Yale Shaw-Box YK, Shaw-Box SK Operation, Service & Parts Manual
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”)
YALE YK &
SHAWBOX SK ONLY
P/N: 11532620 REV. AA September 2018
CMK_12322 Yale Rotating Axle End Truck Parts 11532619-REV AD_mec.indd 1 10/16/18 2:07 PM
SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES
WITH INDIVIDUAL MOTOR DRIVEN
END TRUCKS
P/N: 11532620 REV. AA September 2018
YALE/SHAWBOX HOIST PARTS AND SERVICES ARE AVAILABLE IN
THE UNITED STATES AND IN CANADA
As a YALE/SHAWBOX 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 efciently. To quickly obtain the
name of the Master Parts Depot or Service Center located nearest you, call (800) 888-0985, Fax:
(716) 689-5644, visit HYPERLINK "http://www.cmworks.com" www.cmworks.com.
LAS PIEZAS Y REPARACIONES DE LOS POLIPASTOS DE YALE/SHAWBOX ESTÁN
ASEGURADAS EN ESTADOS UNIDOS Y CANADÁ
Como usuario de un polipasto y carro de YALE/SHAWBOX 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 ecaz. 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, visita HYPERLINK "http://www.cmworks.com" www.cmworks.com (sólo en
Estados Unidos y Canadá).
LE SERVICE DE RÉPARATION ET DE PIÈCES POUR PALANS YALE/SHAWBOX
EST DISPONIBLE AUX ÉTATS-UNIS ET AU CANADA
Soyez assurés qu'en temps d'utilisateur de palan et treuil YALE/SHAWBOX, d'un service de
réparation et de pièces able 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
efcacement des besoins de réparation de pièces. Appelez le (800) 888-0985, Fax: (716) 689-5644,
visite HYPERLINK "http://www.cmworks.com" www.cmworks.com pour obtenir rapidement le
nom du dépôt de pièces maîtresses ou du centre de service situé le plus près.
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SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES
WITH INDIVIDUAL MOTOR DRIVEN
END TRUCKS
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FOREWORD
This manual contains important information to help you install, operate, maintain and service your new top running single or double girder
bridge crane. We recommend that you study its contents thoroughly before putting the bridge crane into use. With proper installation,
application of correct operating procedures, and practicing the recommended maintenance suggestions you will be assured of the maximum
service from your bridge crane.
The bridge cranes described in this manual are intended for indoor service. Bridge cranes to be used for outdoor service require special
considerations.
IMPORTANT
When ordering replacement parts be sure to include Catalog, Part and Serial Numbers of the endtrucks and or drive gearmotor along with
individual part numbers of components needed as identied elsewhere in this manual.
Information given in this manual is subject to change without notice.
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SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES
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GENERAL
GENERAL
These top running bridge cranes are designed to operate on parallel
crane runway beams with ASCE Rail from 25# to 105# rail or square
bar. Specic rail range is wheel diameter dependant. Motors are
designed for operation on three phase power supplies from 190 to
415 V-50 Hz and 200 to 575 V-60 Hz. Bridge motors and brakes
are designed and intended strictly for variable frequency control
operated by pushbutton 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 single girder
plug & play crane kits described herein are built to 1 through 15
tonne capacities with spans to 60 feet (18.2 meter). Standard top
running double girder plug & play crane kits described herein are
built to 1 through 20 tonne with spans to 60 feet (18.2 meter). Higher
capacities & spans are available and reviewed upon individual
application. Cranes are designed per CMAA Specications 70 and
74 to meet Class C Moderate Duty Service classication.
BASIC CONSTRUCTION
The basic construction of single and double girder bridges consist
of American Standard S, W Section or fabricated box girder(s) rigidly
connected to the top and side of each endtruck. Each endtruck
has a drive and trailer wheel which run on the runway rails. The
wheels are double anged, at tread with an 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.
INSTALLATION
GENERAL
The runways on which these cranes will operate must be sufciently
strong enough to support bridge crane, hoisting equipment and
rated load. Runway rails must be level and parallel. Reference CMAA
70/74 Table 1.4.2-1 for details. Rail joints must be smooth and held
rmly in alignment either by bolted splice bars or by welding. Rails
should be securely fastened to the runway beam.
INSTALLING BRIDGE CRANE
The installation of the crane on the runway shall be performed only
by a qualied crane installer.
For information regarding attaching, lifting and moving the loads
during installation, refer to ANSI B30.2-latest edition, Chapter
2-3 Overhead and Gantry Cranes (Top Running Bridge, Single
or Multiple Girder, Top Running Trolley Hoist; ANSI B30.17-latest
edition, Chapter 17-3 Overhead and Gantry Cranes (Top Running
Bridge, Single Girder, Underhung Hoist) and other applicable codes.
bridge crane at this time so that all wiring connections can be
completed.
TYPICAL CONNECTION OF BRIDGE TO
ELECTRICAL SERVICE
The crane inter-connection diagram is shown in Figure 10.
CAUTION
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
not operate crane until "Start Up and Pre-Operational
Inspection" are made.
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 standards and regulations for specic
requirements.
CAUTION
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.
RUNWAY CONDUCTORS
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
accordance with National, State and Local codes.
RUNWAY COLLECTORS
Install, adjust and align collectors with runway conductors.
Connect collectors to appropriate crane wiring as shown in
Crane Inter-Connection Diagram Figure 10.
NOTICE
A minimum of two collector shoes for each conductor bar
is required when using variable frequency drives (inverters)
on bridge and/or hoist controls, per Section 5.14.7 of
CMAA Specications #70 and #74. Yale•Shaw-Box
standard bridge controls utilize variable frequency drive.
CROSS CONDUCTORS & PUSHBUTTON FESTOON
In most cases, the cross conductors and pushbutton festoon, if
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
followed. Connect all wiring on the crane (main collectors to bridge
3
Before installing the crane on the runway, lock the runway
conductor disconnect switch in the open (off) position.
Prior to the start of any crane erection the building should be
measured to conrm span and clearances. These measurements
should be checked against the corresponding crane measurements
to insure correctness of “t”. After assuring that the crane ts the
building, determine orientation of crane position with respect to
the runway. In addition, verify building and runway power supply to
ensure it matches the power requirements of the crane.
These types of cranes are usually lifted into position on the runway
in one piece. Total weight of this crane should be checked against
lifting equipment selected for erection of this crane.
Immediately after the crane is placed on the runway rails check the
wheel ange clearances to the rail. Clearance between the side
of rail head and inside ange of wheel should be between a total
of 3/4” and 1-1/8”, depending on the wheel and rail combination
and whether or not the truck is centered on the rail. Total wheel
oat should not be less than the 3/4" as recommended by CMAA
Specications #70 and #74.
Note: It is suggested that the trolley and hoist be installed on the
WARNING
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INSTALLATION CONTINUED
panel, bridge panel to cross conductors, bridge panel to bridge.
motor) in accordance with the appropriate crane interconnection
wiring diagram as shown in Figure 10. If bridge motors quick
connection plugs are not pre-wired, connect leads on motor cables
from the bridge control panel per Figure 1.
Figure 1. Bridge Gear Motor Quick Connection Plug
CAUTION
Gearmotors provided with this crane kit are intended for
variable frequency control only. The brake used on the
gearmotor is a holding brake with no provision for torque
adjustment. Severe load swing will result without the
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
and premature failure of these units and void any warranty.
NOTICE
Prior to placing the crane into service, the crane shall
receive an initial inspection. This inspection should be
performed by a qualied person in accordance with
ANSI/ASME B30.2 or B30.17, local, state and provincial
standards and regulations.
and attachments are properly tightened and that all electrical
connections are secure.
5. Inspect and adjust the motor brake air gap. Refer to the
MAINTENANCE SECTION of this manual.
6. The hoist/trolley should be inspected as instructed in the hoist/
trolley manufacturers instruction manual. For a single girder crane
inspect the clearance between the trolley wheels and toe of ange
on bridge girder beam per manufacturers requirements. For a double
girder crane inspect the clearance between wheel anges and the
girder rail per manufacturers requirements. If hoist is equipped with
adjustable limit switches, conrm settings meet the applications
requirements.
7. Inspect the alignment of the trolley end stops to the trolley and the
runway end stops to the bridge endtrucks.
8. Turn power on at both disconnects and mainline. Inspect hoist
for reverse phase condition by ensuring push button operation
corresponds to intended direction of travel and correct if necessary
per manufacturer’s instructions.
9. Operate the crane to verify both motors operate in the same
direction, in both bridge directions.
10. With no load operate hoist/trolley back and forth the full length
of bridge girder and operate the crane the full length of the runway.
During the operation ensure and verify proper clearances from
obstructions per CMAA, ASME B30.2, ASME B30.17 and OSHA
requirements.
11. Load testing the crane should be performed in accordance with
ANSI/ASME B30.2 or B30.17, local, state and/or provincial codes
and regulations. A written report should be prepared during the
performance of this test and placed on le.
OPERATION
OPERATOR QUALIFICATIONS
Safe and efcient crane operation requires skill, extreme care, good
judgment, alertness, concentration and knowledge of and rigid
adherence to proven safety rules and practices. No person should
be permitted to operate a crane or hoist:
1. who does not possess the above characteristics.
2. who is not qualied or has handicaps that could adversely affect
such operation.
3. who has not been properly instructed.
4. who has not been informed and does not have a thorough
knowledge of all applicable safe operating practices, including those
in this book as well as of rigging equipment and practices.
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 to
placing into service, as a minimum the following inspections should
be made by a qualied person.
1. Check the main collector system for proper adjustment to
maintain proper contact with conductors. Check along runway
for possible interference if power is supplied by a cable reel or
festooned cable.
Lock main runway disconnect switch in open position
before attempting to adjust main collectors or conductors.
2. Check the cross and pushbutton festoon conductors for
adjustment, including cable loop depth, and tracking.
3. Check oil level in both drive gearcases and axle bearing grease
ttings (if provided) for proper lubrication. If lubrication is required
refer to the LUBRICATION SECTION of this manual.
4. Inspect crane to make certain that all bolted connections
WARNING
See applicable National, State and Local Safety Codes
and regulations for additional requirements relating to Safe
Operating Practices, including ANSI B30.2 or ANSI B30.17
OPERATING RULES
Operating rules listed below are an earnest effort to encourage
SAFETY and are not intended to take precedence over individual
plant safety rules and regulations or rules set forth by various
applicable codes.
A good operator operates his crane as smoothly as possible and
knows and follows the suggested rules below for safe, efcient
crane handling.
4
NOTICE
- latest edition
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SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES
WITH INDIVIDUAL MOTOR DRIVEN
END TRUCKS
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OPERATING PRECAUTIONS
WARNING
These bridge cranes are not designed nor intended to be
used for support or transport of people or for transporting
loads over people.
Safe operation of an overhead hoist is the operator’s responsibility.
Listed below are some basic rules that can make an operator aware
of dangerous practices to avoid and precautions to take for his own
safety and the safety of others. Observance of these rules in addition
to frequent examinations and periodic inspection of the equipment
may save injury to personnel and damage to the equipment.
DO NOT load bridge beyond rated capacity.
DO NOT subject bridge crane to side loads. Always center trolley
over load when hoisting.
DO NOT stand and DO NOT cause or allow others to stand or get
under any load the bridge crane is supporting.
DO keep clear, and make sure others keep clear, of any load the
bridge crane is supporting.
DO NOT attempt to operate bridge crane before completing tests
and adjustments.
DO NOT run bridge crane into end stops, other bridge cranes, or
any obstruction on beam. Improper and careless operation can
result in a hazardous condition for operator and load.
ALWAYS be sure load is clear of obstruction before traversing
load.
CAUTION
If bridge crane is mounted on an open-end runway rail, then
end stops must be installed to prevent bridge crane 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.
Refer to hoist and trolley instruction manuals for safety warnings
on hoists and trolleys.
Read and comply with ANSI B30.2 or B30.17-latest edition.
Read and comply with all local, state and national safety codes.
GENERAL
Motor driven cranes are usually operated from a pendant push button
station or radio control, which controls the bridge electrically. The
push button may be suspended from the bridge, trolley or hoist. Push
button control stations, supported by a strain cable, have a built-in
interlock to prevent energizing opposing motions at the same time.
CAUTION
Make sure all INSTALLATION AND START-UP
INSPECTION have been made in accordance with
instructions furnished with the HOIST and TROLLEY
before turning on the power.
LEARNING THE CONTROLS
After making certain the crane is completely and properly installed,
with the crane connected to the electrical service and all the
installation and start-up inspections made, the crane operator(s)
should learn and become acquainted with the controls.
On cranes having any or all motions electrically operated, the
operator should locate the runway disconnect and make sure this
switch is locked open (POWER OFF). The operator should now
operate the various push buttons to get the “feel” and determine
that they do not bind or stick in any position. The operator should
become familiar with push button location for their respective
motions as well as the “stop” buttons (normally the top red button),
which operate the crane main line contactor. The mainline contactor
will shut off power to all motions.
WARNING
If any push button binds or sticks in any position - Do
not turn the power on - Determine the cause of the
malfunction and correct it before operating the crane.
LEARNING THE CONTROLS WHILE OPERATING
CRANE WITH NO LOAD
Having inspected and tried the control, the crane operator is now
ready to try the crane under power.
CAUTION
ALWAYS ALLOW THE BRIDGE CRANE TO COME TO
A COMPLETE STOP BEFORE CHANGING DIRECTION.
ABRUPT CHANGE OF BRIDGE DIRECTION WHILE
IN MOTION MAY CAUSE ADVERSE OPERATING
CHARACTERISTICS OR DAMAGE TO BRIDGE AND
DRIVE COMPONENTS.
STEP 1.
Close the crane runway disconnect switch.
STEP 2.
Close the crane disconnect switch mounted on the crane. The
crane main disconnect switch is located in the bridge panel and
is operable from the front of the panel without opening the panel.
The switch is operated by rotating the handle. The “OFF” and “ON”
positions of the switch are marked on the switch assembly.
The bridge control panel also contains a 3-pole mainline contactor.
This contactor is connected in the electrical system on the load side
of the crane main disconnect switch, so that all the crane power
ows through this contactor. The mainline contactor is opened
and closed (turned off and on) by means of the stop button on the
pendant push button station. This stop 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.
STEP 3.
Turn the stop button clockwise to release the mainline contractor
which will apply power to all control devices. The crane is now ready
for use.
STEP 4.
The drive motors on the endtrucks of this crane are controlled
by inverters, programmable variable frequency control. Standard
programming on Yale•Shaw-Box provided controls is two step
innitely variable. The motion buttons on the pushbutton for the
crane, typically labeled “FWD” and “REV” are two step buttons, for
this programming. The rst step is the initial starting speed of the
crane and it also performs a speed hold function. The second step
of the button performs an acceleration function.
To operate the crane, press the button for desired direction, FWD
or REV, to the rst step. The crane will start moving and accelerate
to its programmed starting speed. Press the same button further to
the second step and the crane will accelerate up to full speed. If the
crane reaches a desired speed during this acceleration, back the
button off to the rst 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 rst 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.
Practice operating the crane in both directions, accelerating to
intermediate and full speeds, decelerating to a slower speed,
and bringing it to a stop. Get acquainted with the operating
characteristics of this crane, acceleration, deceleration and stopping
distances, to ensure smooth load movement, accurate load
positioning, and to minimize load swing.
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SINGLE & DOUBLE GIRDER TOP-RUNNING BRIDGES
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END TRUCKS
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OPERATING PRECAUTIONS CONTINUED
NOTICE
If default settings for the bridge’s variable frequency
control, inverter, does not meet your specic requirements
it can be re-programmed. Programming of the inverter
shall be done by a qualied crane technician per the
manufacturer’s instruction manual. Each crane has a
maximum speed setting based on its capacity, span, duty
classication, etc. Do NOT exceed maximum speed for
which the crane was specified when ordered.
STEP 5.
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.
NOTICE
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 specic
details on its operation.
STEP 6.
Once the operator(s) are acquainted and comfortable operating the
crane and the hoist/trolley, they shall learn the Pre-Shift inspection
procedure. Refer to the INSPECTION section of this manual.
WARNING
If, when depressing the hoist "Up" button, the hook should
lower - STOP AT ONCE - Do not attempt to operate
again. Report this condition to the proper supervisor for
correction with the instructions furnished with your hoist
manual by a qualied crane technician.
Set lower limit switches of the hoist and insure proper functioning
per the Hoist Manufacturer's Manual.
When operating the hoist in the up direction CAREFULLY OBSERVE
the relationship of the hook block and the bottom of the hoist frame.
The hoist upper limit switch, when working properly, should cause
the hoist up motion to stop and/or reverse direction.
WARNING
Do not contact or strike the hoist frame with the hook
block. If the hoist motion is not interrupted by the limit
switch, stop the hoist by removing your nger 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
Jogging is the rapid and repeated pressing of a motion
pushbutton (hoist, trolley or bridge) to get the equipment
to move in short increments or “inching”. Although jogging
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, resulting in their thermal protection to disable
bridge motion until cooled.
WARNING
THIS EQUIPMENT IS NOT DESIGNED OR SUITABLE
AS A POWER SOURCE FOR LIFTING, LOWERING, OR
TRANSPORT OF PERSONS.
OPERATING THE CRANE
Once the crane has successfully passed its Start-up
and Pre-Operational (Initial) inspection, and all the crane
operators have been successfully trained and/or licensed, it
is now ready to be placed into service.
WARNING
Do not operate a crane, hoist or trolley having unusual
vibrations, sounds, warnings or with anything wrong or
apparently wrong. Danger may be present that the crane
operator cannot see. Determine and correct the cause of
the unusual conditions and make certain that the crane
can be operated SAFELY.
STEP 1.
Turn power on to the crane, disconnects and mainline. If not already
done so, perform Pre-Shift Inspection, refer to the Inspection
Section of this manual.
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.
WARNING
Prior to attaching or lifting a load, know the weight of
the load and the below the hook lifting devices (spreader
or lifting beams, magnets, grabs, slings, etc.). The total
weight of the load and lifting devices shall not exceed the
rated capacity of the hoist and/or crane.
STEP 3.
Attach load to load hook. Slowly raise the hook until the slack has
been taken out of the below the hook devices. When the oor man
signals and the operator is satised 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 oor man
gives the signal to stop.
STEP 4.
Starting slowly and increasing speed as distance permits, move
the bridge toward the point where the load is to be lowered.
Decelerate and stop by releasing the push button. Final spotting is
accomplished by pressing the button to the rst step to creep into
position.
STEP 5.
Learn to judge the stopping distance of the bridge and trolley, both
with light and full loads. This will enable you to “spot” loads with the
minimum amount of jogging and excessive load swing.
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OPERATING PRECAUTIONS CONTINUED
Figure 2. Operator Hand Signals
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