVE RISE TO ANY LIABILITY
(i) SUCH WARRANTY WITH RESPECT TO THE ELECTRICAL COMPONENTS OF
OR OBLIGATION.
ANY GOOD SHALL BE VALID OR ENFORCEABLE UNLESS BUYER’S WRITTEN
Seller warrants that on the date of delivery to carrier the goods are free from NOTICE THEREOF IS RECEIVED BY SELLER WITHIN ONE (1) YEAR FROM THE
defects in workmanship and materials. DATE OF SELLER’S DELIVERY TO THE CARRIER AND (ii) SUCH WARRANTY
WITH RESPECT TO THE MECHANICAL COMPONENTS OF ANY GOOD SHALL
SELLER’S SOLE OBLIGATION IN THE EVENT OF BREACH OF WARRANTY
BE VALID OR ENFORCEABLE UNLESS BUYER’S WRITTEN NOTICE THEREOF
OR CONTRACT OR FOR NEGLIGENCE OR OTHERWISE WITH RESPECT TO
IS RECEIVED BY SELLER WITHIN ONE (1) YEAR FROM THE DATE THE DATE
GOODS SOLD SHALL BE EXCLUSIVELY LIMITED TO REPAIR OR REPLACEMENT,
ANY ALLEGED CLAIM ACCRUES. EXCEPT FOR THE WARRANTY SET FORTH
F.O.B. SELLER’S POINT OF SHIPMENT, OF ANY PARTS WHICH SELLER
ABOVE, SELLER MAKES NO OTHER WARRANTIES WITH RESPECT TO THE
DETERMINES TO HAVE BEEN DEFECTIVE or if Seller determines that such
GOODS, WHETHER EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTIES
repair or replacement is not feasible, to a refund of the purchase price upon
OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, QUALITY
return of the goods to Seller.
AND/OR THOSE ARISING BY STATUTE OR OTHERWISE BY LAW OR FROM
Any action against Seller for breach of warranty, negligence or otherwise, must ANY COURSE OF DEALING OR USE OF TRADE, ALL OF WHICH ARE HEREBY
be commenced within one year after such cause of action occurs. EXPRESSLY DISCLAIMED.
NO CLAIM AGAINST SELLER FOR ANY DEFECT IN THE GOODS SHALL BE C. IN NO EVENT SHALL SELLER BE LIABLE TO BUYER OR ANY THIRD PARTY
VALID OR ENFORCEABLE UNLESS BUYER’S WRITTEN NOTICE THEREOF IS WITH RESPECT TO ANY GOOD, WHETHER IN CONTRACT, TORT OR OTHER
RECEIVED BY SELLER WITHIN ONE YEAR FROM THE DATE OF SHIPMENT. THEORY OF LAW, FOR LOSS OF PROFITS OR LOSS OF USE, OR FOR ANY
Seller shall not be liable for any damage, injury or loss arising out of the use of INCIDENTAL, CONSEQUENTIAL, SPECIAL, DIRECT OR INDIRECT DAMAGES,
the goods if, prior to such damage, injury or loss, such goods are (1) damaged HOWSOEVER CAUSED. SELLER’S MAXIMUM LIABILITY TO BUYER WITH
or misused following Seller’s delivery to carrier; (2) not maintained, inspected, RESPECT TO THE GOODS SHALL IN NO EVENT EXCEED THE PRICE PAID BY
or used in compliance with applicable law and Seller’s written instructions and BUYER FOR THE GOODS THAT ARE THE SUBJECT OF THE APPLICABLE CLAIM.
recommendations; or (3) installed, repaired, altered or modified without compliance
D. Seller shall not be liable for any damage, injury or loss arising out of the use of
with such law, instructions or recommendations.
the Goods if, prior to such damage, injury or loss, such Goods are: (1) damaged
UNDER NO CIRCUMSTANCES SHALL SELLER BE LIABLE FOR INCIDENTAL OR or misused following Seller’s delivery to the carrier; (2) not maintained, inspected,
CONSEQUENTIAL DAMAGES AS THOSE TERMS ARE DEFINED IN SECTION or used in compliance with applicable law and Seller’s written instructions and
2-715 OF THE UNIFORM COMMERCIAL CODE. recommendations; or (3) installed, repaired, altered or modified without compliance
INDEMNIFICATION AND SAFE OPERATION with such laws, instructions or recommendations.

Buyer shall comply with and require its employees to comply with directions set E. This warranty is limited and provided only to the original end user. Each Good
forth in instructions and manuals furnished by Seller and shall use and require must be registered within sixty (60) days of receipt of each product to establish
its employees to follow such instructions and manuals and to use reasonable eligibility. Please register at https://www.columbusmckinnon.com/en-us/warranty-
care in the use and maintenance of the goods. Buyer shall not remove or permit registration/ or submit registration card via US mail.
anyone to remove any warning or instruction signs on the goods. In the event F. Any action against Seller for breach of warranty, negligence or otherwise must
of personal injury or damage to property or business arising from the use of the be commenced by Buyer within one (1) year after: (a) the date any alleged claim
goods, Buyer shall within 48 hours thereafter give Seller written notice of such accrues; or (b) the date of delivery of the Goods to Buyer, whichever is earlier.
injury or damage. Buyer shall cooperate with Seller in investigating any such
injury or damage and in the defense of any claims arising therefrom.
If Buyer fails to comply with this section or if any injury or damage is caused,
in whole or in part, by Buyer’s failure to comply with applicable federal or state
safety requirements, Buyer shall indemnify and hold Seller harmless against any
WARNING
claims, loss or expense for injury or damage arising from the use of the goods.
Alterations or modifications of equipment and use of
CMCO Warranty (HOISTS) non-factory repair parts can lead to dangerous operation
A. Columbus McKinnon Corporation (“Seller”) warrants to the original end user and injury.
(“Buyer”) that, for a period of one (1) year from the date of Seller’s delivery of
the goods (collectively, the “Goods”) to the carrier, the Goods will be free from
defects in workmanship and materials. TO AVOID INJURY:
B. IN THE EVENT OF ANY BREACH OF SUCH WARRANTY, SELLER’S SOLE • Do not alter or modify equipment.
OBLIGATION SHALL BE EXCLUSIVELY LIMITED TO, AT THE OPTION OF SELLER, • Do use only factory replacement parts.
REPAIR OR REPLACEMENT, F.O.B. SELLER’S POINT OF SHIPMENT, OF ANY

SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES

WITH INDIVIDUAL MOTOR DRIVEN 24 P/N: 11532619 REV. AD August 2022
END TRUCKS
OPERATION, SERVICE & PARTS MANUAL
 Single & Double Girder Top Running Bridges With Individual Motor Driven End Trucks
Operation, Service, & Parts Manual

Phone 800.888.0985 • 716.689.5400 • www.columbusmckinnon.com

© 2022 Columbus McKinnon Corporation. All Rights Reserved. P/N: 11532619 REV. AD August 2022