GORBEL GLC Series Instruction manual

TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Installation
Step 1 - Pre-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Step 2 - Hanger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Step 3 - Runway Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Step 4 - Splice Joint Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Step 5 - Bridge and End Truck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13
Step 6 - Hoist Trolley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-16
Step 7 - Festoon Stack Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Step 8 - Festooning Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-21
Step 9 - Final Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Applied Forces to the Supporting Structure . . . . . . . . . . . . . . . . . . . . . . . .22
Sway Bracing and Thrust Bracing Guidelines . . . . . . . . . . . . . . . . . . . . . .23
Crane Operator Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
General Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Inspection and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Questions? Concerns? Comments? Please call [phone] (US and Canada) or
[phone] (outside US).

INTRODUCTION
Thank you for choosing Gorbel Ceiling Mounted Work Station Cranes to solve your material handling needs. The
innovative design and heavy-duty construction of the Gorbel Work Station Cranes will provide a superior quality
product that will offer years of long term value. All Gorbel cranes are pre-engineered for powered hoist operation.
The hoist weight allowance is 15% of the crane’s capacity (for example, a crane rated for 1000 pounds, allows for a
1000-pound live load plus 150 pounds for the weight of the hoist). There is also an allowance of 25% of the crane
capacity for impact caused by hoist use. Gorbel Work Station Cranes will provide many years of dependable
service by following the installation and maintenance procedures described herein.
Dimensions contained in this installation manual are for reference only and may differ for your particular
application. Please refer to the enclosed General Arrangement Drawing for actual dimensions.
Normal safety precautions: These include, but are not limited to:
•Checking for obstructions in crane travel
•Checking that all bolts and threaded rods are tight and have lockwashers
•Making sure that end stops are in place
•Making sure that festooning cannot be snagged or pinched, whether it is electric or pneumatic
For additional safety precautions, see page 24.
INSTALLATION
STEP 1 - PRE-ASSEMBLY
1.1 Read entire installation manual before you begin installing your crane.
1.2 Check packing list to make sure correct quantity of parts is included.
1.3 Tools and materials typically needed to assemble crane are as follows:
• Hand tools • Powered metal-cutting saw
• Leveling tools • Steel shims (for flush mounted hangers)
• Ladders/man lifts • Torque wrench (able to torque up to 200-ft. lb.)
WARNING
Equipment described herein is not designed for, and should not be used for, lifting, supporting or transporting humans. Failure to
comply with any one of the limitations noted herein can result in serious bodily injury and/or property damage. Check State and
Local regulations for any additional requirements.
WARNING
Crane cannot be utilized as a ground: A separate ground wire is required. For example, systems with 3-phase power require
three conductors plus one ground wire.
WARNING
Before installing any crane system, it is critical you determine that your building will safely support the loads. Gorbel, Inc.
assumes no responsibility for adequacy or integrity of the mounting surface.
WARNING
Sway bracing is required (except when using flush mounted hangers). For more information see page 23.
WARNING
Reference the American Institute of Steel Construction (AISC) Manual of Steel Construction (9th edition), Part 5, Specification for
Structural Joints using ASTM A325 or A490 Bolts (section 8.d.2) for the proper procedures to follow when using any torque-
tightening method.
TIP: Packing list can be found in plastic pocket attached to the hardware box: General Arrangement Drawing
and additional inserts can be found enclosed in this installation manual.
Æ
1
9/05

STEP 2 - HANGER INSTALLATION
Top Hanger Assemblies
2.1 Mark top hanger placement on the building support
beams and runway/monorail track (refer to the General
Arrangement Drawing, inserted in this manual, for
hanger placement). Installation parameters can be
found on page 22.
2.2 To attach threaded rod to top hanger bracket:
Assemble top hanger assembly (diagram 2A). Refer to
Chart 2A for proper nut torque.
2.3 Bolt top hanger bracket assembly and beam clips to building support beam
(diagram 2B). Note:Flange thickness may vary and require shimming. Shimming
may be needed to assure that the beam clip hardware is vertical.
TIP: Standard top hanger brackets are designed for flange
widths from 1”-3”, 3-1/4”-5-1/4”, 5-1/2”-7-1/2”, 8”-10”.
WARNING
Threaded rod must have a minimum of two threads
beyond the hexnut.
Chart 2A. Torque Chart.
4000#250-2000#
Diagram 2A. Attaching threaded rod to top hanger bracket.
WARNING
250-2000# 4000#
Diagram 2B. Bolting top hanger bracket and beam clips to existing support beam.
29/05
“Center hole” of the top hanger bracket assembly must be centered on building support
beam.
Æ
Bridge Crane
Monorail
Bolt Diameter
1/2”
5/8”
3/4”
Torque
50 ft.-lb.
95 ft.-lb.
150 ft.lb.
TORQUE CHART

STEP 2 - HANGER INSTALLATION (CONTINUED)
Lower Hanger Assemblies
2.4 For untrussed (plain) track:
Slide lower hanger assembly over the runway track and bolt into place with clamping bolts
(diagram 2C).
Note:Install the vertical bolts for beam clips (Step 3.2, on page 5) on the Perpendicular
Flush Mount Hanger 250-2000# (diagram 2C), before sliding it on the track.
For trussed track:
Bolt the lower hanger assembly and
lower spine clamp plate to the top
truss tube of runway (diagram 2D).
Torque nuts (chart 2A,page 2, for
proper torque rating).
Note: Sway brace brackets should
be installed at this time (see page
23).
WARNING
Do not over-tighten clamping bolts on the lower hanger assemblies: this will cause
permanent damage to the runway track.
Plain Track 250-2000# Perpendicular Flush Mount 250-2000# Parallel Flush Mount 250-2000#
Plain Track 4000# Perpendicular Flush Mount 4000# Parallel Flush Mount 4000#
Diagram 2C. Installing lower hanger assemblies on untrussed (plain) track.
WARNING
Bolts must have a minimum of two threads beyond hexnut.
Trussed Track 250-2000# Trussed Track 4000#
Diagram 2D. Bolting lower hanger assembly and spine
clamp plate to trussed track.
3
9/05

STEP 2 - HANGER INSTALLATION (CONTINUED)
Perpendicular Flush Mount
2.5 For trussed track:
Position spine clamp angles (or plates) so they are centered under top tube of runway at
hanger locations. Bolt spine clamp angle (or plate) and top hanger brackets together
leaving maximum amount of threaded rod available above top hanger bracket for
installation of beam clips (diagram 2E).
Position runway top tube flush and perpendicular to building support beam. Bolt top
hanger brackets and beam clips to support beam. Torque nuts (chart 2A, page 2, for
proper torque rating).
Note: Flange thickness may vary and require shimming. Shimming may be needed to
assure that the beam clip hardware is vertical. Refer to Step 3, on page 5, for
further runway installation instructions.
WARNING
Threaded rod must have a minimum of two threads beyond hexnut.
WARNING
“Center hole” of top hanger brackets must be centered on building support beam.
Diagram 2E. Installing Perpendicular Flush Mounted Hangers on trussed track.
49/05
Trussed track with 1-1/2” to 2-1/2” top tube. Trussed track with 3” to 6” top tube.

STEP 3 - RUNWAY INSTALLATION
3.1 Lift the runway/monorail into place for installation.
3.2 Hangers
For hangers with threaded rod drop:
Insert threaded rod into bolt hole on
the lower hanger assembly and bolt
into place (diagram 3A).
Torque nuts (chart 2A, page 2, for
proper torque rating).
For flush mounted hangers:
Bolt flush mounted hanger and beam
clips to building support beam
(diagram 3B).
Torque nuts (chart 2A, page 2,
for proper torque rating).
TIP: The closer the runways/monorails are to level and
parallel, the better the crane will perform.
Æ
WARNING
Threaded rod must have a minimum of two threads
beyond the hexnut.
WARNING
Threaded rod must be allowed to hang “plumb” and
should not be bent to accommodate sloped ceilings.
Untrussed (Plain) Track Trussed Track
Diagram 3A. Attaching lower hanger assembly to top hanger assembly.
Parallel Flush Mounted Perpendicular Flush Mounted
Diagram 3B. Attaching flush mounted hangers to building support beam.
5
9/05
Bridge Crane
Monorail

STEP 3 - RUNWAY INSTALLATION (CONTINUED)
3.3 Level track:
Check to make sure that the lower flange of track is level (within +/-1/8”) and parallel to
opposite runway (within +/-1/8”) over a 20’-0” distance.
3.4 If you do have additional runways/monorail sections
proceed to Step 4, on page 7.
If you do not have additional runways/monorail sections:
Install end stops (diagram 3C) (molded bumper with
through bolt), in runway end opposite festooning end.
For more information on festooning, refer to Step 8, on
page 18.
Tighten nut on through bolt until lockwasher is flat.
If you have a bridge crane, go to Step 5, on page 8.
If you have a monorail, go to Step 6, on page 14.
WARNING
Do not deviate from the bridge “span” dimension shown on the General Arrangement
drawing. Bridge “span” is the distance between runways (centerline to centerline).
Diagram 3C. Installing end stop.
69/05

STEP 4 - SPLICE JOINT INSTALLATION
4.1 Attach hardware to splice joint. Slide splice joint over track
of installed runway/monorail.
4.2 Slide next runway/monorail section into splice joint,
bringing runway/monorail ends as close as possible
(diagram 4A or 4B).
Center the splice joint over the track ends.
4.3 For trussed track: Place a truss splice plate on each
side of runway truss tube and bolt into place
(diagram 4B). Tighten hexnuts, but do not torque
until you have completed Steps 4.4 and 4.5.
4.4 Refer to Step 2.4, on page 3, for lower hanger
installation.
Attach runway to upper hanger by repeating Steps
3.2, on page 5 and 3.3, on page 6.
4.5 Adjust track for smooth transition:
Tighten clamping bolts along the top of splice
joint to force track down onto lower flanges of
splice. Check to see that the transition from
one track to the other is smooth: no raised
areas to inhibit trolley or end truck operation.
Tighten clamping bolts along the sides of
splice joint to align track laterally. Check to
see that track portion of runway/monorail is
horizontally and vertically flush.
Tighten jam nuts, on both the top and sides of
the splice joint, to lock clamping bolts in place
(diagram 4A or 4B).
4.6 For trussed track: After you have adjusted the track for smooth transition, torque the
truss splice plate hexnuts (chart 2A, on page 2).
4.7 For additional runways repeat Steps 4.1 through 4.6.
4.8 Install end stops (Step 3.4, on page 6).
TIP: If using trussed track, use both the splice joint and the
splice plate.
WARNING
Do not deviate from the dimensions specified in the General
Arrangement Drawing for maximum space from hanger point to
splice joint. Installation parameters can be found on page 22.
Æ
Diagram 4A. Splicing untrussed track.
Do not “over-tighten”
clamping bolts on splice joints: this will cause permanent damage
to the runway track. Clamping bolts are utilized for alignment purposes.
WARNING
Diagram 4B. Splicing trussed track.
7
9/05
Bridge Crane
Monorail

STEP 5 - BRIDGE AND END TRUCK INSTALLATION
5.1 Make sure end stops have been installed in the runway
end opposite the festooning (leaving festooning end open
for bridge installation).
5.2 Prior to adding bridge, clean inside flanges of track with
clean, dry cloth (do not use any kind of cleaning
solution) to remove grit or debris that may have collected
during shipping, storage, or installation.
5.3 If your end trucks look like:
Standard End Trucks
250# - 2000# Steel Bridges
5.4 Slide an end truck over festooning end of
bridge (refer to the General Arrangement
Drawing for exact end truck location, end
truck sleeve should be 1” from first
vertical) and clamp into place with
hardware provided (diagram 5A).
Note: The festooning end of the bridge
will have a hole that is inset the same or
greater distance from the end of the
bridge than the hole in the opposite end
of the bridge.
5.5 Slide and position the non-clamping end
truck on the other end of bridge (refer to
the General Arrangement Drawing for
exact location, end truck sleeve should
be 1” from first vertical).
5.6 Go to Step 5.37, on page 13.
TIP: ONLY ONE end truck is clamped to the bridge: the
other is not. The clamping end truck must be oriented
with the festooning side of the track (refer to Step 8,
on page 18 for festooning). The non-clamping end truck
allows adjustment for any runway misalignment.
Æ
(Shipped Assembled)
go to Step 5.4 (Shipped Assembled)
go to Step 5.7 (Shipped Unassembled)
go to Step 5.17 (Shipped Unassembled) go to Step 5.27
Diagram 5A. Installing standard clamping end truck.
See TIP.
Æ
89/05
Bridge Crane

STEP 5 - BRIDGE AND END TRUCK INSTALLATION (CONTINUED)
Standard End Trucks (continued)
250# - 500# Aluminum Bridges
5.7 Slide an end truck over festooning end of
bridge (refer to the General Arrangement
Drawing for exact end truck location) and
clamp into place (diagram 5B).
Note: The festooning end of the bridge will
have a hole that is inset the same or greater
distance from the end of the bridge than the
hole in the opposite end of the bridge.
5.8 Slide and position the non-clamping end
truck on the other end of bridge (refer to the
General Arrangement Drawing for exact
location).
5.9 Go to Step 5.12.
1000# - 2000# Aluminum Bridges & 250# - 500# Coped Aluminum Bridges
5.10 Slide an end truck over coped brackets on the
festooning end of bridge (refer to the General
Arrangement Drawing for exact end truck
location) and clamp into place (diagram 5C).
Note: The festooning end of the bridge will have
an end stop hole that is inset the same or greater
distance from the end of the bridge than the end
stop hole in the opposite end of the bridge.
5.11 Slide and position the non-clamping end truck on
the other end of bridge (refer to the General
Arrangement Drawing for exact location).
5.12 At both ends of bridge, install a shear lug bolt in
hole at top of bridge (or in the coped brackets)
to prevent bridge from sliding out of end trucks
(diagrams 5B & 5C).
Note: Install bolts with head of bolt on underside of top flange with threads pointing up.
5.13 If a tow arm is not being utilized on the end truck, go to Step 5.37, on page 13.
If a tow arm is being utilized on the end truck, go to Step 5.14, on page 10.
Note: Festoon tow arms are not recommended for use on 4000# systems or systems
with extended end trucks. They are not necessary on systems with festoon trolleys.
TIP: ONLY ONE
end truck is clamped to the bridge: the other is not. The clamping end truck
must be oriented with the festooning side of the track (refer to Step 8, on page 18 for
festooning). The non-clamping end truck allows adjustment for any runway misalignment.
TIP:
Make sure nylon spacers are attached to end truck before installing end truck on bridge.
Æ
Æ
Æ
Diagram 5B. Installing clamping end truck on aluminum
bridge. See TIP.
Diagram 5C. Installing clamping end truck on
coped aluminum bridge. See TIP.
Æ
WARNING
Failure to install shear lug bolt assemblies may result in the bridge, hoist, and load falling
to the floor.
9
9/05

STEP 5 - BRIDGE AND END TRUCK INSTALLATION (CONTINUED)
Standard End Trucks (continued)
5.14 Assemble the tow arm weldment on the end truck that
will be located on the festooning side of the system
(diagram 5D). Be sure that the tow arm is located on
the festooning side of the end truck itself when
installed.
5.15 Assemble the tow arm spacer on the end truck located
at the opposite end of the bridge (diagram 5E). Be
sure the spacer is mounted on the same side of the
end truck as the tow arm weldment.
5.16 After the bridge has been installed, loosen the nuts
on the end of the U-bolt enough to thread cable/air
hose between the two legs of the U-bolt and the
festoon clamp plate. Secure cable/air hose by
tightening nuts at the end of the U-bolt, forcing the
festoon clamp plate snug against the cable/air hose.
Extended End Trucks
All 4000# Steel Bridges & All Steel Bridges
> 23 ft. long
5.17 Locate extended end truck tubes, support
weldment, wheel plates, and required
hardware.
5.18 Slide an extended end truck tube halfway
through each side of the end truck support
weldment (diagram 5F). Insert a support
bolt in each hole of the support weldment,
passing through both end truck tubes and
all spacers (if required, diagram 5G).
5.19 Place nylock nut on end of each bolt and
tighten snug against end truck support
weldment.
TIP: ONLY ONE end truck is clamped to the bridge: the other is not. The clamping end truck
must be oriented with the festooning side of the track (refer to Step 8, on page 18 for
festooning). The non-clamping end truck allows adjustment for any runway misalignment.
TIP: Extended end truck should be assembled before attaching to bridge.
Æ
Æ
Æ
Diagram 5F. Assembling extended end truck.
Diagram 5G. Spacer placement (if required)
WARNING
Do not “over-tighten” nylock nut: could
cause damage to end trucks. Nylock nut
can only be used once. If this item is
disassembled, then nut must be replaced.
10 9/05
Diagram 5D. Installing tow arm on end truck.
Diagram 5E. Installing tow arm spacer on
end truck.

STEP 5 - BRIDGE AND END TRUCK INSTALLATION (CONTINUED)
Extended End Trucks (continued)
5.20 Place a wheel plate between the end truck
tubes. Insert 1” dia. bolt into first tube,
through the wheel plate and out the
opposite tube (diagram 5H).
5.21 Place nylock nut on end of bolt and tighten
snug against extended end truck tube.
Note: Wheel plates should pivot freely.
5.22 Repeat steps 5.20 and 5.21 for remaining wheel plate.
5.23 Repeat steps 5.17 to 5.22 for remaining extended end trucks.
5.24 Slide an end truck over festooning end
of bridge (refer to the General
Arrangement Drawing for exact end
truck location, end truck sleeve should
be 1” from first vertical) and clamp into
place (diagram 5I).
Note: The festooning end of the bridge
will have a hole that is inset the same
or greater distance from the end of the
bridge than the hole in the opposite
end of the bridge.
5.25 Slide and position the non-clamping end
truck on the other end of bridge (refer to
the General Arrangement Drawing for
exact location, end truck sleeve should be
1” from first vertical).
5.26 Go to Step 5.37, on page 13.
TIP: ONLY ONE
end truck is clamped to the bridge: the other is not. The clamping end truck
must be oriented with the festooning side of the track (refer to Step 8, on page 18 for
festooning). The non-clamping end truck allows adjustment for any runway misalignment.
TIP: Extended end truck should be assembled before attaching to bridge.
Æ
Æ
Diagram 5I. Installing extended clamping end truck.
See TIP.
11
9/05
Diagram 5H. Installing wheel plates.
WARNING
Do not “over-tighten” nylock nut: could
cause damage to end trucks. Nylock nut
can only be used once. If this item is
disassembled, then nut must be replaced.

STEP 5 - BRIDGE AND END TRUCK INSTALLATION (CONTINUED)
Extended End Trucks (continued)
All 4000# Aluminum Bridges & All Aluminum Bridges > 23 ft. long
5.27 Locate extended end truck tubes,
support weldment, wheel plates, and
required hardware.
5.28 Slide an extended end truck tube
halfway through each side of the end
truck support weldment (diagram 5J).
Insert a support bolt in each hole of the
support weldment, passing through both
end truck tubes and all spacers (if
required, diagram 5K).
5.29 Place nylock nut on end of each bolt
and tighten snug against end truck
support weldment.
5.30 Place a wheel plate between the end
truck tubes. Insert 1” dia. bolt into first
tube, through the wheel plate and out
the opposite tube (diagram 5L).
5.31 Place nylock nut on end of bolt and
tighten snug against extended end
truck tube.
Note: Wheel plates should pivot
freely.
5.32 Repeat steps 5.30 and 5.31 for remaining wheel plate.
5.33 Repeat steps 5.27 to 5.32 for remaining extended end trucks.
TIP: ONLY ONE end truck is clamped to the bridge: the other is not. The clamping end truck
must be oriented with the festooning side of the track (refer to Step 8, on page 18 for
festooning). The non-clamping end truck allows adjustment for any runway misalignment.
TIP: Extended end truck should be assembled before attaching to bridge.
TIP: Make sure nylon spacers are attached to end truck before installing end truck on bridge.
Æ
Æ
Æ
Diagram 5L. Installing wheel plates.
WARNING
Do not “over-tighten” nylock nut:
could cause damage to end trucks.
Nylock nut can only be used once. If
this item is disassembled, then nut
must be replaced.
12 9/05
Diagram 5J. Assembling extended end truck.
Æ
Diagram 5K. Spacer placement (if required)
WARNING
Do not “over-tighten” nylock nut: could
cause damage to end trucks. Nylock nut
can only be used once. If this item is
disassembled, then nut must be replaced.

STEP 5 - BRIDGE AND END TRUCK INSTALLATION (CONTINUED)
Extended End Trucks (continued)
5.34 Slide an end truck over festooning end
of bridge (refer to the General
Arrangement Drawing for exact end
truck location) and clamp into place
(diagram 5M).
Note: The festooning end of the bridge
will have a hole that is inset the same or
greater distance from the end of the
bridge than the hole in the opposite end
of the bridge.
5.35 Slide and position the non-clamping end
truck on the other end of bridge (refer to
the General Arrangement Drawing for exact location).
5.36
At both ends of bridge, install a shear lug bolt in the hole in the coped brackets to prevent
bridge from sliding out of end trucks (diagram 5M).
Note: Install bolts with head of bolt on underside of top flange with threads pointing up.
5.37 Install an end stop to the end of the bridge
opposite the festooning (diagrams 5N or 5O).
5.38 Lift bridge up to runways and
simultaneously insert end trucks into
open ends of runways. Make sure
festooning end of bridge is oriented
with festooning runway. For
information on festooning, refer to
Step 8, on page 18.
5.39 Immediately install end stops in
open ends of runways to prevent
bridge from exiting runways
(diagrams 5N or 5O).
5.40 Roll bridge down length of runways
to check for smooth travel. If travel
is not smooth, check track for level
and parallel (Step 3.3, page 6) and
check to make sure that only one
end truck on bridge is clamped.
TIP: ONLY ONE
end truck is clamped to the bridge: the other is not. The clamping end truck
must be oriented with the festooning side of the track (refer to Step 8, on page 18 for
festooning). The non-clamping end truck allows adjustment for any runway misalignment.
Æ
Diagram 5N. Installing end stop.
Diagram 5O. Installing end stop.
13
9/05
Diagram 5M. Installing extended clamping end truck.
See TIP.
WARNING
Failure to install shear lug bolt assemblies may
result in the bridge, hoist, and load falling to the
floor.

STEP 6 - HOIST TROLLEY INSTALLATION
6.1 If your hoist trolley looks like:
150#, 250#, 500#, 1000# and 2000# Hoist Trolley
6.2 Clean inside flanges of track with a clean, dry cloth (do not use any kind of cleaning
solution) to remove grit or debris that may have collected during shipping, storage, or
installation.
6.3 Be sure end stop is installed opposite the festooning end of bridge/monorail.
6.4 Attach hoist to hoist trolley by snapping hoist suspension hook over the trolley saddle
clevis pin of hoist trolley.
6.5 If hoist suspension is too large or hoist has a suspension device other than a hook,
remove trolley saddle clevis pin and install suspension device (by others). Insert clevis
pin back into place. Slide washers on clevis pin and insert cotter pin through trolley
saddle clevis pin (diagrams 6A, 6B, and 6C).
6.6 Bend back both legs of cotter pin (diagram 6D).
6.7 If a tow arm is not being utilized on the trolley, go to
Step 6.12, on page 15.
If a tow arm is being utilized on the trolley, go to Step
6.8, on page 15.
Note: Festoon tow arms are not recommended for use
on 4000# systems or systems with extended end trucks.
They are not necessary for systems with festoon trolleys.
(shipped assembled)
go to Step 6.2 (shipped assembled)
go to Step 6.15
Diagram 6A. Installing hoist on
150-250# hoist trolley. Diagram 6B. Installing hoist on 500# hoist trolley. Diagram 6C. Installing hoist on 1000-2000# hoist trolley.
WARNING
Fully bend both legs of cotter pin (diagram 6D). If cotter
pin is cracked or fatigued it must be replaced.
Diagram 6D. Installing cotter pin
through trolley saddle clevis pin.
14 9/05
Bridge Crane
Monorail

STEP 6 - HOIST TROLLEY INSTALLATION (CONTINUED)
6.8 Remove wheels from festoon end of trolley
(as needed). Keep snap rings.
6.9 Assemble the tow arm weldment on the
festooning end of the hoist trolley
(diagram 6E).
6.10 Re-assemble wheels and snap rings (as
needed).
6.11 After the hoist trolley has been installed,
loosen nuts on end of U-bolt enough to
thread cable/air hose between the two
legs of the U-bolt and festoon clamp plate.
Secure cable/air hose by tightening nuts
at the end of the U-bolt, forcing the
festooning clamp plate snug against the
cable/air hose.
6.12 Roll hoist trolley into open end of track on bridge/monorail.
6.13 Install end stop on the festooning end of bridge/monorail (diagram 3C, on page 6).
6.14 If you do not have festooning, go to Step 9, on page 21.
If you do not have a festoon stack section, go to Step 8, on page 18.
Otherwise go to Step 7, on page 17.
Diagram 6E. Installing tow arm on trolley.
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9/05

STEP 6 - HOIST TROLLEY INSTALLATION (CONTINUED)
Loadbar Hoist Trolley, 4000# Steel / 2000# - 4000# Aluminum
6.15 Clean inside flanges of track with a clean, dry cloth (do
not use any kind of cleaning solution) to remove grit
or debris that may have collected during shipping,
storage, or installation.
6.16 Be sure end stop is installed opposite the festooning end
of bridge/monorail.
6.17 Bend both legs of all cotter pins (diagram 6F).
6.18 Attach hoist to hoist trolley by snapping hoist suspension hook over the clevis bolt (center
bolt) on hoist trolley loadbar.
6.19 If hoist suspension hook is too large or hoist has a suspension device other than a hook,
you will need to remove clevis bolt and install suspension device (by others). Insert clevis
bolt back into place. Place nylock nut on end of bolt and tighten (diagram 6G).
6.20 Roll hoist trolley into open end of track on bridge/monorail.
6.21 Install end stop on festooning end of bridge/monorail (diagram 3C, on page 6).
6.22 If you do not have festooning, go to Step 9, on page 21.
If you do not have a festoon stack section, go to Step 8, on page 18.
Otherwise go to Step 7, on page 17.
Diagram 6F. Installing cotter pin
through trolley saddle clevis pin.
WARNING
Fully bend both legs of cotter pin (diagram 6F). If cotter pin is cracked or fatigued it
must be replaced.
WARNING
Hang hoist from clevis bolt (center bolt) of hoist trolley only.
WARNING
Be sure to tighten nut on the clevis bolt (center bolt) of hoist trolley. Do not “over-
tighten” nylock nut: could cause damage to trolleys. Nylock nut on clevis bolt should
only be used once. If this item is disassembled, then nut must be replaced.
Diagram 6G. Installing hoist on loadbar hoist trolley.
16 9/05

STEP 7 - FESTOON STACK SECTION INSTALLATION
7.1 Remove end stop on festooning end of runway/monorail.
For All Systems With Festoon Gliders, or Systems
With Festoon Trolleys and 1000, 2000, or 4000 Series
Track (diagram 7A)
7.2 Slide festoon stack section over open
runway/monorail end.
7.3 Re-install end stop (diagram 7A).
7.4 Use leveling screws located at top of
festoon stack section to align it with the
runway/monorail.
For Systems With Festoon Trolleys
and 250 or 500 Series Track (diagram 7B)
Note:Welding is required to attach festoon stack section to runway/monorail when using
festoon trolleys with 250 or 500 series track.
7.5 Slide festoon stack section over open runway/monorail end.
7.6
Use leveling screws located at top of festoon stack section to align it with runway/monorail.
7.7 Weld festoon stack section to runway/monorail at locations (diagram 7B).
Note:
Because trolleys are too large to roll under the end stop on the 250 and 500 series
track, the end stop and accompanying hardware (which held the festoon stack section to
the runway/monorail) is positioned
at the end of the festoon stack
section. To prevent festoon stack
section from sliding off the
runway/monorail, the festoon
stack section is welded.
7.8 Install end stop (removed in step
7.1) in end of festoon stack
section (diagram 7B).
TIP: Festoon stack section allows festooning to stack up at
the end of the system, permitting full use of
runway/monorail.
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Festoon Glider Festoon Trolley
Diagram 7A. Installing festoon stack section.
WARNING
Do not “over tighten” leveling screws: this will cause permanent damage to the track.
WARNING
All welds must meet American Welding Society (AWS) specification D1.1 using E70xx
electrodes.
Diagram 7B. Welding festoon stack section on 250-500# series track.
17
9/05
Bridge Crane
Monorail

STEP 8 - FESTOONING INSTALLATION
8.1 If you are using:
Festoon Gliders (Steel Bridges / Runways only)
If you have a monorail go to Step 8.4.
8.2 Slide festoon gliders through end
of bridge that corresponds with
festooning on runway. Space
festoon gliders every 3’-0” along
bridge.
8.3 Slide festoon clamp into place at
festooning end of bridge and
tighten clamp bolt (diagram 8A).
8.4 Slide festoon gliders into festoon
stack section end of
runway/monorail track (on
festooning side of
runway/monorail). Space festoon
gliders every 6’-0” along
runway/monorail, between bridge
and festoon stack section.
8.5 Slide festoon clamp into end of runway/monorail/festoon stack section (diagram 8A).
Tighten clamp bolt until lockwasher is flat.
8.6 Proceed to Step 8.15, on page 20.
festoon gliders, go to Step 8.2 festoon trolleys, go to Step 8.7
Diagram 8A. Installing festoon clamp on runway or bridge.
18 9/05
Bridge Crane
TIP: Festoon gliders are comprised of a glider body (with
upper saddle) and lower saddle (a separate piece that
clips onto the glider body).
TIP: Enough carriers (festoon gliders or festoon trolleys are
supplied to support festoon conductor every 6’ on
runway/monorail and every 3’ on bridges.
Note: Every 6’ on vacuum hose trolley.
Monorail
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