SHAW-BOX SERIES 800 Wire Rope Electric Hoists OPERATION, SERVICE & PARTS MANUAL

OPERATION, SERVICE & PARTS MANUAL
Before installing hoist, fill in the
information below. Refer to the
Hoist and Motor data plates.
Model No. _________________
Serial No. _________________
Purchase Date _____________
Voltage ___________________
Rated Load ________________
SERIES 800
SHAW-BOX
®
WIRE ROPE ELECTRIC HOISTS
INCLUDING
WEIGHT WATCHER
OVERLOAD CLUTCH MODELS
RATED LOADS 1/2 THRU 5 TONS
February, 2004
COPYRIGHT 2004, YaleŸLift-Tech, division of Columbus McKinnon Corporation
Part No. 113533-72
Page 1
FOREWORD
This manual contains important information to help you install, operate,
maintain and service your new SHAW-BOX electric hoist. We
recommend that you study its contents thoroughly before putting the
hoist into use. Read ANSI B30.16 safety code for hoists. Then, thru
proper installation, application of correct operating procedures, and by
practicing the recommended maintenance suggestions you can expect
maximum lifting service from the hoist.
It will likely be a long time before parts information found in Section IX
is needed; therefore, after the hoist is installed and you have completely
familiarized yourself with operation and preventive maintenance
procedures, we suggest that this book be carefully filed for future
reference.
When ordering replacement parts from this book, it will be necessary
that you include, with your order, the Hoist Serial Number, Model
Number and Catalog Number which is found on the nameplate attached
to the hoist electrical cover. For your convenience, a space has been
provided on the front cover of this Manual for entering this information.
We recommend that you fill it out immediately so it is readily at hand
when needed.
The contents of this manual are of necessity, general in nature and
may cover features not incorporated on your hoist; therefore, the user
must exercise care in applying instructions given in this manual. If
specific information not in this manual is required, contact the factory
at Muskegon, Michigan 49443.
THE INFORMATION CONTAINED IN THIS MANUAL IS FOR
INFORMATIONAL PURPOSES ONLY AND LIFT-TECH
INTERNATIONAL DOES NOT WARRANT OR OTHERWISE
GUARANTEE (IMPLIEDLY OR EXPRESSLY) ANYTHING OTHER
THAN THE COMPONENTS THAT LIFT-TECH MANUFACTURES AND
ASSUMES NO LEGAL RESPONSIBILITY (INCLUDING, BUT NOT
LIMITED TO CONSEQUENTIAL DAMAGES) FOR INFORMATION
CONTAINED IN THIS MANUAL.
NOTICE: Information contained in this book is subject to change without notice.
SECTION I
Paragraph
Paragraph
Paragraph
INDEX
GENERAL DESCRIPTION
Page
1-1 General ................................................................................................................................................................................. 3
1-2 Basic Construction ............................................................................................................................................................... 3
1-3 Differences Between Models ............................................................................................................................................... 3
SECTION II
Paragraph
Paragraph
Paragraph
Paragraph
INSTALLATION
2-1 General .................................................................................................................................................................................
2-2 Suspending Hoist .................................................................................................................................................................
2-3 Connecting Hoist to Electrical Service ...............................................................................................................................
2-4 Pre-Operation Checks .........................................................................................................................................................
3
3
4
4
SECTION III
Paragraph
Paragraph
Paragraph
Paragraph
OPERATION
3-1 General .................................................................................................................................................................................
3-2 Push Button Operation ........................................................................................................................................................
3-3 Overload Clutch Operation (Optional) .................................................................................................................................
3-4 Operating Precautions .........................................................................................................................................................
6
6
6
6
SECTION IV
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
LUBRICATION
4-1 General .................................................................................................................................................................................
4-2 Change Gear Case Oil .........................................................................................................................................................
4-3 Lubricate Hoist Cable ..........................................................................................................................................................
4-4 Lubricate Upper Sheave and Lower Block Assembly ........................................................................................................
4-5 Lubricate Limit Stop Lever ...................................................................................................................................................
4-6 Lubricate Limit Switch ..........................................................................................................................................................
7
7
7
7
8
8
SECTION V
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
INSPECTION AND PREVENTIVE MAINTENANCE
5-1 General ................................................................................................................................................................................. 8
5-2 Inspect Lower Block ............................................................................................................................................................. 9
5-3 Inspect Upper Block and Hoist Suspension ....................................................................................................................... 9
5-4 Inspect Electrical Controls ................................................................................................................................................... 9
5-5 Inspect Motor Brake ........................................................................................................................................................... 11
5-6 Inspect Mechanical Load Brake, Gearing and Overload Clutch (Optional) .................................................................... 11
5-7 Inspect Rope Drum and Shaft ........................................................................................................................................... 13
5-8 Rope Inspection, Maintenance and Replacement ........................................................................................................... 14
5-9 Rope Reeving ..................................................................................................................................................................... 14
5-10 Testing Hoist and Overload Clutch (Optional) .................................................................................................................. 17
SECTION Vl
TROUBLE SHOOTING CHART .............................................................................................................................................. 19-20
SECTION Vll
Paragraph
Paragraph
Paragraph
Paragraph
Paragraph
ADJUSTMENTS
7-1 Mechanical Load Brake ..................................................................................................................................................... 21
7-2 Motor Brake ........................................................................................................................................................................ 21
7-3 Block Operated Limit Switch ............................................................................................................................................. 21
7-4 Screw- Type Limit Switch ................................................................................................................................................... 21
7-5 Overload Clutch Adjustment .............................................................................................................................................. 22
SECTION VIII WIRING DIAGRAMS
SECTION IX
Paragraph
Paragraph
PARTS LIST
9-1 General ............................................................................................................................................................................... 22
9-2 List of Parts Illustrations .................................................................................................................................................... 22
No part of this document may be reproduced in any form, in an electronic retrieval system or otherwise, without prior written permission of the publisher.
Page 2
SECTION I — GENERAL DESCRIPTION
1-1. GENERAL. SHAW-BOX electric hoists are precision built
wire rope and drum type hoists which are made in five rated
load sizes (1/2, 1, 2, 3 and 5 tons) with various lifts, lifting
speeds and electrical service. Equipped with an integrally welded
mounting lug, they are designed to be rigidly attached to an
overhead structure or mounted on SHAW-BOX rigid mount
trolleys for operation on runway beams. On certain models
optional base mounting or other supporting methods may be
obtained. For full information apply to factory at Muskegon,
Michigan 49443.
NOTICE
SHAW-BOX hoists are available with an optional built-in
mechanical overload clutch. Hoists having this device
are identified with words WEIGHT WATCHER on the
hoist.
The WEIGHT WATCHER overload clutch permits operation of
your hoist within its rated load and helps prevent lifting of
excessive loads which could cause permanent deformation of
a properly maintained hoist or trolley.
1-2. BASIC CONSTRUCTION. All models are of the same basic
construction and consist of a rugged welded steel frame which
houses a lifting drum and serves as the suspension for carrying
the entire hoist load. A mounting lug, for attaching the hoist to a
trolley or overhead support, is located on top of the frame. An
aluminum alloy gearcase and cover, attached to one end of
frame, houses a three-reduction gear train and a mechanical
load brake. An electric driving motor with disc-type motor brake
is located beside the frame, face mounted on the back of the
gearcase. Electrical system components, located on the end of
the frame (opposite gearcase end) and enclosed by a steel
cover, control operation and rotating direction of a driving motor.
A hoisting rope and an enclosed lower block assembly are
used for lifting loads. An upper limit stop is used to limit travel of
the lower block in the raising direction, to protect hoist from
damage. A push button control station, for operating the hoist,
is suspended from the electrical compartment.
1-3. DIFFERENCES BETWEEN MODELS. The main differences
between models are in rope reeving and frame size as described
below.
a. Rope Reeving. There are four types of rope reeving used:
Two parts of rope single reeved, four parts of rope single reeved,
six parts of rope single reeved and two parts of rope double
reeved. Single reeved hoists have one end of the rope anchored
to the drum, whereas, double reeved hoists have both ends
anchored to the drum. On single reeved models, the lower
block travels sideways as rope winds on drum, double reeved
models offer true vertical lift. For illustrations, refer to Section V,
paragraph 5-9, “Rope Reeving” instructions.
b. Frame Size. Length of frame furnished is dependent on hoist
capacity and lift. Four frame lengths are used; short frame, long
frame, first and second extensions.
Short frame hoists have
a rope drum flange to flange distance of approximately 9-3/4",
whereas this distance on a long frame hoist is approximately
16-3/4". First extension frame hoists have a flange to flange
distance of 22-15/16" and second extensions have 35-3/8".
c. Motor Brake. Hoists are equipped with a disc brake mounted
on the motor end bell and operated by a short stroke solenoid.
This brake requires periodic adjustment.
SECTION II — INSTALLATION
2-1. GENERAL. SHAW-BOX electric hoists are lubricated and
tested before being shipped from the factory. To place hoist in
service, attach to a suitable suspension (paragraph 2-2), connect
to electrical service (paragraph 2-3) and perform pre-operation
tests and checks (paragraph 2-4).
WARNING
Before attempting installation of hoist or trolley, the
main power switch must be locked in the open
position (off).
2-2. SUSPENDING HOIST. The hoist may be suspended in a
fixed location servicing only the area directly below the hoist
(Lug Mounted) or the hoist may be attached to a moveable
trolley or trolleys which in turn may be mounted on an l-beam
attached to a building or crane, servicing a larger area (Trolley
Mounted).
WARNING
DO NOT use small holes for attaching this hoist
unless rated load on lower block is 1 (one) ton (2000
Ibs.) or less.
a. Lug Mounted hoists attach to adequate supports welded or
bolted to a building or other structure. The supporting structure
must have sufficient strength with appropriate safety factor, to
support the weight of the hoist and rated load as well as other
loads to which the supporting structure may be subjected.
WARNING
Design and installation of hoist support shall be
performed only by qualified persons.
Steel angles or plates used to suspend hoist should be spaced
as close to the hoist suspension lug as possible. Mounting
bolts or threaded studs, attaching hoist to mounting structure,
shall have a diameter not less than recommended by
manufacturer and material equivalent to ASTM A 325. Make
certain that mounting bolts or studs are long enough so that
the threads do not engage the mounting support and that
mounting bolts or studs are secured with nuts and lockwashers,
self-locking nuts or cross bolting, if unthreaded.
b. Trolley Mounted hoists are attached to moveable trolleys. If
the hoist is mounted on an existing trolley, a qualified person
shall determine that the trolley and its supporting structure are
adequate to support the rated load and weight of the hoist.
Hoist/trolley units may be shipped from the factory with trolley
packaged separately. If the trolley can be installed directly over
the end of the supporting beam, assemble trolley to hoist. Be
certain that the spacing between wheel flanges, after assembly,
is 1/4" greater than exact width of beam flange. (See Figure 2-1
below and instruction sheet furnished with trolley.) Using proper
equipment, carefully lift trolley and hoist and install on end of
beam.
Page 3
For trolleys which are to be mounted along the span of a beam
not having open ends, measure exact width of beam flange
and assemble trolley to hoist so that spacing between wheel
flanges is 1/4" (see Figure 2-1) greater than beam width (3/8" if
beam has curves). This is accomplished by rearranging the
spacer washers on the bolts connecting trolley side plates to
hoist mounting lug. If trolley is shipped separate from hoist, see
instruction sheets furnished with trolley for orientation and
installation.
When proper spacing has been determined, loosen mounting
nuts (item 1, Figure 2-1) to allow trolley wheels to spread far
enough to pass over edges of beam flange. (Some installations
may require complete removal of one trolley side plate.) Using
adequate equipment, carefully lift the hoist and trolley so the
wheel treads will rest on the lower beam flange. Replace side
plate and washers if removed for installation. Replace
suspension stud nuts.
CAUTION
Recheck spacer washers to make certain that the number
of washers between the side plate and hoist suspension
lug are equal, and also the number on the outside of each
side plate are equal. The suspension stud nuts should
only be snugged up on the lockwashers until a load has
been applied on the hook. A partial load (approx. 25%
rated hoist load) placed on the hook will properly seat hoist
in the trolley. Tighten suspension stud nuts only after hoist
has been properly seated in the trolley.
WARNING
Mounting of the hoist/trolley unit on the monorail
and final pre-operation inspection shall be performed
only by qualified persons properly supervised.
WARNING
Be certain that electrical power supply is OFF and
locked in the open position before attempting any
electrical connections to the hoist. This equipment
must be effectively grounded according to the National
Electric Code, or other applicable codes. If the
grounding method used is through the trolley wheels,
then each section of track must be grounded by metalto-metal connection to the building ground. Certain
environments may prevent proper grounding by this
means. In this case a separate grounding conductor
should be provided.
a. Follow National, State and Local Electrical Codes when
providing electrical service to the hoist.
CAUTION
208/230/460V single speed motors are reconnectable at
the motor. See motor nameplate. Transformer may be
reconnected for 200/230/460/575V. See transformer.
Check with wiring diagram to make certain that motor,
transformer and brake leads are properly connected.
b. Make electrical connections using the appropriate wiring
diagrams furnished with the hoist. All electrical connections,
including connections to collectors or power cord, shall be
made only by qualified journeymen electricians.
WARNING
The green wire provided in the power supply cable
(when furnished) is a grounding wire and must be
connected to a proper ground.
c. When trolley is shipped separate from hoist, see special
instructions furnished with trolley for orientation and installation.
11207A
2-4. PRE-OPERATION CHECKS
a. Check Oil Level and Grease Fittings. The gearcase has been
filled with oil to the proper level and grease points for lower and
upper sheaves have been lubricated at the factory. However,
this should be checked before operating hoist. Check oil level
by removing oil level plug with hoist in a level position. Oil level
should be at the bottom edge of the plug hole. If not, add oil as
specified in Section IV. Grease fittings in lower and upper sheave
pins should show evidence of grease.
Figure 2-1. Sectional View of Trolley showing proper wheel and
washer spacing
2-3. CONNECTING HOIST TO ELECTRICAL SERVICE.
Electrical service to the hoist may be power cable or a guarded
system having sliding shoe collectors
Page 4
CAUTION
Overfilling of the gearcase may result in the excess fluid
being expelled through the breather.
b. Check Push Button Operation and Phasing.
WARNING
On three phase hoists it is possible to have “Reverse
Phasing” causing the lower block to lower when the
á button is depressed. When this condition exists,
the automatic limit stop switch is inoperative and
hoist operation will be dangerous.
When floating rod is raised, stop switch is actuated first and
then the reversing switch is actuated (Figure 2-3). Stop switch
stops hoist. Reversing switch lowers hook block in case of
floating rod over-travel. If limit switch does not function in this
manner, refer to trouble shooting chart Section Vl for possible
remedy.
To properly check the phase of the hoist, follow the steps
below:
(1) With “POWER OFF” operate all the push buttons and
determine that they do not bind or stick in any position
WARNING
If any push button binds or sticks in any position —
DO NOT TURN POWER ON — determine the cause
and correct the malfunction before operating.
Figure 2-3. Electrical Compartment Cover Removed Showing Limit
Switch and Reversing Switch Arrangement
(2) Temporarily connect hoist to power source.
(3) Operate á button briefly to determine direction of hook
travel.
(4) If hook raises, phase is correct. Turn power off and
make temporary connections permanent.
(5) If hook lowers, hoist is “Reverse Phased”. TURN POWER
OFF and correct by interchanging any two leads at power
source connection. Do not change internal wiring of
hoist.
c. Check Limit Switch Operation.
(1) A block operated upper limit stop (Figure 2-2) is furnished
as standard equipment. This limit stop is factory set to
stop lower block in its high position and guard against
over-travel and possible damage to hoist. (Note mounting
position of floating lever for 3 and 5 ton hoists.) No
adjustment can be made. Limit switch operation should
be tested when hoist is installed. Move hook to a low
position by depressing push button marked â. Now
depress button marked á to raise hook. While hook is
traveling upward, manually (or with an extension pole)
raise limit stop mechanism (Figure 2-2).
11403
Figure 2-2. Limit Stop Mechanism
Being Tripped By Lower Block
WARNING
Do not attempt to make above test with hook in a
high position near hoist.
(2) A screw-type upper and lower limit switch is provided
optionally when both upper and lower limit stops are
required (Figure 7-2). This switch is adjustable and must
be adjusted, at time hoist is installed, to desired high
and low limits of lower block travel. Refer to Section Vll.
d. Check Lower Block and Hoisting Cable. Depress â push
button and run lower block to its lowest position. No less than
two wraps shall remain on the drum with the loaded hook in its
lowest position, unless hoist is equipped with a lower limit
switch in which case no less than one and one half wraps shall
remain on the drum. Also check to see that lower block and
rope does not twist excessively. If it does twist to the extent that
two ropes rub against each other, disengage rope from the
frame anchor and twist rope four or five turns in a direction
opposite to that which the block turns. Reconnect rope to anchor
(Figure 2-4), holding firmly to eliminate rope twisting back to its
original position. Operate hoist up and down a few times. If
lower block still rotates, repeat process until twisting is corrected.
e. Lubricate Hoisting Cable. For longer cable life, it is
recommended that the cable be lubricated at time of installation
by applying a Chain and Cable Fluid as outlined in Section IV,
paragraph 4-3.
Figure 2-4. Rope End Anchor
Page 5
SECTION III — OPERATION
3-1. GENERAL. Operation of Series 800 SHAW-BOX electric
hoists is controlled by a convenient pendant push button station.
With it, the hoist can be controlled to give fast lifting and lowering;
or controlled to lift or lower load in small increments, providing
accurate spotting. The pushbutton station has a built-in interlock
to prevent depressing opposing buttons simultaneously.
When first using hoist, break-in by operating under lighter loads
to full travel before applying maximum load.
e.
f.
g.
h.
i.
3-2. PUSH BUTTON OPERATION
a. Depress push button marked á to raise load.
j.
k.
b. Depress push button marked â to lower load.
c. Jogging the push button will give “hairline” load movement.
The quickness of the depressing motion will determine the
amount of movement. Excessive use of this “Jogging” feature
will cause premature burning of contact tips and motor
overheating.
l.
m.
n.
o.
d. On two-speed hoists, partial depression of button operates
the hoist at slow speed; depressing button completely operates
the hoist at fast speed.
3-3. OVERLOAD CLUTCH OPERATION (Optional). The
overload clutch, when furnished with the hoist, is factory preset
and tested so that the hoist will lift its full rated load but will
refuse to lift overloads which could cause deformation or
weakening of your hoist. If the load to be lifted exceeds the
clutch setting, the hoist motor will continue to run when the á
button is depressed and rotate the load brake gear without
lifting the load. Whenever this slipping occurs, immediately
release the á button to prevent overheating of the clutch friction
surfaces and the hoist motor.
p.
q.
r.
s.
t.
u.
v.
w.
NOTICE
Always know load to be lifted. Lift-Tech does not
recommend lifting loads greater than the rated load of
your hoist.
3-4. OPERATING PRECAUTIONS.
WARNING
Equipment covered herein is not designed or suitable
as a power source for lifting or lowering persons.
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 equipment.
a.
b.
c.
d.
DO read ANSI B30.16 Safety Standard for Overhead
Hoists and the Operation, Service and Parts Manual.
DO be familiar with hoist operating controls, procedures
and warnings.
DO make sure hook travel is in the same direction as
shown on controls.
DO make sure hoist limit switches function properly.
Page 6
x.
y.
z.
aa.
ab.
ac.
ad.
ae.
af.
ag.
ah.
ai.
aj.
ak.
al.
DO maintain firm footing when operating a hoist.
DO make sure that load slings or other approved single
attachments are properly sized and seated in the hook
saddle.
DO make sure that the hook latch, is closed and not
supporting any part of the load.
DO make sure that load is free to move and will clear
all obstructions.
DO take up slack carefully, check load balance, lift a
few inches and check load holding action before
continuing.
DO avoid swinging of load or load hook.
DO make sure that all persons stay clear of the
suspended load.
DO warn personnel of an approaching load.
DO protect wire rope from weld splatter or other
damaging contaminants.
DO promptly report any malfunction, unusual
performance, or damage of the hoist.
DO inspect hoist regularly, replace damaged or worn
parts, and keep appropriate records of maintenance.
DO use the hoist manufacturer’s recommended parts
when repairing a hoist.
DO use hook latches.
DO apply lubricant to wire rope as recommended.
DO NOT lift more than rated load.
DO NOT use a damaged hoist or a hoist that is not
working correctly.
DO NOT use the hoist with twisted, kinked, damaged or
worn wire rope.
DO NOT lift a load unless wire rope is properly seated
in its drum groove(s).
DO NOT use wire rope as a sling or wrap rope around
the load.
DO NOT lift a load if any binding prevents equal loading
on all supporting ropes.
DO NOT apply the load to the tip of the hook.
DO NOT operate unless load is centered under hoist.
DO NOT allow your attention to be diverted from
operating the hoist.
DO NOT operate the hoist beyond limits of wire rope
travel.
DO NOT use limit switches as routine operating stops
unless recommended. They are emergency devices
only.
DO NOT use hoist to lift, support or transport people.
DO NOT lift loads over people.
DO NOT leave a suspended load unattended unless
specific precautions have been taken.
DO NOT allow sharp contact between two hoists or
between hoist and obstructions.
DO NOT allow the rope or hook to be used as a ground
for welding.
DO NOT allow the rope or hook to be touched by a live
welding electrode.
DO NOT remove or obscure the warnings on the hoist.
DO NOT adjust or repair a hoist unless qualified to
perform hoist maintenance.
DO NOT attempt to lengthen the wire rope or repair
damaged wire rope.
am. DO NOT allow personnel not physically fit or properly
qualified to operate hoist.
an. DO NOT operate hoist unless limit switch is operating
properly.
ao. DO be sure there is no twist in wire rope.
ap. DO avoid operating hoist when hook is not centered
under hoist. Avoid side pulls and swinging of load or
load hook when traveling hoist.
recommended. The reason for this is, on hoists installed out-ofdoors and in unheated areas, a “cold test” lubricant is required
in cold (below freezing) climates making seasonal changes
necessary.
4-2. CHANGE GEARCASE OIL. (Figure 4-1)
a. Remove oil drain plug from bottom of gearcase and drain out
oil. (Two drain plugs, one on front and one on back of gearcase.)
b. Flush out housing using petroleum solvent. Reinstall drain
plug.
WARNING
DO NOT operate hoist with the hoisting rope out of
the drum grooves. Such operation may result in the
rope breaking and dropping the load which can cause
damage to equipment and injury to operator or other
personnel. Hoist rope will remain in the drum grooves
during operation under normal operating conditions,
however, slack or kinked rope, excessive side pulls,
swinging or jerking of load, or similar abuse, may
cause the rope to leave the grooves.
aq. DO operate hoist within recommended duty cycle and
do not “jog’’ unnecessarily.
ar. DO conduct regular visual inspections for signs of
damage or wear.
as. DO NOT operate hoist with hooks that have opened up.
See Figure 5-1.
at. DO provide supporting structure or anchoring means
that has a load rating at least equal to that of the hoist.
au. DO NOT use hoists in locations that will not allow
operator movement to be free of the load.
av. DO, when starting to lift or pull, move the load a few
inches at which time the hoist should be checked for
proper load holding action. The operation shall be
continued only after the operator is assured that the
hoist is operating properly.
aw. DO NOT leave a loaded hoist unattended at the end of
a work shift or for extended periods during the work
shift. Where operations are such that this condition
cannot be avoided the operator must be assured that
the condition does not create a hazard to personnel or
property.
ax. DO NOT use the hoist load limiting device to measure
the load.
ay. DO NOT operate hoist unless hook moves in the same
direction as indicated on the pushbutton. If opposite
direction occurs, see pre-operation checks, Paragraph
2-4.b.
az. Observe recommended inspection and maintenance
procedures.
ba. DO use common sense and best judgement whenever
operating a hoist. Observe American National Standard
Safety standard, ANSI B30.16, Iatest issue.
SECTION IV — LUBRICATION
4-1. GENERAL. The lubrication services outlined in paragraphs
4-2 thru 4-6 should be performed at regular intervals to maintain
top hoist performance and ensure long life. Intervals of at least
six (6) months, coinciding with spring and fall seasons, are
c. Refill thru oil hole cover to proper level (bottom of oil level
plug hole) using 10 pints of Automatic Transmission Fluid,
DEXRON III Type, suitable for all temperature ranges.
11413A
Figure 4-1. View Showing Location of One Oil Drain Plug
4-3. LUBRICATE HOISTING CABLE. Hoists are shipped from
the factory without an exterior coating on hoisting cable. It is
recommended, where conditions permit, that the cable be
thoroughly coated at installation and kept well lubricated with
LUBRIPLATE Chain and Cable Fluid, or equal, suitable for all
temperature ranges.
4-4. LUBRICATE UPPER SHEAVE AND LOWER BLOCK
ASSEMBLY.
a. All hoists have grease fittings located in ends of sheave pins.
Apply (*) NLGI No. 2 grease for operating temperatures from
+50°F to +125°F. For colder temperatures, (-20°F to +50°F) use
NLGI No. 1 grease.
b. Apply a few drops of S.A.E. No. 50 oil to hook thrust bearings.
(*) National Lubricating Grease Institute.
4-5. LUBRICATE LIMIT STOP LEVER.
a. Apply a few drops of S.A.E. No. 50 oil to pivot points of limit
rod.
b. Apply a few drops of S.A.E. No. 50 oil to shaft bearing at rear
of electrical compartment.
4-6. LUBRICATE LIMIT SWITCH. Provide a light film of NLGI
No. 2 grease on bevel gear of limit switch.
Page 7
SECTION V
INSPECTION AND PREVENTIVE MAINTENANCE
be used to record scheduled inspection and maintenance
services required.
5-1. GENERAL. SHAW-BOX, Series 800, hoists are inspected
and tested at the factory. Regular in service inspection and
preventive maintenance programs not only help reduce overall
maintenance costs but may also prevent serious shutdowns by
forewarning of problems that could cause these shutdowns.
Regular inspections, periodic minor adjustments, regular
cleaning and lubrication and replacement of worn parts can
help preserve good performance and operation of your hoist.
The user should revise the inspection interval, add additional
units or provide a similar form to suit particular conditions
which may exist. However, written, dated and signed inspection
reports should be maintained particularly on critical items, such
as hoist hooks, hoisting ropes, sheaves, drums and brakes.
Periodic review of old inspection reports can point out service
life of hoist components, forecasting need for adjustment, repair
or replacement of these components.
Many factors influence the inspection and preventive
maintenance program required for your hoist. Frequency and
severity of service and material handled, local environmental
conditions and various applicable codes are some of the factors
that the user must consider to adjust inspection and
maintenance program outlined in this section to meet his specific
conditions.
As a matter of expedience, appointed maintenance personnel
inspecting the hoist can also take care of minor adjustments,
repairs and cleaning, where required. Note the column on
Inspection Schedule and Maintenance Report form headed
Corrective Action and Notes. When corrective action is made
during inspection, note condition of part or unit as inspected in
appropriate Condition column with a check mark (ü). Note
“during inspection” corrective action taken and date in space
provided. In this manner, items requiring further attention will
be checked (ü) without showing corrective action. This will
advise the designated person responsible for hoist operation
and safety, who reviews the reports, that deficiencies exist. The
designated person will check all deficiencies as listed and
reexamine or otherwise determine whether they constitute a
safety
The inspection and maintenance services outlined in this section
are considered minimum. Recommended in the schedule are
minimum inspection and maintenance intervals based on
average daily use in a normal environment. Average daily use
is based on 1000 operational hours per year maximum and
intermittent operation of the hoist eight hours per day, five days
per week with a maximum 40% “on” time and the average
loading not exceeding 65% of rated load.
Environmental conditions in which the hoist operates are also
important considerations for the user when adjusting hoist
inspection and maintenance programs to local conditions.
Frequency of inspection and maintenance must be increased if
hoist is subjected to severe atmospheric environmental
conditions, such as corrosive vapors, extreme heat or cold,
cement or dust and other airborne contaminants. The user
should carefully consider all environmental conditions and adjust
frequency and degree of maintenance for his local conditions.
Consult Lift-Tech Field Service Department for advice for unusual
environmental conditions.
Various codes also regulate inspection and maintenance
programs. Attention must be given to applicable Federal
Standards, OSHA regulations, National Standards, state and
local codes which may include mandatory rules relating to
hoist inspection and maintenance. The user should become
familiar with all applicable codes for his area and be guided
accordingly.
Listed on the Recommended Inspection and Maintenance
Schedule are inspection frequencies and requirements. Perform
these inspections regularly as scheduled and additional
inspections as may be required for activity, service and
environment of your hoist. The hoist operator must be
responsible for determining the operating conditions and severity
of service.
Inspection Schedule and Maintenance Report Form.
Shown on page 10 of this manual is a recommended Inspection
Schedule and Maintenance Report form which lists various
components of the hoist. The form also includes trolley
components, runway components, and miscellaneous items.
This form is suggested as a guide for written inspection reports.
Inspections are recommended each month and should be
performed thoroughly enough to inform the hoist user of
deficiencies for any item listed. This form does not supersede
the Inspection and Maintenance Schedule listed below but may
Page 8
WARNING
Deficiencies may be hazardous to personnel and
equipment. Do not operate a hoist having deficiencies
unless a designated qualified person has determined
that these deficiencies DO NOT constitute a safety
hazard.
Written, dated and signed inspection reports for many items
are mandatory under OSHA regulations, and many state safety
codes. It is strongly recommended that the Inspection Schedule
and Maintenance Report, shown herein, be completed by a
qualified person designated with the responsibility for hoist
operation and safety or an inspector appointed by this person.
Inspection records can point out the service life of hoist
components and help forecast the need for adjustments, repairs
and ordering of replacement parts. File and review these reports
after each inspection.
WARNING
Do not operate a hoist having unusual vibrations,
sounds or other conditions. Danger may be present
that the hoist operator cannot see. Determine and
correct cause of unusual conditions and make certain
the hoist can be operated safely. Be certain to
disconnect power to the hoist whenever electrical
cover is removed.
5-2. INSPECT LOWER BLOCK
a. Check lubrication of all parts. If the thrust bearing is not
equipped with a grease fitting, lubricate with SAE No. 50 oil.
Also lubricate the shank of the hook which passes through the
lower block body.
b. Check each sheave to ensure rope groove is smooth and
free from burrs, or other surface defects.
c. Check each sheave for freedom of rotation; replace bearings
if defective.
d. Make certain that dowel pin, holding the hook nut to the
hook, is securely in position.
d. Check hoist suspension bolts on lug suspended hoists; make
certain that bolts are secure, properly tightened and free from
damage.
e. Inspect suspension lug at top of hoist frame for
damage,
cracks, hole elongation or other signs of wear. On all hoists, the
suspension lug is integral with hoist frame and the entire frame
must be replaced when suspension lug is damaged and requires
replacement.
e. If hook is equipped with a safety latch or rotational lock,
check to determine that they are in good operating condition.
f. Check throat opening of hook. (Refer to Figure 5-1.) It is
recommended that upon receipt of the hoist a measurement be
made and recorded of the hook throat opening. OSHA Standards
require that the hook be replaced if the throat opening exceeds
15 percent of the original opening, or if the hook is twisted
more than 10 degrees from the unbent plane. A gage block,
properly identified to the hoist, similar to the one shown in
Figure 5-1, is suggested to be made for each hook for use in
these measurements.
Note: Hooks and hook openings shown are based on
hooks normally furnished with standard hoists. For
dimensions of hooks having a special size, shape or
material, consult the Muskegon, Michigan factory. For
hooks with certain kinds of safety latches it may be
necessary to remove latch to measure hook opening.
g. Hooks showing signs of cracks must be replaced. Hooks
should be inspected at least once per year using dye penetrants,
magnetic particle or other suitable crack detecting methods.
WARNING
Do not operate a hoist having worn or damaged
suspension bolts.
f. Reinstall all parts following procedure in reverse of
disassembly.
5-4. INSPECT ELECTRICAL CONTROLS. Arrangement of
electrical control equipment varies with the type of control,
physical space and the optional control features ordered with
the hoist.
a. Disconnect electrical power to hoist, remove electrical
compartment cover (Figure 9-1, Ref. No. 29) and inspect wiring
and terminals. Terminals should be securely crimped to wires
and electrical insulation should be sound. Terminal screws
should be tight.
b. Check condition of contactor assembly, transformer, and limit
stop and reverse switches.
11202A
Hoist
Rated
Loads
Hook
Size
Correct "L"
Dimension
(in tons)
(standard)
(new hook)
1/2
G
1-1/8"
1
G
1-1/8"
2
H
1-1/4"
3
I
1-1/2"
5
J
1-3/4"
Figure 5-1. Proper Hook Opening
(shown with latch removed for clarity)
h. Check wear of the hook, especially at the saddle and replace
if badly worn.
5-3. INSPECT UPPER BLOCK AND HOIST SUSPENSION
a. Check upper block sheaves (when hoist is so equipped) for
wear, damage and freedom of rotation. If sheaves do not rotate
freely, disassemble block and inspect bearings. Replace worn
or damaged bearings, washers, pins or sheaves.
b. Make certain that all sheaves, bearings and hanger pins are
free of foreign material and properly lubricated. Bearings without
grease fittings are lubricated for the life of the bearing and
require no further lubrication. After inspection, lubricate all upper
block lubrication fittings.
c. Make certain that rope guide pins are not bent, loose or
otherwise distorted; guide pins must have close clearance to
sheave flange to keep rope in sheave grooves.
Page 9
INSPECTION SCHEDULE AND MAINTENANCE REPORT
HOIST SERIAL NO. (MFGRS) _______________________
RATED LOAD _________________
TYPE ________________________
VOLTAGE _____________________
Cleaning or
Painting Required
(Low Oil or Grease,
Rust or Corrosion)
Lubrication
Required
(Worn or Damaged)
Replacement
Required
(Loose Parts or
Wires)
Repair Required
CONDITION
(Check column best indicating condition when
part or unit is inspected. Use note column to
the right if condition is not listed below.)
Adjustment
Required
Annual
Monthly
Semi-Annual
LOCATION
COMPONENT,
UNIT OR
PART
Recommended
Inspection
Interval
Good
*
COMPONENT, UNIT OR PART
and location
CUSTOMER CRANE IDENTITY NO. _______________________
LOCATION IN PLANT __________________________________
THIS INSPECTION IS MONTHLY o
ANNUAL o
SEMI-ANNUAL o
INSPECTED BY: ________________
DATE _____________
CORRECTIVE ACTION
NOTES
(Indicate corrective action taken during inspection and note date. For
corrective action to be done after inspection, a designated person must
determine that the existing deficiency does not constitute a safety hazard
before allowing unit to operate. When corrective action is completed,
describe and note date in this column.)
DATE
Motor
Motor Brake
Mechanical Load Brake
Overload Clutch
Couplings
HOIST
Gears, Shafts & Bearings
Upper Block
Lower Block
Hook & Throat Opening
X
Record Hook Throat Opening
Hoist Rope
Rope Drum
Guards
CONTROL
STATION OR
PUSH BUTTON
Limit Switch
Pushbutton
Wiring
Motor
Brake (when so equipped)
TROLLEY
Couplings
Gears, Shafts & Bearings
Frame
Wheels
Bumpers
Guards
Conductors
RUNWAYS
RESISTORS
Collectors
Hoist
Trolley
Monorail Joints
Monorail
Main Conductors
Main Collectors
MISC.
General Condition
Load Attachment Chains
Rope Slings & Connections
Change Gearcase Lub.
Grounding Faults
*
See text for DAILY & WEEKLY REQUIREMENTS.
INSPECTION INTERVAL.
SIGNED & DATED REPORT REQUIRED – OSHA.
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.
Page 10
12375B
TIME INTERVAL
INSPECTION OR MAINTENANCE
Daily or start
of each shift
(\/isual)
Check operation of all functional mechanisms including limit switch operation, brakes and
control. Check hoist cable for kinks, abrasions, corrosion or broken wires or evidence of
improper spooling on drum. Inspect hooks, upper and lower blocks, and all load bearing
components for damage.
1 Month
* HOIST CABLE - Inspect and lubricate per paragraph 5-8.
1 - 3 Months
* ELECTRICAL CONTROLS - Inspect per paragraph 5-4.
Check hoist gearcase oil level - add oil as required per paragraph 4-2.
6 Months
* LOWER BLOCK - Inspect per paragraph 5-2.
UPPER BLOCK - Inspect per paragraph 5-3.
Annually
Motor brake and actuating mechanisms. Inspect and adjust per paragraph 5-5.
* Inspect hooks with suitable crack detecting procedures per paragraph 5-2.
Drain and refill hoist gearcase per paragraph 4-2.
6 Months or
500 - 750 hours
“on” time
Inspect electrical controls per paragraph 5-4. Change hoist gearcase oil — Fill
with oil per paragraph 4-2. Lubricate hoist cable per paragraph 4-3. Lubricate
* upper and lower hook block per paragraph 4-4. Lubricate limit stop lever per
paragraph 4-5. If a screw type limit switch is furnished, add a light film of
NLGI No. 2 grease to bevel gear.
5 Years elapsed
time or 5000
hours “on” time
Complete inspection, disassembly, and maintenance required. It is recommended
* that your SHAW-BOX Repair Station be contacted for this service.
*Perform services described by paragraph indicated.
Figure 5-2. Inspection and Maintenance Schedule
5-5. INSPECT MOTOR BRAKE. See Figure 9-4.
a. Remove acorn nuts holding brake cover and remove brake
cover.
b. Remove brake mounting plate screws and lift brake assembly
off.
c. Check braking surfaces for wear and scoring. Replace badly
worn or scored parts.
d. Reinstall parts in reverse of disassembly.
e. Adjust brake as explained in Section Vll.
5-6. INSPECT MECHANICAL LOAD BRAKE, GEARING AND
OVERLOAD CLUTCH (optional)
a. The mechanical load brake and gearing may be inspected
and serviced with hoist suspended. To do so, remove lower
block and wire rope, drain oil from gearcase, remove 12 hex
head bolts and lockwashers holding gearcase cover, and pull
cover from gearcase (Figure 5-3).
11404
Figure 5-3. View of Gearcase – Cover Removed
b. To inspect gearing, pull out intermediate gear and pinion
assembly and roller thrust bearings (Figure 5-4), and load brake
assembly (Figure 5-5). Do not remove drum gear unless visual
inspection indicates replacement is necessary.
c. Inspect gears and pinions for signs of tooth wear and damage.
If replacement of any parts appears necessary, disassemble
drum gear, intermediate gear and pinion assembly, and load
brake assembly as directed on following page.
Page 11
(2) Using a puller tool, remove brake flange from shaft. A
groove is provided around outer diameter for this purpose. See
Figure 5-7. Remove key from shaft and lift off 2 friction discs,
and the pawl and ratchet assembly (Figure 5-8).
11421
11421
Figure 5-4. Removing Intermediate Gear and Pinion Assembly
10334
Figure 5-7. View Showing Load Brake Flange Removed
(3) Remove load brake gear. If replacement of spring, spring
retainer or cam is necessary, press off shaft
(Figure 5-9).
1142211422
(4) The load brake pawl and ratchet is a riveted assembly
and is not to be disassembled.
(5) Clean all parts thoroughly and inspect for wear and
damage. Replace all parts that are excessively worn
or damaged. Hard surface or glazed friction discs should
be replaced.
Figure 5-5. Removed Load Brake Assembly
d. To disassemble drum gear, remove external snap ring from
splined shaft, using heavy-duty snap ring pliers, and pull off
gear.
e. To disassemble intermediate gear and pinion, press pinion
shaft from gear using an arbor press.
f. It is recommended that load brake assembly be returned to
an Authorized Repair Station for inspection and repair. If it is
necessary that you make your own inspection and repair,
instructions below must be followed:
(1) Place load brake assembly, flange up, in a vise equipped
with brass or copper jaw plates to protect pinion gear teeth.
Remove snap ring from end of load brake shaft (Figure 5-6).
10335A
Figure 5-8. Removing Pawl and Ratchet Assembly
From Load Brake Shaft
10333
Figure 5-6. Remove Snap Ring From Load Brake Shaft
Page 12
g. Reassemble gearing and load brake parts following reverse
procedure of disassembly. In assembling load brake, observe
assembly steps (1) through (4).
(1) Before installing spring in its retainer (Figure 5-9), apply
a good grade of ball bearing grease to inside of retainer.
Spring must be positioned exactly as illustrated, butted
against pin at side of cam.
10610
10436
Load Brake - Standard
Figure 5-10. Winding Load Brake Gear using a Strap Wrench to set
up Load Brake Spring
11927
Load Brake - Overload Clutch
Figure 5-9. Load Brake Gear Removed From Load Brake
Showing Load Brake Spring
(2) When installing pawl and ratchet assembly on load brake
shaft, be certain that teeth on ratchet face are in the
same direction as shown in Figure 5-8. The ratchet
assembly should rotate freely when turned
counterclockwise and the pawl should engage ratchet
teeth when unit is turned clockwise.
(3) When installing brake flange, position it with chamfer
facing friction disc (Figure 5-7).
(4) The brake spring must be pre-loaded at assembly to a
torque of from 10 to 14 lb.-ft. This is accomplished using
a plumber’s strap wrench to wind (rotate) load brake gear
to set up spring (Figure 5-10) while pressing brake flange
into place using an arbor press. Clamp pinion end of
shaft into a portable vise to keep brake from rotating in
press. Use brass or copper jaw plates on vise to protect
pinion gear teeth. Wind gear counterclockwise (viewing
brake from flange end) with strap wrench and press down
on flange until snap ring groove in shaft is exposed
allowing snap ring to be installed. Use extreme care not
to over wind spring as yield will result and final spring
torque will be reduced. Do not wind gear beyond point
necessary to install snap ring in groove.
h.Install gearing and load brake assembly in gearcase in reverse
order of disassembly. Be certain roller thrust bearings are
installed at both ends of intermediate gear shaft as shown in
Figure 5-4 and that thrust washers are properly installed at
both ends of load brake shaft as noted below:
(1) A steel thrust washer with 5/8" I.D. must be installed on
the brake flange end (end opposite pinion) of load brake
as shown in Figure 5-5.
(2) A bronze thrust washer with a lug on one side goes on
pinion end of load brake shaft and it must be installed
so that its lug engages the special slot located on the
spot face surrounding the load brake bearing bore inside
gearcase cover. Use heavy grease to hold it in place on
cover as cover is installed.
On hoists with 18 or 20 tooth load brake pinion, an 11/
16" I.D. steel thrust washer is installed between pinion
and bronze thrust washer.
j. At completion of reassembly of gearing and load brake in
gearcase, refill gearcase to proper level using correct grade of
oil, as outlined in Section IV — LUBRICATION.
k. For hoists equipped with an overload clutch (optional) which
has been functioning properly, visually inspect clutch adjusting
nut and spring washer for signs of damage or looseness. With
a small hex allen wrench, make certain two set screws in
Page 13
adjusting nut are tight. DO NOT TURN ADJUSTING NUT OR
DISASSEMBLE CLUTCH. If spring washer, adjusting nut or
gear is loose or damaged, or the clutch did not function properly
before disassembly of hoist for inspection, consult the nearest
SHAW-BOX Authorized Repair Station for repair or adjustment.
5-7. INSPECT ROPE DRUM AND SHAFT
a. To remove drum, remove wire rope, electrical compartment
cover and electrical panel assembly (Figure 9-1) and gearing
and load brake assembly (paragraph 5-6).
b. Remove four hex socket head bolts securing gearcase to
cover. Three bolts are accessible from inside frame (Figure 2-2,
Section II) and the fourth is accessible from electrical end of
frame thru special access hole using a socket hex key wrench
with an extension (Figure 5-11). With bolts removed, pry
assembled gearcase and motor from frame. Exercise caution
so that gearcase and motor assembly does not fall as it comes
free of frame. This disassembly operation is not recommended
with hoist suspended. Drum will remain in frame and can be
lifted from drum shaft. To remove shaft, remove internal retaining
ring from bearing bore in frame.
Inspections revealing but not limited to the following conditions
should cause the inspector to question remaining strength of
rope and consider replacement:
(1) Twelve randomly distributed broken wires in one rope
lay or four broken wires in one strand.
(2) Wear of one-third of the original diameter of outside
individual wires.
(3) Kinking, crushing or bird caging.
(4) Heat damage from any cause.
(5) Reductions from nominal diameter of more than
1/64" for 3/16", 1/4", and 5/16" diameter rope.
(6) Rope corrosion, internal or external.
(7) Effects from improper lubrication.
(8) Rope idle for month or more due to shutdown.
Special attention should be exercised when inspecting rope
normally hidden during inspecting procedures.
b. Maintenance. Keep rope well lubricated to help reduce internal
friction and prevent corrosion. Lubricant, as described in
paragraph 4-3, should be applied as a part of the regular
maintenance program. Special attention is required to lubricate
sections of rope over equalizing sheaves and other hidden
areas.
Avoid dragging ropes in dirt or around sharp objects which will
scrape, nick, crush or induce sharp bends in the rope.
c. Replacement. When recommended by an authorized
inspector, the rope should be replaced. Replacement rope
assemblies are shipped from the factory carefully coiled to
prevent damage by kinking. Care must be taken to avoid twisting
or kinking when uncoiling and handling during reeving.
Figure 5-11. Removing Bolt Securing Gearcase to Frame
Before replacing rope, check condition of grooves in sheaves
and drums to determine if they are excessively worn.
c. Check parts for wear and damage. Replace drum if there are
any signs of cracks or other damage.
5-8. ROPE INSPECTION, MAINTENANCE AND
REPLACEMENT
WARNING
Wire rope improperly handled or abused can create
a SAFETY HAZARD. Read and comply with inspection,
maintenance and replacement information given
herein.
a. Inspection. Wire rope on your hoist is one of the most
important components requiring frequent inspection and
maintenance. All wire ropes will eventually deteriorate to a
point where they are not safe and will require replacement.
WIRE ROPE SHOULD BE THOROUGHLY INSPECTED AT
REGULAR MONTHLY INTERVALS BY AN AUTHORIZED
PERSON AND A DETERMINATION MADE WHEN FURTHER
USE OF THE ROPE WOULD CONSTITUTE A SAFETY
HAZARD. Each inspection should include a written, dated and
signed report of rope condition. Reports should be filed and
reviewed each month and any rope deterioration carefully noted.
Page 14
WARNING
Use only factory approved rope with swagged wire
rope sockets.
When first using the hoist after rope replacement, break-in
rope by operating under lighter loads to full travel before applying
maximum load.
5-9. ROPE REEVING
a. General. Before unreeling rope from a coil or reel, be sure
floor is clean. Dirt picked up by the rope can cause excessive
wear and abrasion. Uncoil the rope by rolling the coil or reel
along the floor; or, place reel on a stand with a shaft thru the
center of reel so rope can be pulled straight out with the reel
rotating.
CAUTION
It is imperative that the rope reel or coil rotates as rope
unwinds. If coil or reel does not rotate, the wire will be
twisted as it is uncoiled and kinking will result. A kinked
rope may be damaged and unsafe for maximum service.
Before removing the old rope, refer to reeving diagrams, (Figures
5-12, 5-14, 5-15 and 5-17). Face the rope drum on your hoist
from the side which the rope comes off drum. To assist with
rereeving your hoist, select the reeving diagram for your hoist.
Note the description (such as 2 part double reeved, Figure 517) and refer to the paragraph below with the same description
which describes rereeving procedure.
b. Removing old rope - for all reevings.
(1) Lower the bottom block to a scaffold located 6 to 7
feet below hoist to relieve tension on wire rope. (Bottom
block may be lowered to floor if desired; however, to
handle less weight and for ease of rereeving adequate
scaffold below the hoist is recommended.)
(2) Remove bottom block sheave guard.
(3) Remove key plates from both sides of sheave pin and
slide sheave pin from bottom block.
(4) Lift out sheaves from the top of the bottom block and
remove wire rope.
(5) Remove key plates or snap rings from upper block
sheave(s) and slide out upper block sheave pins,
releasing upper block sheaves. Remove wire rope from
sheaves.
(6) Make certain all personnel are clear of hoist and operate
hoist â to completely unwind all wire rope from drum.
Stop hoist so drum anchor slot(s) is accessible. Remove
live rope and socket(s) from drum.
(7) TURN OFF POWER TO HOIST
(8) Remove the bolt and lockwasher in the end of the rope
anchor fitting. Remove rope from slot in top of anchor.
c. Installing new rope.
WARNING
Winding rope on rope drums with power can be
hazardous. Keep hands safe distance from drum, wear
gloves and use extreme care when winding rope.
DOUBLE REEVED HOISTS
Stretch new cable on floor in one continuous length. Make
certain there are no twists in rope.
(1) Pull far end of rope toward end of rope nearest hoist,
until both ends are even and a loop is formed. Place
fittings on both ends of rope in anchor slots on rope
drum. Be sure end fittings are properly seated.
(2) With all personnel clear of hoist - TURN ON POWER.
(3) Operate hoist á guiding rope into grooves at both ends
of drum, until the distance from the drum to the loop is about 28' for 2 part double reeved.
(4) Proceed with reeving as described in appropriate
paragraph below and the reeving diagram for your hoist.
d. Reeving - 2 part single.
See Figure 5-12 for diagram.
See Figure 9-11 for block parts.
With new rope installed on the drum as described in paragraph
5-9c single reeved above, proceed with rereeving following
steps below:
(1) Pass other end of rope thru bottom opening of hoist,
between floating limit rod and motor, and attach rope to
cast dead end anchor fitting. A slot is located at top of
fitting to accept cable. Reinstall bolt and lockwasher in
end of anchor fitting to lock rope compression fitting in
place.
(2) Grasp loop, formed after installing end anchor, and place
bottom block sheave in loop. Lower sheave into bottom
block and insert sheave pin. Replace key plates and
bolts holding sheave pin in place.
(3) Replace sheave guard. Make certain rope is not twisted.
Should the two parts of rope tend to wind around each
other, remove cable from anchor slot and untwist cable.
Reattach the cable anchor.
(4) Lubricate cable per paragraph 4-3.
SINGLE REEVED HOISTS
Stretch new cable on floor in one continuous length. Make
certain there is no twist in rope.
(1) Place one end of rope in rope drum anchor slot. Be sure
end fitting is properly seated.
(2) With all personnel clear of hoist - TURN ON POWER.
(3) Operate hoist á, guiding new rope into drum grooves
with gloved hand, until the following lengths remain
unwound:
(a) 2 part single reeved - about 14'-0".
(b) 4 part single reeved - about 28'-0".
(c) 6 part single reeved - about 42'-0".
12203A
(4) Proceed with reeving as described in appropriate
paragraph below and the reeving diagram for your hoist.
Figure 5-12. Hoist Reeving - Two Part Single
Page 15
e. Reeving - 4 part single.
See Figure 5-14 for diagram.
See Figure 9-13 for block parts.
With new rope installed on the drum as described in paragraph
5-9c single reeved above, proceed with rereeving following
steps below:
(1) Grasp the cable near the middle (about 14'-0") of the
unwound end and form a loop. Place upper sheave in
this loop. Slide upper sheave with cable into sheave
pocket.
(2) Insert sheave pin into sheave. Replace key plates and
bolts to hold sheave pin in place.
(4) Place one sheave in each loop. Install one sheave with
cable in bottom block, partially insert sheave pin to hold
sheave in place. Note: Some blocks have spacer
washers between sheaves. Be certain that washers are
installed between sheaves, when shown on parts
illustration. Install second sheave with cable into bottom
block. Slide sheave pin through sheave. Replace key
plates and bolts securing sheave pin.
(5) Replace sheave guard.
(6) Lubricate cable per paragraph 4-3.
f. Reeving - 6 part single.
See Figure 5-15 for diagram.
See Figure 9-13 for block parts.
With new rope installed on the drum as described in paragraph
5-9c single reeved above, proceed with rereeving following
steps below:
11776A
(1) Grasp cable at a point one-third (approx. 14’0") the
distance hanging below the rope drum and form a loop.
Place one upper sheave in this loop. Slide upper sheave
with cable into sheave pocket; partially insert sheave
pin to hold sheave in place.
(2) Repeat (1) above and install second upper sheave with
rope. Insert sheave pin and install key plates and bolts
to secure sheave pin.
Figure 5-13. Upper Sheave Installed
(Typical 3 and 5 Ton)
(3) Pass free end of rope thru bottom opening of hoist
between floating limit rod and motor, and insert rope in
anchor fitting at hoist frame. Be certain power is off
before attempting to place rope in anchor fitting. With
end fitting properly seated in anchor, replace bolt and
lockwasher in end of socket. Two loops have now been
formed for bottom block sheaves.
12205A
Figure 5-15. Hoist Reeving - Six Part Single
(3) Pass free end of rope thru bottom opening of hoist
between floating limit rod and motor and insert in rope
anchor fitting at hoist frame. Be certain power is off
before attempting to place rope in anchor fitting. With
end fitting properly seated in anchor, replace bolt and
lockwasher in end of socket. Three loops have now
been formed for bottom block sheaves.
12204A
Figure 5-14. Hoist Reeving - Four Part Single
Page 16
(4) Place sheave in each loop. Install one sheave with cable
in bottom block; partially insert sheave pin to hold sheave
in place. Note: Be certain that washers are installed
between sheaves, as shown on parts illustration.
(5) Repeat step 4 for remaining bottom block sheaves. Install
sheave pin through sheaves. Replace key plates and
bolts securing sheave pin.
(1) To remove rope twist in single reeved hoists.
(a) Observe direction block tends to rotate.
(6) Replace sheave guard.
(b) Lower the block to a low position and turn off power.
(7) Lubricate cable per paragraph 4-3.
(c) Rotate rope near the anchor end several turns in a
direction tending to correct block rotation. This rotates
rope end fitting in the anchor.
g. Reeving - 2 part double.
See Figure 5-17 for diagram.
(d) Turn on power; raise and lower the block several
times to feed the correcting twist in the rope through
the reeving.
See Figure 9-12 for block parts.
With new rope installed on the drum as described in paragraph
5-9c double reeved above, proceed with rereeving following
steps.
(1) Form loops in the two ropes coming from rope drum.
Place these loops into bottom block pockets and slide
pipe or rod through sheave pin holes. Note position of
ropes passing limit stop bar.
(2) Partially insert upper block sheave pin in opening and
install one spacer washer. Raise remaining rope up to
hoist, form a loop and place upper sheave in this loop.
(e) If block still tends to twist, repeat the above procedure
until block rotation is corrected.
(2) To remove rope twist in double reeved hoists.
(a) Observe direction block tends to rotate.
(b) Lower the bottom block unspooling rope from rope
drum until only one quarter (1/4) turn remains to
rope end anchors in drum.
(c) Rotate rope near ends entering drum in a direction
tending to correct block rotation. This rotates rope
end fittings in the drum.
(d) Turn on power; raise and lower the block several
times to feed the correcting twist in the rope through
the reeving.
(e) If block still tends to twist, repeat the above procedure
until block rotation is corrected.
5-10.TESTING HOIST AND OVERLOAD CLUTCH (optional)
11405
Figure 5-16. Upper Sheave Installed (Typical)
(3) Place sheave with rope into upper sheave pocket and
slide pin partially thru sheave. Install remaining washer
and push pin thru side plates. Install snap ring on each
end of pin to secure pin in place.
a. General. Before placing hoist in service or after disassembly
and reassembly, hoist should be tested. To test suspend hoist
from an overhead supporting member of sufficient strength to
support the weight of the hoist and the rated load. Hoists having overload clutches, require an overhead supporting structure capable of supporting with appropriate safety factor, a load
equal to 200 percent rated load and the weight of the hoist.
Connect hoist to power supply as shown on hoist nameplate
and perform the checks listed in b and c below.
b. Check hoist as outlined in PRE-OPERATION CHECKS,
Section II, paragraph 2-4.
c. Check hoist with capacity load.
(1) Attach rated load to lower hook.
(2) Depress á push button and raise load. When push
button is released, hoist should immediately stop and
hold load at that level.
(3) Depress â push button, lower load a short distance
and release button. Hoist should stop immediately and
hold load at that level.
Note: If load drifts downward slowly in step 2 or 3 above,
motor brake requires adjustment - see MOTOR BRAKE
ADJUSTMENT - Section Vll - paragraph 7-2.
(4) Insert lower sheave pin into bottom block removing pipe
as sheave pin is inserted. Be certain washers are
replaced as shown on parts illustration. With sheave pin
installed, replace key plates and bolts to secure sheave
pin.
12206A
Figure 5-17. Hoist Reeving - Two Part Double
Page 17
(5) Replace sheave guard.
(6) Lubricate rope per paragraph 4-3.
h. Checking for and removal of rope twisting.
Although rereeving of hoist may have been done carefully,
sometimes after new rope has been installed twisting may occur.
With new rope installed, the hoist block should be raised and
lowered several times with gradually increasing loads, through
full lift. If the block still rotates excessively at no load, the rope
may have twists which should be removed.
d. Overload Clutch. The overload clutch (optional) must be
tested for proper operation before placing hoist in service or
after disassembly and reassembly of hoist. For test procedure
follow instructions listed below.
(2) Increase load in steps from rated load, TO A MAXIMUM
OF 200% of the rated load, attempting to lift load with
each increase in weight. Hoist Overload Clutch should
slip and refuse to lift load before 200% of the rated load
is reached. Should hoist lift 200% of the rated load STOP TEST - A CLUTCH ADJUSTMENT IS REQUIRED.
(See paragraph 7-5 - “OVERLOAD CLUTCH
ADJUSTMENT”.)
(3) Run hoist with load causing clutch to slip (hoist refusing
load) five cycles of approximately 1 second each.
WARNING
BEFORE ATTEMPTING TO TEST THE OVERLOAD
CLUTCH, MAKE CERTAIN THE FOLLOWING
PREREQUISITES ARE STRICTLY OBSERVED:
CAUTION
To prevent overheating, release the hoist control
button at once when the hoist refuses to lift the load.
a. An appointed person must determine, before
starting, that all structures supporting the hoist are
adequately strong to withstand the test load of 200%
of the rated load, plus the weight of the hoist, whether
hoist is tested in installed position or moved to a
designated test facility.
(4) Remove weights added in step (2) and return to hoist
rated load. Lift rated load one final time. Clutch should
not slip.
b. Loads used for testing must be accurately known.
WARNING
c. Test must be made ONLY by a qualified operator,
thoroughly familiar with the hoist and the purpose of
the test.
Do not lift more than rated load except for test
purposes.
d. Adequate and proper rigging must be provided to
ensure that test loads are securely attached, properly
balanced, and lifted level. Failure to provide adequate
support could cause injury to personnel and/or
damage to equipment.
Notice
ALWAYS KNOW LOAD TO BE LIFTED, LIFT-TECH DOES
NOT RECOMMEND LIFTING LOADS GREATER THAN
THE RATED LOAD OF YOUR HOIST.
NOTES
Page 18
(1) Using a known load, equal to the hoist rated load,
energize hoist to lift the load. Raise this load just high
enough to be certain hoist is lifting the entire load. Clutch
should not slip with the rated load. Lower load to rest
position. If clutch slips with rated load, adjustment is
required. (See paragraph 7-5. - “OVERLOAD CLUTCH
ADJUSTMENT”.) If hoist will lift rated load, proceed to
step (2).
SECTION Vl - TROUBLE SHOOTING
Trouble
6-1. Hoist Will Not Operate
6-2. Hook Moves in Wrong
Direction
6-3. Hook Will Raise But
Not Lower
6-4. Hook Will Lower But
Not Raise
Probable Cause
Remedy
a. No power to hoist
a. Check switches, circuit breakers or fuses and
connections in power supply lines. Check power
collectors.
b. Wrong voltage
b. Check voltage required on motor data plate against
power supply.
c. Loose or broken wire
connections in hoist electrical
system
c. Shut off power supply, remove electrical cover on
hoist and check wiring connections. Also check
connections in push button station and limit
switches.
d. Contactor assembly not
functioning
d. See that necessary jumper wires are properly
installed. Verify that the contactor armatures are
free to move. If binding occurs, replace contactor.
Check for burned out contactor coils.
e. No control voltage
e. Check transformer fuse. If blown, check for
grounding and/or shorts in the push button station.
Check the transformer coil for signs of overheating.
Replace transformer if burned out. Verify the
transformer secondary is the same voltage as the
coils to which it is connected.
f. Motor burned out
f. Replace motor. Check input power supply. Check
hoist motor connections.
a. Reverse phasing on threephase hoists
a. Interchange any two power supply line leads. Refer
to Section II, paragraph 2-4 b.
b. Hoist wired wrong
b. Check wiring connections with appropriate wiring
diagram.
a. Lower electrical circuit open
a. Check for loose connections. See that necessary
jumper wires are properly installed on contactor.
b. Contactor assembly not
functioning
b. See that necessary jumper wires are properly
installed. Verify that the contactor armatures are
free to move. If binding occurs, replace contactor.
Check for burned out contactor coils.
c. Down, push button inoperative
c. Check push button contacts and wires.
a. Excessive load
a. Reduce loading to rated load of hoist, as shown on
nameplate.
b. Hoist electrical circuit open
b. Check for loose connections. See that necessary
jumper wires are properly installed on contactor.
Check limit switch mounting and connections.
c. Contactor assembly not
functioning
c. See that necessary jumper wires are properly
installed. Verify that the contactor armatures are
free to move. If binding occurs, replace contactor.
Check for burned out contactor coils.
d. Up, push button inoperative
d. Check push button contacts and wires.
Page 19
SECTION Vl - TROUBLE SHOOTING (Continued)
Trouble
6-5. Hoist Will Not Lift Rated
Load
6-6. Hoist Motor Overheats
6-7. Load Drifts Excessively
When Hoist Is Stopped
Probable Cause
Remedy
a. Low voltage
a. See that power supply current is same voltage Iisted
on motor data plate. Check hoist motor connections.
Check size of power supply lines.
b. Overload Clutch not properly
adjusted
b. See Section VII, paragraph 7-5.
a. Excessive load
a. Reduce loading to rated load of hoist, shown on
nameplate.
b. Excessive duty-cycle
b. Reduce frequency of lifts or amount of jogging.
c. Wrong voltage or frequency
c. Check current rating on motor data plate against
power supply. Check hoist motor connections.
d. Defective motor or worn
bearings in hoist frame
d. Disassemble hoist and inspect for defective, worn
or damaged parts.
e. Overload Clutch slipping without
lifting load
e. See Section VII, paragraph 7-5.
a. Excessive load
a. Reduce loading to rated load, as shown on
nameplate.
b. Motor brake not holding
b. With No Load, check hoist for drift. If drifting is
excessive, inspect motor brake (Section V, paragraph
5-5) and adjust as outlined in Section VII, paragraph
7-2.
c. Load brake not holding
c. (1) After determining that the motor brake is working
properly, attach rated load to hook and operate hoist.
If the load accelerates during lowering, the load
brake is not functioning properly. See Section V,
paragraph 5-6 for replacing worn or damaged parts.
(2) If load brake checks O.K., magnetic motor brake
needs adjustment (see b. above).
6-8. Hoist Operates
Intermittently
Page 20
a. Collectors make poor contact
a. Check collectors for free movement of spring arm,
weak spring or electrical connections.
b. Loose connections
b. Check all wiring for loose connections.
SECTION Vll - ADJUSTMENTS
7-1. MECHANICAL LOAD BRAKE. The mechanical load brake
on Series 800 SHAW-BOX hoists is a pawl and ratchet “Weston”
type automatic brake. The brake is not adjustable and requires
only periodic inspection and occasional replacement of the
friction washers.
7-2. MOTOR BRAKE. Instructions for adjusting the brake are
inside the brake cover and are repeated below. Check brake
adjustment after the first 30 days of service and regularly
thereafter during the six-month inspection procedure. Two
versions of the motor brake occur in this manual.
c.On the early version of the brake (Figure 7-1), if the tang is
below the midway position of the two adjustment points shown
on the brake, the brake should be adjusted to bring the tang
back up alongside the NORMAL position on the brake.
d.Remove the hex key (1/8" size) from the holster on the cover
mounting stud and carefully turn the ADJUSTING SCREW
(located above the solenoid coil) clockwise. The indicating tang
will move a large distance for a small turn of the adjusting
screw, therefore turn the screw no more than one quarter turn
before checking adjustment.
e.After adjustment operate the brake by hand to assure brake
disc running clearance. The outboard brake pad should separate
from the brake disc by approximately .010".
f. Replace hex key in holster.
g. Replace brake cover.
7-3. BLOCK OPERATED LIMIT SWITCH. The block operated
upper limit stop, furnished as standard equipment, is
nonadjustable and designed to stop lower block at its high
point of travel to guard against over-travel with possible damage
to hoist. When high point is reached, limit stop switch
automatically stops hook travel. If hook drifts upward slightly
after stop switch is actuated, a reversing switch will close and
automatically reverse direction of hook travel.
12759C
Figure 7-1A. Motor Brake - Later Version
7-4. SCREW-TYPE LIMIT SWITCH. This limit switch has a
rotary screw driven by a gear reduction which is coupled to the
end of the drum shaft. Adjustment discs operate the contacts of
separate switches; one for the hoisting circuit and one for the
lowering circuit. The switch assembly must be wired in
accordance with the appropriate wiring diagram, which is
packaged with hoist. Adjustment of this screw-type limit switch
is accomplished as follows: (Refer to Figure 7-2).
WARNING
Before attempting actual adjustments, be certain main
power switch is OFF and locked in the open position.
12758B
12759
Switch
Figure 7-1. Motor Brake - Early Version
a. Examine position of indicating tang located below the solenoid
coil (Figure 7-1 or 7-1A).
b. On the later version of the brake (Figure 7-1A), if the tang is
below the line by more than 1/8", the brake should be adjusted
to bring the top of the tang back up alongside the line on the
adjust label.
Locking
Plate
Adjustment
Discs
Switch
Figure 7-2. Screw-Type Limit Switch Adjustment
(Wires not Shown for Clarity.)
a. Remove four screws and lift off switch cover.
b. Loosen locking plate screws. Slide locking plate away from
adjustment discs.
Page 21
c. Turn proper adjustment disc (right for up, left for down) toward
stitch to reduce hook travel or away from switch to increase
hook travel.
d. Slide locking plate back into position ensuring slots on
adjustment discs are fully engaged, tighten locking plate screws
to 4 in-lbs.
e. Replace cover.
components used in their construction. A print of the correct
wiring diagram for each hoist is furnished as a separate insert
and shipped with hoist. We suggest you carefully file the wiring
diagram with this book for future reference.
WHEN ORDERING PARTS OR INFORMATION ON THIS
EQUIPMENT, ALWAYS INCLUDE MODEL AND SERIAL
NUMBER ON ORDER.
SECTION IX — PARTS LIST
WARNING
Check limit switch operation carefully, without load,
before placing hoist in service. If misadjusted,
SEVERE DAMAGE AND/OR A DROPPED LOAD
COULD RESULT. Allow 6" for hook drift in both
directions. Never allow less than 1-1/2 complete wraps
of rope on drum with hook in lowest position.
Provide a light film of NLGI No. 2 grease on bevel gear of limit
switch.
7-5. OVERLOAD CLUTCH ADJUSTMENT. When properly
adjusted, the overload device is designed so that the hoist will
lift its full rated load but will refuse to lift an excessive overload.
The overload clutch is not externally adjustable. It is necessary
to remove the overload clutch assembly from the hoist for proper
adjustment. Therefore, it is strongly recommended that when
adjustment and/or replacement parts are required, a SHAWBOX Authorized Repair Station be contacted. Consult your
SHAW-BOX Distributor for nearest Repair Station.
SECTION VIII — WIRING DIAGRAMS
Wiring diagrams for SHAW-BOX electric hoists have been
omitted from this book because of many possible variations.
This is due to different currents and types of electrical
9-1. GENERAL. The parts lists and illustrations in this section
of the manual, cover parts for all standard 800 SHAW-BOX
Electric Hoists. A typical hoist is shown as the basis for the
exploded parts illustrations; therefore, certain variations may
occur from the information given. For this reason, always give
the Hoist Serial Number, Catalog Number, Motor Horsepower,
Voltage, Phase, Frequency and Rated Load of Hoist when
ordering parts.
Certain parts of your hoist will, in time, require replacement
under normal wear conditions. It is suggested that these parts
be purchased for your hoist as spares for future use. These
parts are indicated by a (†) symbol at the right side of the parts
reference numbers.
WARNING
NON-FACTORY AUTHORIZATIONS OR MODIFICATION
OF EQUIPMENT AND USE OF NON-FACTORY REPAIR
PARTS CAN LEAD TO DANGEROUS OPERATION AND
INJURY.
TO AVOID INJURY:
• Do not alter or modify equipment without
factory authorization.
• Do use only factory provided replacement parts.
The numbers assigned to the parts of our various assemblies in our parts lists are not the part numbers used in
manufacturing the part. They are identification numbers, that when given with the model number, permit us to
identify, select or manufacture, and ship the correct part needed.
9-2.
Figure No.
9-1
9-2
9-3
9-4
9-5
9-6
9-7
9-8
9-9
9-10
9-11
9-12
9-13
9-14
Page 22
INDEX OF EXPLODED VIEW PARTS ILLUSTRATIONS
Title
Page No.
Frame, Gearcase and External Parts ........................................................................................................... 23
Gearing and Load Brake Parts ..................................................................................................................... 26
Hoist Motor Brake - Later Version ................................................................................................................. 28
Hoist Motor Brake - Early Version............................................................................................ .................. 30
Three Phase Motor Assembly ....................................................................................................................... 32
Upper Limit Switch Parts ............................................................................................................................... 33
Electrical Control Equipment ......................................................................................................................... 34
Push Button Station Assembly and Conductor Cable (Single Speed) ........................................................ 35
Push Button Station Assembly and Conductor Cable (Two Speed) - Later Version ................................... 36
Push Button Station Assembly and Conductor Cable (Two Speed) - Early Version ................................... 38
Lower Block Assembly — 2 parts rope, single reeved ................................................................................ 40
Lower Block Assembly — 2 part double reeved ........................................................................................... 41
Upper and Lower Block Parts (3 & 5 Ton) .................................................................................................... 42
Screw-Type Limit Switch Parts ...................................................................................................................... 43
11455C
Figure 9-1. Frame, Gearcase and External Parts
Ref.
No.
1
2
3
4†
5
6
Part
Number
800-197
800-192
800-105
800-106
800-107
800-109
800-111
800-2100
800-108
800-110
800-2101
7
800-113
800-115
800-112
800-114
800-2102
800-2103
8
9
800-2104
800-2105
800-116
800-117
800-118
Description
Plug - Oil Level
Cover & Bearing Assembly - Gearcase
Dowel
Gasket - Gearcase
Gearcase & Bearing Assembly
Drum & Hub Assembly (Double Reeved Models)
1/2 & 1 Ton (3/6" Dia. Rope)
18' Lift
34' Lift
47' Lift
2 Ton (1/4" Dia. Rope)
14' Lift
25' Lift
36' Lift
Drum & Hub Assembly (Single Reeved Models)
1/2 & 1 Ton (1/4" Dia. Rope)
25' Lift
50' Lift
2 Ton (5/16" Dia. Rope)
20' Lift
40' Lift
3 Ton (5/16" Dia. Rope)
30' Lift
45' Lift
5 Ton (5/16" Dia. Rope)
20' Lift
30' Lift
Screw - Hex, Socket Button Head - Self-Locking
Frame Assembly (Single Reeved Models)
1/2, 1 & 2 Ton
Short Frame
Long Frame
Qty.
Req’d
2
1
2
1
1
1
1
4
1
† Recommended spares
Continued on next page
Page 23
Figure 9-1. Frame, Gearcase & External Parts. (continued)
Ref.
No.
Part
Number
800-2106
800-2107
800-2108
800-2109
9A
12
14
15
19
20
21
22†
23
24
25
26
27
29
30
32
34
35
41
43
44
45†
800-2110
800-2111
800-2112
800-121
800-124
800-125
800-130
800-131
800-2113
800-2114
800-132
800-133
800-134
800-135
800-136
800-137a
800-138
800-139
800-194c
800-2121
800-146a
800-2122
800-149
See Fig. 9-3
& Fig. 9-4
800-155
800-156
800-158
800-161
800-157
800-160
800-2115
800-2116
47
48
49
50
51
52
53
54†
55†
800-2117
800-2118
800-164
800-165
800-166
800-167
800-168
800-169
800-170
800-171
800-172
Description
3 Ton
First Extension
Second Extension
5 Ton
First Extension
Second Extension
Frame Assembly (Double Reeved Models)
1/2, 1 & 2 Ton
Short Frame
Long Frame
First Extension
Closure - 1/2" Plug
Nut - Hex (Double Reeved Models)
Lockwasher (Double Reeved Models)
Shaft - Extension, Drum
Short Frame
Long Frame
First Extension
Second Extension
Key - Woodruff (“Hi-Pro” Type)
Ring - Retaining, Hub (Internal)
Bearing - Drum Shaft
Ring - Retaining, External
Ring - Retaining, Beveled Hub (Internal)
Plate Assembly - Base
Lockwasher
Screw - Hex Socket Head Cap
Cover Assembly - Electrical
Screw - Self-Tapping
Plate Assembly - Base (Short Frame)
Shell - Brake, Short Frame
Screw - Self-Tapping
Motor & Brake
Screw - Hex Socket Head
Lockwasher
Rope & Thimble Assembly (Single Reeved Models)
1/2 & 1 Ton (1/4" Dia. Rope)
25' Lift
50' Lift
2 Ton (5/16" Dia. Rope)
20' Lift
40' Lift
3 Ton (5/16" Dia. Rope)
30' Lift
45' Lift
5 Ton (5/16" Dia. Rope)
20' Lift
30' Lift
Screw - Hex Socket Head
Roll Pin
Lockwasher
Screw - Hex Head Cap
Key Plate
Shaft - Sheave (Double Reeved Models)
Bracket, Sheave (Double Reeved Models)
Bearing, Sheave (Double Reeved Models)
Sheave Assembly, Upper (Double Reeved Models) Includes Bearing
† Recommended spares
Continued on next page
Page 24
Qty.
Req’d
1
3
4
4
1
1
1
1
1
1
1
16
4
1
2
1
1
2
1
1
1
1
4
2
2
2
1
1
1
1
1
Figure 9-1. Frame, Gearcase & External Parts. (continued)
Ref.
No.
Part
Number
56†
800-174
800-176
800-2119
57
58
61
800-173
800-175
800-2120
800-177
800-178
800-196
Description
Rope & Thimble Assembly (Double Reeved Models)
1/2 & 1 Ton (3/16" Dia. Rope)
18' Lift
34' Lift
47' Lift
2 Ton (1/4" Dia. Rope)
14' Lift
25' Lift
36' Lift
Plug, Pin
Bolt, Hex Head
Label, Rated Load (Specify Rated Load)
Qty.
Req’d
1
2
12
1
† Recommended spares
NOTES
Page 25
11456LC
Figure 9-2. Gearing and Load Brake Parts
Ref.
No.
1†
2†
3†
4
5
7
Part
Number
800-201
800-202
800-203
800-204
800-205
800-266
800-206
800-2205A
800-207
800-209
800-210
800-2209
8
15
17
800-211
800-212
800-2211
800-219
800-221
Description
Bearing Assembly - Needle, Intermediate & Drum Gear Shaft
Race - Thrust Bearing
Bearing Assembly - Needle Thrust
Gear - Intermediate
104 Teeth
109 Teeth
103 Teeth
90 Teeth
107 Teeth
Key - Woodruff
Gear - Drum
71 Teeth
61 Teeth
71 Teeth
Shaft - Intermediate Gear
14 Teeth
24 Teeth
14 Teeth
Ring - Retaining, Drum Shaft Bearing
Ring - Retaining
† Recommended spares
Continued on next page
Page 26
Qty.
Req’d
2
4
2
1
1
1
1
1
1
Figure 9-2. Gearing and Load Brake Parts. (continued)
Ref.
No.
18†
19
20
21†
22†
23†
24
25
26
27
28*
29
30
31
32
33†
34†
35
36
37
Part
Number
800-222
800-269
800-224
800-225
800-226
800-227
800-228
800-229
800-230
800-231
800-267
800-232
800-2232A
800-233
800-234
800-235
800-236
800-237
800-238
800-239
800-240
800-241
800-242
800-243
38†
39†
40†
*
**
800-244
800-245
800-268
800-246
800-2246A
800-247
800-248
800-249
800-250
800-251
43
44
45
46
47
48
49
800-254
800-253
800-252
800-260
800-263
800-261
800-262
Description
Qty.
Req’d
Bearing Assembly - Roller, Intermediate Shaft
Cover - Oil Hole
Pipe Plug - Hex Socket
Oil Seal - Motor Shaft
Bearing Assembly - Ball, Motor Shaft
Bearing Assembly - Needle, Load Brake Shaft
Ring - Retaining, Motor Shaft Bearing
Washer - Thrust (Steel)
Brake Assembly - Load, Complete (Includes Items 26 thru 37)
23 Teeth
36 Teeth
24 Teeth
18 Teeth
20 Teeth
Ring - Retaining, Brake Flange
Flange - Load Brake
Washer - Friction
Pawl & Ratchet Assembly - Load Brake (Available Only As An Assembly)
Bushing - Ratchet
Gear & Center Assembly
Pin - Groove
Cam - Load Brake
Spring - Load Brake
Retainer - Spring, Load Brake
Key - Woodruff
Shaft & Integral Pinion - Load Brake
23 Teeth
36 Teeth
24 Teeth
18 Teeth
20 Teeth
Washer - Thrust (Used With 800-246 Only)
Washer - Thrust (Bronze)
Bearing Assembly - Needle, Load Brake Shaft
Load Brake - Clutch Assembly With Bearings (Complete)
Load Brake - Clutch Assembly (Includes Items 26 thru 30, 34, 36 thru 38
and 43 thru 45)
Spring Retainer
Available only as part of
Brake Gear, Center
0-250 or 800-251 above
Clutch Assembly
Ring - Retaining
Oil Seal - Drum Shaft
Bearing Assembly - Ball, Drum Shaft
Shaft - Drum
}
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
1
1
1
80
3
1
1
1
† Recommended spares.
* Recommended Replacement Kit for Load Brake Clutch (Complete).
** Replacement Complete, Less Bearings and Thrust Washers.
For hoists built prior to March, 1997, gearing part numbers, with four digits (rather than three) after “800-”, must be replaced in sets.
For hoists built between March 1, 1997 and July 1, 1997, contact the factory for gearing requirements.
NOTES
Page 27
12756H
Figure 9-3. Hoist Motor Brake - Later Version
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Part
Number
800-2401
*
800-2402
*
*
*
*
*
800-2410†
*
*
800-2411
*
800-2403
*
*
*
*
*
*
*
*
*
*
800-2404
*
*
*
Description
Motor Brake Assembly (Includes Ref. Nos. 1 thru 31)
Acorn Nut - Plated (#10-32)
Brake Cover Assembly (Includes Brake Cover and Label Inside Cover)
Cover Stud
Gasket
Phillips Pan Head Self Tapping Screw - Plated (#10-32 x 1-3/4)
Solenoid Frame Cover Assembly
Hex Key (1/8 - 3/4 x 2)
Solenoid Coil Assembly
Tubing
Hex Nut - Plated (#10-32)
Solenoid Frame
Hex Head Self Locking Nut - Plated (#10-32)
Solenoid Support
Hex Washer Head Thread Forming Screw - Plated (#10-32 x 1/4)
Solenoid Plunger
Hex Socket Head Set Screw - Oval Point (1/4-28 x 1)
Hex Socket Shoulder Screw (#10-24 x 1)**
Hex Head Self Locking Nut - Plated (#10-24)**
Brake Spring (Use Red Spring Only)
Brake Lever Assembly
Pressure Pad
Brake Disc (Nonasbestos)
Brake Support Stud
Separating Spring
Brake Mounting Plate
Hex Socket Head Self Locking Set Screw - Cup Point (1/4-20 x 3/8)
Brake Hub
Hex Socket Head Screw (3/8-16 x 3/4)
Lock Washer (3/8)
Wire Nuts - Not Shown (No. 22 thru 14 AWG)
† Recommended spares
* Not available as individual parts. See replacement kits listed on page 29. Kits include quantities shown above
** Later models have a hex socket head screw (1/4-20 x 1-1/2) with a hex head self locking nut - plated (1/4-20)
Continued on next page
Page 28
Qty.
Req’d
1
2
1
2
1
4
1
1
1
3
2
1
2
1
2
1
1
1
1
1
1
2
1
2
2
1
2
1
2
2
4
Figure 9-3. Hoist Motor Brake. (continued)
Kit Description
Part Number
Reference Numbers Included
Brake Disc
800-2405†
23, 24, 26
Brake Lever
800-2406
6, 15, 17, 18, 19, 20, 21 (Red Color), 22,
Adjusting Screw Label, Brake Adjust Label Discard Zinc Colored Spring
Rectifier
800-2407
12, 13, 4 Wire Nuts
Hardware
800-2408
1, 3, 4, 5, 7, 9, 10, 12, 16, 18, 20, 25, 28, 30, 31,
Instruction Label, Power Warning Label
Brake Hub
800-2409
28, 29, Hub Drive Key (Shown Elsewhere)
† Recommended spares
NOTES
Page 29
12756A
Figure 9-4. Hoist Motor Brake - Early Version
Ref.
No.
Part
Number
1
2
3
4
5
6
7
8
9
10
11
14
15
16
17
18
20
21
22
23
24
25
26
27
28
29
30
31
32
800-1400
800-1401
*
800-1402
*
*
*
*
*
*
*
*
*
*
800-1403
*
*
800-1404
*
*
*
*
*
*
*
*
*
*
*
800-1405
*
Description
Motor Brake Assembly (Includes Ref. Nos. 1 thru 32)
Short Frame Models Only
Other Models
Acorn Nut (#10-32)
Brake Cover Assembly (Includes Brake Cover and Label Inside Cover)
Cover Stud
Gasket
Hex Washer Head Thread Forming Screw (#10-32 x 1 -3/4)
Solenoid Frame Cover Assembly
Hex Key (1/8-3/4 x 2-1/4)
Solenoid Coil Assembly
Tubing
Hex Nut (#10-32 Pltd.)
Solenoid Frame
Hex Head Self-Locking Nut (#10-24)
Solenoid Support
Hex Washer Head Thread Forming Screw (#10-32 x 1/4)
Solenoid Plunger
Hex Socket Head Self-Locking Set Screw - Oval Point (1/4 - 28 x 1)
Clevis Pin (3/16 x 1-1/4)
Flat Washer
Brake Spring
Brake Lever Assembly
Pressure Pad
Brake Disc (Nonasbestos)
Brake Support Stud
Separating Spring
Hex Socket Head Self-Locking Set Screw - Cup Point (1/4 - 20 x 3/8)
Brake Hub
Hex Socket Head Screw (3/8 - 16 x 3/4)
Brake Mounting Plate
Wire Nuts - Not Shown (No. 22 thru 16 AWG)
* Not available as individual parts. See replacement kits listed on page 31. Kits include quantities shown above.
Continued on next page
Page 30
Qty.
Req’d
1
2
1
2
1
4
1
1
1
3
2
1
2
1
2
1
1
1
2
1
1
2
1
2
2
2
1
2
1
4
Figure 9-4. Hoist Motor Brake. (continued)
Kit Description
Brake Disc
Part Number
800-1406
Reference Numbers Included
24, 25, 27
Solenoid
800-1407
5, 6, 8, 11, 17
Brake Lever
800-1408
18, 20, 21, 22, 23
Brake Hub
800-1409
28, 29, Hub Drive Key (Shown Elsewhere)
Special Hardware
800-1410
3, 4, 9, 26, Instruction Label inside cover,
Adjust Label, Adjusting Screw Label on
brake lever assembly, Power Warning Label
on cover
Hardware
800-1411
1, 5, 7, 10, 12, 14, 16, 18, 20, 21, 28, 30
† Recommended spares
NOTES
Page 31
12724
Figure 9-5. Three Phase Motor Assembly
Ref.
No.
Part
Number
800-1301
800-1302
800-1303
800-1304
800-1305
800-1306
800-1307
800-1308
800-1309
800-1310
800-1311
800-1312
800-1313
800-1314
800-1315
800-1316
800-1317
800-1318
800-1319
800-1320
800-1321
1
2
3
4
5
6
7
8
800-1322
800-1323
800-1324
800-1325
*
*
*
*
*
*
*
*
Description
Motor Assembly (Includes Ref. Nos. 1 thru 8)
1 Horsepower (1 Speed)
200 Volt
230/460 Volt
575 Volt
2 Horsepower (1 Speed)
200 Volt
230/460 Volt
575 Volt
4 Horsepower (1 Speed)
200 Volt
230/460 Volt
575 Volt
1 - 1/3 Horsepower (2 Speed)
200 Volt
230 Volt
460 Volt
575 Volt
2 - 2/3 Horsepower (2 Speed)
200 Volt
230 Volt
460 Volt
575 Volt
3 - 1 Horsepower (2 Speed)
200 Volt
230 Volt
460 Volt
575 Volt
4 - 2 Horsepower (2 Speed)
200 Volt
230 Volt
460 Volt
575 Volt
Bell - End
Ring - Retaining
Bearing - Ball
Ring - Retaining
Key - Brake
Rotor and Shaft Assembly
Stator Assembly
Bolt - Motor
* Furnished only as part of motor assembly
Page 32
Qty.
Req’d
1
1
1
1
1
1
1
1
4
11460
Figure 9-6. Upper Limit Switch Parts
Ref.
No.
Part
Number
1
2
800-501
800-502
800-503
800-526
800-527
3
4
5
6
7
8†
9
10†
11
12
13
14
15
16
17
18
19
20
800-504
800-505
800-528
800-529
800-506
800-507
800-525
800-509
800-510
800-511
800-512
800-513
800-514
800-515
800-516
800-517
800-518
800-519
800-520
800-521
800-522
Description
Pin - Pivot
Arm - Lever
Short Frame
Long Frame
First Extension
Second Extension
Lever - Floating
Short Frame
Long Frame
First Extension
Second Extension
Washer
Pin - Cotter
Coupling
Pin - Roll
Switch Assembly - Limit, Reversing (Includes Wire Leads)
Connector - Wire
Switch Assembly - Limit, Stop (Includes Wire Leads)
Screw - Round Head
Screw - Socket Head Shoulder
Shaft & Cam Assembly
Insulator - Limit Switch
Bearing - Nylon
Screw - Socket Head Cap
Lockwasher
Nut - Lock
Bracket Assembly - Mounting
Nut - Hex
Qty.
Req’d
2
1
1
2
2
1
2
1
3
1
4
1
1
1
2
2
2
1
1
2
† Recommended spares
Page 33
12748A
Figure 9-7. Electrical Control Equipment
Ref.
No.
3
5
6†
7†
8
9†
10
11†
12
13
14
Part
Number
800-670
800-654
800-655
800-656
800-657
800-671
800-663
800-672
800-673
800-674
800-675
800-676
Description
Cord Grip - Conductor
Screw - Self-Tapping
Contactor - Two Speed
Contactor
Screw - Self-Tapping
Transformer
Screw - Self-Tapping
Terminal Board (Reconnectable Hoist Only)
Fuse, Fuse Holder and Wire Assembly
Fuse Only (2A, 300V)
Brake Module
Screw - Self Tapping
† Recommended Spares
NOTES
Page 34
Qty.
Req’d
2
4
1
1
2
1
4
1
1
1
1
2
12763
Figure 9-8. Push Button Station and Conductor Cable Assembly.
Single Speed Hoists
Ref.
No.
Part
Number
800-2701
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
800-2702
*
*
*
800-2703
*
800-2704
800-2705
*
*
*
*
*
*
800-2706
*
800-2707
800-2708
Description
Push Button Station and Conductor Cable Assembly
(Includes Ref. Nos. 1 thru 17)
Push Button Station (Includes Ref. Nos. 1 thru 15)
Type 1 Pan Head Machine Screw (M 3.5 x 0.6 x 12 Pltd.)
Lockwasher (M 3.5 Pltd.)
Rear Cover
Gasket
Type 1 Pan Head Thread Cutting Screw (M 4 x 15 Pltd.)
Contact Assembly
Button Assembly
Type 1 Pan Head Machine Screw (M 6 x 1 x 12 Pltd.)
Lockwasher (M 6 Pltd.)
Plain Washer (M 6 Pltd.)
Type 1 Pan Head Machine Screw (M 3.5 x 1 x 14 Pltd.)
Lockwasher (M 3.5 Pltd.)
Housing Cap
Grommet
Housing
Conductor Cable Assembly
Plastic Warning Tag
Qty.
Req’d
1
1
7
7
1
1
2
1
1
1
1
1
2
2
1
1
1
1
1
* Not available separately. Order Push Button Station
Page 35
12721A
Figure 9-9. Push Button Station and Conductor Cable Assembly.
Two Speed Hoists Only - Later Version
Ref.
No.
Part
Number
800-1821
1
7
11
12
13
14
15
16
17
18
19
20
21
800-1822
800-1823
800-1812
800-1813
800-1814
*
*
*
*
*
*
*
*
*
Description
Push Button Station and Conductor Cable Assembly
(Includes Ref. Nos. 1 thru 30)
Grommet
Conductor Cable
Operator Warning Label
Push Button Station (Includes Ref. Nos. 12 thru 30)
Sleeve - Conductor
Support - Strain Cable
Screw - Slotted Head
Lockwasher
Enclosure - Rear
Gasket
Screw - Slotted Head
Screw - Slotted Head
Clamp - Conductor
Contact Block Assembly
* Not available separately. Order Push Button Station
Continued on next page
Page 36
Qty.
Req’d
1
1
As Req’d
1
1
1
1
4
4
1
1
2
2
1
1
Figure 9-9. Push Button Station and Conductor Cable Assembly. (continued)
Ref.
No.
22
23
24
25
26
27
28
29
30
Part
Number
800-1815
800-1816
*
800-1817
800-1818
**
*
**
**
**
**
**
**
Description
Contact Block (ZB2-BE101)
Contact Block (ZB2-BE201)
Interlock - Mechanical
Up Push Button Assembly (Includes 1 Each of Ref. Nos. 23 and 25 thru 29)
Down Push Button Assembly (Includes 1 Each of Ref. Nos. 23, 25 thru 28 and 30)
Ring - Retaining
Enclosure - Front
Seat - Spring
Spring
Seal
Plate - Push Button
Push Button - Up
Push Button - Down
Qty.
Req’d
2
2
1
1
1
2
1
2
2
2
2
1
1
* Not available separately. Order Push Button Station
** Not available separately. Order Push Button Assembly
NOTES
Page 37
12721
Figure 9-10. Push Button Station and Conductor Cable Assembly.
Two Speed Hoists Only - Early Version
Ref.
No.
Part
Number
800-1801
1
2
3
4
5
6
7
8
9
10
11
12
800-1802
800-1803
800-1804
800-1805
800 1806
800-1807
800-1808
800-1809
800-1810
800-1811
800-1812
800-1813
800-1814
Description
Push Button Station and Conductor Cable Assembly
(Includes Ref. Nos. 1 thru 30)
Anchor Bracket - Strain Cable
Grip Assembly - Conductor
Connector - Strain Cable
Thimble - Strain Cable
Connector - Conductor to Strain Cable
Clamp - Conductor
Conductor Cable
Strain Cable
Sleeve - Pressure
Tie - Conductor
Operator Warning Label
Push Button Station (Includes Ref. Nos. 12 thru 30)
Sleeve - Conductor
Continued on next page
Page 38
Qty.
Req’d
1
1
1
1
2
1
1
1
1
1
As Req’d.
1
1
1
Figure 9-10. Push Button Station and Conductor Cable Assembly. (continued)
Ref.
No.
Part
Number
13
14
15
16
17
18
19
20
21
*
*
*
*
*
*
*
*
*
800-1815
800-1816
*
800-1817
22
800-1818
23
24
25
26
27
28
29
30
**
*
**
**
**
**
**
**
Description
Support - Strain Cable
Screw - Slotted Head
Lockwasher
Enclosure - Rear
Gasket
Screw - Slotted Head
Screw - Slotted Head
Clamp - Conductor
Contact Block Assembly
Contact Block (ZB2-BE101)
Contact Block (ZB2-BE201)
Interlock - Mechanical
Up Push Button Assembly (Includes 1 Each of Ref. Nos. 23 and
25 thru 29)
Down Push Button Assembly (Includes 1 Each of Ref. Nos. 23,
25 thru 28 and 30)
Ring - Retaining
Enclosure - Front
Seat - Spring
Spring
Seal
Plate - Push Button
Push Button - Up
Push Button - Down
Qty.
Req’d
1
4
4
1
1
2
2
1
1
2
2
1
1
1
2
1
2
2
2
2
1
1
* Not available separately. Order Push Button Station
** Not available separately. Order Push Button Assembly
NOTES
Page 39
11464
Figure 9-11. Lower Block Assembly - Two Parts Rope, Single Reeved
Ref.
No.
1
2
3
4
5
6
†
7
8
†
7
8
9
10†
†
11
12†
†
13
14
15
Part
Number
800-801
800-802
800-803
800-804
800-805
800-806
800-807
800-808
800-809
800-810
800-811
800-812
800-813
800-814
800-815
800-816
800-817
800-818
800-819
800-820
800-821
800-822
800-823
800-824
800-825
800-826
800-827
800-828
800-829
800-830
800-831
800-832
800-833
800-834
Description
Block Assembly - Lower, Complete, 2 Ton
Block Assembly - Lower, Complete, 1 Ton
Block Assembly - Lower, Complete, 1/2 Ton
Screw - Flat Head, Self-Threading
Cover - 2 Ton
Cover - 1 Ton
Cover - 1/2 Ton
Ring - Retaining, 2 Ton
Ring - Retaining, 1/2 & 1 Ton
Lube Fitting
Pin - Sheave, 2 Ton
Pin - Sheave, 1/2 & 1 Ton
Spacers - 2 Ton
Spacers - 1/2 Ton & 1 Ton
Sheave Assembly - 2 Ton (Consists of Items 7 and 8)
Bearing
Sheave
Sheave Assembly - 1/2 & 1 Ton (Consists of Items 7 and 8)
Bearing
Sheave
Cover - Lower Block, 2 Ton
Cover - Lower Block, 1 Ton
Cover - Lower Block, 1/2 Ton
Hook Assembly - (Consists of Hook, Nut & Grooved Pin), 2 Ton
Hook Assembly - (Consists of Hook, Nut & Grooved Pin), 1/2 & 1 Ton
Shroud - Thrust Bearing, 2 Ton
Shroud - Thrust Bearing, 1/2 & 1 Ton
Bearing Washer - Thrust, 2 Ton
Bearing Washer - Thrust, 1/2 & 1 Ton
Body - Lower Block, 2 Ton
Body - Lower Block, 1/2 & 1 Ton
*Safety Hook Latch Kit - 2 Ton
*Safety Hook Latch Kit - 1/2 & 1 Ton
Screw - Flat Head, Self-Threading
† Recommended Spares
* Furnished as standard with hook
Page 40
Qty.
Req’d
1
1
1
2
1
1
1
2
2
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
11465
Figure 9-12. Lower Block Assembly—Two Parts Double Reeved
Ref.
No.
1
2
3
4
5
6
†
7
8
9
10
11†
†
12
13†
†
14
15
Part
Number
800-851
800-852
800-853
800-804
800-854
800-806
800-807
800-809
800-810
800-855
800-814
800-818
800-819
800-820
800-856
800-834
800-824
800-825
800-826
800-827
800-828
800-829
800-857
800-858
800-832
800-833
Description
Block Assembly - Lower, Complete, 2 Ton
Block Assembly - Lower, Complete, 1 Ton
Block Assembly - Lower, Complete, 1/2 Ton
Screw - Flat Heads Self-Threading
Cover - Lower Block, 2 Ton
Cover - Lower Block, 1 Ton
Cover - Lower Block, 1/2 Ton
Ring - Retaining
Fitting - Lube
Pin - Sheave
Spacer
Sheave Assembly - (Consists of Items 7 and 8)
Bearing
Sheave
Cover - Intermediate
Screw - Flat Head, Self-Threading
Hook Assembly - (Consists of Hook, Nut & Grooved Pin), 2 Ton
Hook Assembly - (Consists of Hook, Nut & Grooved Pin), 1/2 & 1 Ton
Shroud - Thrust Bearing, 2 Ton
Shroud - Thrust Bearing, 1/2 & 1 Ton
Bearing - Thrust, 2 Ton
Bearing - Thrust, 1/2 & 1 Ton
Body - Lower Block, 2 Ton
Body - Lower Block, 1/2 & 1 Ton
*Safety Hook Latch Assembly - 2 Ton
*Safety Hook Latch Assembly - 1/2 & 1 Ton
Qty.
Req’d
1
1
1
4
2
2
2
2
1
1
4
2
2
2
1
4
1
1
1
1
1
1
1
1
1
1
† Recommended Spares
* Furnished as standard with hook
Page 41
12197LA
Figure 9-13. Upper and Lower Block Parts (3 & 5 Ton - Typical)
Quantity Required
Ref.
No.
1
2
3
4
5
6
7†
8†
9
11
12†
13†
14
15
16†
17
18†
19
20
21
22
23
24
25
26
27
Part
Number
800-1501
800-1502
800-1503
800-1504
800-1505
800-1506
800-1507
800-1508
800-1509
800-1510
800-1535
800-1513
800-1514
800-1515
800-1516
800-1517
800-1518
800-1530
800-1531
800-1519
800-1520
800-1521
800-1522
800-1523
800-1524
800-1525
800-1526
800-1527
800-1528
800-1529
Reeving
Description
Block Assembly - Lower, 4 Part Single (Complete)
Block Assembly - Lower, 6 Part Single (Complete)
Screw - Hex Head Cap
Lockwasher
Key Plate
Fitting - Grease
Pin - Upper Sheave
Spacer Washer - Upper Sheave
Bearing - Upper Sheave (Includes Outer Race)
Sheave - Upper
Pin - Rope Guide
Spacer Washer - Lower Sheave
Bearing - Lower Sheave (Includes Outer Race)
Sheave - Lower
Pin - Roll, Hook Nut
Nut - Hook*
Bearing - Thrust, Hook
Shield - Bearing (Not Shown)
Washer - Thrust (Not Shown)
Fitting - Grease
Hook Assembly - (includes Hook, Latch & Nut)
Plate - Capacity
Screw - Round Head, Self-Tapping (Capacity Plate)
Guard - Sheave
Body - Lower Block
Pin - Lower Sheave
Screw - Button Head Cap, Self-Locking (Sheave Guard)
Ring - Retaining, External
Lockwasher - (Capacity Plate)
Spacer - Upper Block, 9/16"
† Recommended Spares
* Hook Nuts with roll pins are not interchangeable - Available only as an assembly
Page 42
3-Ton/4 PS
1
2
2
1
1
1
2
1
1
2
4
2
2
1
1
1
1
2
1
1
2
4
1
1
1
4
2
4
2
5-Ton/6 PS
1
2
2
1
1
1
4
2
2
2
6
3
3
1
1
1
1
1
2
4
1
1
1
4
2
4
-
12757A
Figure 9-14. Screw-Type Limit Switch Parts
Ref.
No.
Part
Number
1
2
3
4
800-1655
800-1651
800-1652
800-1657
Description
Limit Switch Assembly (Includes Ref. Nos. 2, 3 and 4)
Cap Screw - Hex Socket Head
Sealing Washer
Drum Shaft Insert
Qty.
Req’d
1
3
3
1
For switch element replacement order 800-1654
NOTES
Page 43
Recommended Spare Parts for Your Shaw-Box Hoist
Certain parts of your hoist will, in time, require replacement under normal wear conditions.
It is suggested that the following parts be purchased for your hoist as spares for future use.
One
One
One
One
One
One
friction disc kit
motor brake solenoid coil
set of contactors
transformer
wire rope assembly
gearcase gasket
Note: When ordering parts always furnish Hoist Serial Number, Catalog Nulmber, Motor Horsepower, Voltage,
Phase, Frequency and Rated Load of Hoist on which the parts are to be used.
Parts for your hoist are available from your local authorized Shaw-Box repair station.
For the location of your nearest repair station, write:
IN USA
YaleŸLift-Tech
P.O. Box 769
Muskegon, MI 49443-0769
Phone: 800 742-9269
Fax:
800 742-9270
WARRANTY
WARRANTY AND LIMITATION OF REMEDY AND LIABILITY
A. Seller warrants that its products and parts, when shipped, and its
work (including installation, construction and start-up), when performed, will meet applicable specifications, will be of good quality and
will be free from defects in material and workmanship. All claims for
defective products or parts under this warranty must be made in
writing immediately upon discovery and in any event, within one (1)
year from shipment of the applicable item unless Seller specifically
assumes installation, construction or start-up responsibility. All claims
for defective products or parts when Seller specifically assumes
installation, construction or start-up responsibility and all claims for
defective work must be made in writing immediately upon discovery
and in any event, within one (1) year from completion of the applicable
work by Seller, provided; however, all claims for defective products
and parts made in writing no later than eighteen (18) months after
shipment. Defective items must be held for Seller’s inspection and
returned to the original f.o.b. point upon request. THE ‘FOREGOING
IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER, EXPRESS, IMPLIED AND STATUTORY, INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS.
B. Upon Buyer’s submission of a claim as provided above and its
substantiation, Seller shall at its option either (i) repair or replace its
product, part or work at either the original f.o.b. point of delivery or at
Seller’s authorized service station nearest Buyer or (ii) refund an
equitable portion of the purchase price.
C. This warranty is contingent upon Buyer’s proper maintenance and
care of Seller’s products, and does not extend to normal wear and
tear. Seller reserves the right to void warranty in event of Buyer’s use
of inappropriate materials in the course of repair or maintenance, or
if Seller’s products have been dismantled prior to submission to Seller
for warranty inspection.
D. The foregoing is Seller’s only obligation and Buyer’s exclusive
remedy for breach of warranty and is Buyer’s exclusive remedy
hereunder by way of breach of contract, tort, strict liability or otherwise. In no event shall Buyer be entitled to or Seller liable for
incidental or consequential damages. Any action for breach of this
agreement must be commenced within one (1) year after the cause
of action has accrued.
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