Yale Lift-Tech SHAW-BOX Operation, Service & Parts Manual
Yale Lift-Tech SHAW-BOX is a high-quality and precision-built electric hoist designed to give you long service life with minimum attention. It's rugged construction and wide-faced helical gearing made of heat-treated steel, ball bearings throughout, large diameter grooved rope drum, and large lower block rope sheave make it a reliable choice for various lifting tasks.
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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 700
SHA W
-BO
X
®
WIRE ROPE ELECTRIC HOISTS
INCLUDING
WEIGHT WATCHER
OVERLOAD CLUTCH MODELS
RATED LOADS THRU 25 TONS
COPYRIGHT 2003, Yale
!!!!!
Lift-Tech, division of Columbus McKinnon Corporation July, 2003 Part No. 113533-60
Page 1
Figure 1-1. Cutaway View of Standard Series “700” SHAW-BOX Electric Hoist
This cutaway view illustrates the high quality and precision construction of your new SHAW-BOX electric hoist. An examination of its makeup will show it is designed and built to give you long service life with a minimum of attention. Notice that it has wide-faced helical gearing made of heat-treated steel, ball bearings throughout, large diameter grooved rope drum and large lower block rope sheave. In addition, this hoist offers unusually easy accessibility to all working parts. It is designed so that you needn’t take your hoist down for servicing. A hinged side cover gives quick access to electrical components. Removable lightweight aluminum end covers provide full access to brake mechanism, motor brake, load brake and gearing.
FOREWORD
This book contains important information to help you install, operate, maintain and service your new SHAWBOX 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 motor end of hoist (Figure 4-1).
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.
Page 2
FOREWORD (Continued)
The contents of this manual are of necessity, general in nature and may cover features not incorporated on your hoist; or, you may have ordered features not covered by this manual.
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 LIFTTECH
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.
INDEX
SECTION I GENERAL DESCRIPTION Page
Paragraph 1-1 General ................................................................................................................................................ 4
Paragraph 1-2 Basic Construction .............................................................................................................................. 4
SECTION II INSTALLATION
Paragraph 2-1 General ................................................................................................................................................ 4
Paragraph 2-2 Suspending Hoist ................................................................................................................................ 4
Paragraph 2-3 Connecting Hoist to Electrical Service ............................................................................................... 5
Paragraph 2-4 Pre-Operation Checks ......................................................................................................................... 5
SECTION III OPERATION
Paragraph 3-1 General ................................................................................................................................................ 7
Paragraph 3-2 Push Button Operation ........................................................................................................................ 7
Paragraph 3-3 Overload Clutch Operation ................................................................................................................. 7
Paragraph 3-4 Operating Precautions ........................................................................................................................ 7
SECTION IV LUBRICATION
Paragraph 4-1 General ................................................................................................................................................ 8
Paragraph 4-2 Change Gearcase Oil .......................................................................................................................... 8
Paragraph 4-3 Lubricate Hoist Cable .......................................................................................................................... 8
Paragraph 4-4 Lubricate Upper Sheave & Lower Block Assembly ............................................................................ 8
Paragraph 4-5 Limit Stop Lever Lubrication ............................................................................................................... 8
Paragraph 4-6 Lubricate Limit Switch ......................................................................................................................... 8
SECTION V INSPECTION AND PREVENTATIVE MAINTENANCE
Paragraph 5-1 General ................................................................................................................................................ 9
Paragraph 5-2 Inspect Lower Block .......................................................................................................................... 10
Paragraph 5-3 Inspect Upper Block and Hoist Suspension ..................................................................................... 10
Paragraph 5-4 Inspect Electrical Controls ................................................................................................................ 12
Paragraph 5-5 Inspect Motor Brake and Actuating Mechanism ............................................................................... 12
Paragraph 5-6 Inspect Mechanical Load Brake and Gearing .................................................................................. 12
Paragraph 5-7 Inspect Rope Drum and Shaft .......................................................................................................... 14
Paragraph 5-8 Rope Inspection, Replacement & Maintenance ............................................................................... 14
Paragraph 5-9 Rope Reeving .................................................................................................................................... 15
Paragraph 5-10 Testing Hoist .................................................................................................................................... 20
SECTION VI TROUBLESHOOTING CHART ................................................................................................................ 20
SECTION VII ADJUSTMENTS
Paragraph 7-1 Mechanical Load Brake ..................................................................................................................... 22
Paragraph 7-2 Motor Brake Adjustment .................................................................................................................... 22
Paragraph 7-3 Block Operated Limit Switch ............................................................................................................. 22
Paragraph 7-4 Geared Rotary Limit Switch Adjustment .......................................................................................... 23
Paragraph 7-5 Overload Clutch Adjustment and Testing ......................................................................................... 23
Paragraph 7-6 Shortening of Push Button Cable ..................................................................................................... 25
SECTION VIII WIRING DIAGRAMS .............................................................................................................................. 25
SECTION IX PARTS LIST
Paragraph 9-1 General .............................................................................................................................................. 25
Paragraph 9-2 List of Parts Illustrations .................................................................................................................... 25
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 3
SECTION I - GENERAL DESCRIPTION
1-1. GENERAL. SHAW-BOX Series “700” electric hoists are wire rope and drum type hoists which are manufactured in two basic models: A standard model, available in four conventional suspensions (Lug Mounted, Push Trolley, Hand Geared Trolley and Motor Driven Trolley); and, a low headroom model with three special low-headroom design trolley suspensions (Push,
Hand Geared and Motor Driven types). The standard model hoist comes in eleven load sizes, ranging from 2 thru 20 tons, with various lifts and lifting speeds, while the low headroom model comes in 7 load sizes, from 2 thru 10 tons, and various lifts and lifting speeds. Both of the basic models are available with single or two-speed lifting control. Deck mounted and base mounted hoists are also available as modifications of the basic hoist models. Deck mounted hoists are available thru 20 ton rated load.
NOTICE
SHAW-BOX hoists thru 15 tons are available with an optional built-in mechanical overload clutch. Hoists having this device are identified with words “WEIGHT
WATCHER” on the hoist.
WARNING
Before attempting installation of hoist or trolley, the main power switch must be locked in the open position
(off).
2-2. SUSPENDING HOIST. Hoist may be suspended in a fixed location servicing only the area directly below the hoist (Lug
Mounted). Hoist may be attached to a moveable trolley or trolleys which in turn may be mounted on an I-beam attached to a building or crane, servicing a large area (Trolley Mounted).
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.
The “WEIGHT WATCHER” overload limiting device 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. Series “700” standard model and low headroom model electric hoists are of the same basic construction, differing primarily in the suspension method and rope reeving. They consist of a rugged 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 trolley or mounting to an overhead suspension (standard model), is located on the top of the frame. An aluminum alloy gearcase, attached to one end of the hoist frame, houses a two-reduction gear train and a mechanical load brake. A gearcase cover and a brake cover, both of aluminum alloy, mounted on the end of the gearcase, houses an automatic motor brake. An electric driving motor is mounted at the other end of the hoist frame.
Electrical system components, located in a compartment at the front of the hoist frame, control operation and rotating direction of driving motor. Hoisting cable and an enclosed lower block assembly is used for lifting loads. An upper limit stop is used to limit the 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 on a wire strain cable attached to hoist frame at the motor end of the hoist.
SECTION II - INSTALLATION
2-1. GENERAL. SHAW-BOX Series 700" electric hoists are lubricated and tested before being shipped from the factory. To place hoist in service, attach a suitable suspension (Paragraph
2-2), connect to electrical service (Paragraph 2-3) and perform pre-operation tests and checks (Paragraph 2-4).
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, selflocking nuts or cross bolting, if unthreaded.
b. Trolley Mounted hoists are attached to moveable trolleys.
If 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.
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.
Page 4
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 percent rated hoist capacity) 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
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
Power supply to the hoist and/or trolley must be the same voltage, frequency and phase that is specified on the hoist and trolley nameplates. Single speed hoists are reconnectable for use on either 460 V. or 230 V.
Check terminal board connections on dual voltage hoists with wiring diagram to make certain that the motor, transformer and brake leads are located on proper terminals.
WARNING
Mounting of the hoist/trolley unit on the monorail and final pre-operation inspection shall be performed only by qualified persons properly supervised.
12207A
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 journeyman electricians.
c. When trolley is shipped separate from hoists, see special instructions furnished with trolley for orientation and installation.
d. For deck mounted three speed hoists, secondary resistors are furnished. These are to be mounted by the customer to suit his requirements. Since resistors generate heat, they are to be located outside of the control panel enclosure in a well ventilated area that will allow the heat to readily dissipate. They must be guarded from accidental contact by personnel (perforated metal covers are often used). Provision must be made to prevent molten metal from falling on personnel (drip trays may be provided).
Figure 2-1. Sectional View of Trolley showing proper wheel and washer spacing
WARNING
Failure to properly mount resistors may be hazardous to personnel and equipment.
2-3. CONNECTING HOIST TO ELECTRICAL SERVICE.
Electrical service to the hoist may be power cable or a guarded system having sliding shoe or wheel type collectors.
2-4. PRE-OPERATION CHECKS.
a. Check Oil Level. (Figure 4-1) The gearcase has been filled with oil to proper level and grease points for upper and lower sheaves (when so equipped) have been lubricated at the factory. However, this should be rechecked before operating hoist.
Page 5
Check oil level by removing plug locate on side of the gearcase adjacent to the embossed words “OIL LEVEL".
When properly filled, oil should be level with bottom of tapped hole. Fill to this level with oil as specified in
Paragraph 4-2.d. Grease fittings in sheave pin ends should show evidence of grease.
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
“Up” button is depressed. When this condition exists the automatic limit stop switch is inoperative and hoist operation will be dangerous.
To properly check the phase of the hoist, follow 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.
(2) Temporarily connect hoist to power source.
(3) Operate “UP” 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 on most Series “700” electric hoists (some long lift and all deck mounted hoists have geared type limit switches as standard).
This limit stop is factory set to stop lower block at safest high position, guarding against overtravel and possible damage to hoist. No adjustment can be made.
However, the hoist should be tested by jogging lower block against limit weight (Figure 2-2) to be sure the limit switch is functioning properly. When lower block lifts limit weight, hoist will automatically stop. If lower block coasts through the stop limit switch when lifting at maximum height, in most SHAW-BOX hoists a reversing switch will automatically close and reverse direction of motion to lowering.
Figure 2-2. Schematic Diagrams of
Upper Limit Stop Arrangement
NOTICE
Under normal operating conditions stop hoist travel before engaging limit switches. Limit switches are safety devices and should not be used as normal operating control.
WARNING
Some hoists are shipped with the electrical controls loose (disconnected) and will not have the upper and lower limit switches connected. DO NOT
OPERATE HOIST UNTIL LIMIT SWITCHES ARE
PROPERLY CONNECTED AND ADJUSTED. Failure to do so may allow hoist to be operated beyond proper travel limits which can cause load to drop, resulting in damage to equipment or injury.
(2) A geared rotary type upper and lower limit switch is provided optionally when both upper and lower limit stops are required (Figure 7-1). This switch is adjustable and although roughly preset by the factory, it should be adjusted at time of installation to the desired high and low limits of lower block travel. Refer to SECTION VII, Paragraph 7-4.
d. Check Lower Block and Hoisting Cable. Depress “DOWN” 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 wrap 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
Page 6
block turns. Reconnect rope to frame anchor, holding firmly to eliminate rope twisting back to i ts 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 heavy coating grease as outlined in SECTION IV, Paragraph 4-3.
SECTION III - OPERATION
3-1. GENERAL. Operation of Series “700” 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 push button 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.
3-2. PUSH BUTTON OPERATION.
a Depress push button marked “UP” to raise load.
b. Depress push button marked “DOWN” to lower load.
c. Jogging the push buttons 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.
d. On two-speed hoists, partial depression of button operates hoist at slow speed; depressing button completely operates hoist at fast speed.
3-3. OVERLOAD CLUTCH OPERATION (optional). The overload clutch 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 “UP” button is depressed and rotate the load brake gear without lifting the load. Whenever this slipping occurs, immediately release the “UP” push button to prevent overheating of the clutch friction surfaces and the hoist motor.
WARNING
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. DO read ANSI B30.16 Safety Standard for Overhead
Hoists and the Operation, Service and Parts Manual.
b. DO be familiar with hoist operating controls procedures and warnings.
c. DO make sure hook travel is in the same direction as shown on controls.
d. DO make sure hoist limit switches function properly.
e. DO maintain firm footing when operating hoist.
f. DO make sure that load slings or other approved single attachments are properly sized and seated in the hook saddle.
g. DO make sure that the hook latch is closed and not supporting any part of the load.
h. DO make sure that load is free to move and will clear all obstructions.
i. DO take up slack carefully, check load balance, lift a few inches and check load holding action before continuing.
j. DO avoid swinging of load or load hook.
k. DO make sure that all persons stay clear of the suspended load.
l. DO warn personnel of an approaching load.
m. DO protect wire rope from weld splatter or other damaging contaminants.
n. DO promptly report any malfunction, unusual performance, or damage of the hoist.
o. DO inspect hoist regularly, replace damaged or worn parts, and keep appropriate records of maintenance.
p. DO use the hoist manufacturer’s recommended parts when repairing a hoist.
q. DO use hook latches.
r. DO apply lubricant to the wire rope as recommended.
s. DO NOT lift more than rated load.
t. DO NOT use the hoist load limiting device to measure the load.
u. DO NOT use damaged hoist or hoist that is not working correctly v. DO NOT use the hoist with twisted, kinked, damaged or worn wire rope.
w. DO NOT lift a load unless wire rope is properly seated in its groove(s).
x. DO NOT use load rope as a sling or wrap rope around the load.
y. DO NOT lift a load if any binding prevents equal loading on all supporting ropes.
z. DO NOT apply the load to the tip of the hook.
aa. DO NOT operate unless load is centered under hoist.
ab. DO NOT allow your attention to be diverted from operating the hoist.
ac. DO NOT operate the hoist beyond limits of load rope travel.
ad. DO NOT use limit switches as routine operating stops unless recommended. They are emergency devices only.
ae. DO NOT use hoist to lift, support or transport people.
Page 7
af. DO NOT lift loads over people.
ag. DO NOT leave a suspended load unattended unless specific precautions have been taken.
ah. DO NOT allow sharp contact between two hoists or between hoist and obstructions.
ai. DO NOT allow the rope or hook to be used as a ground for welding.
aj. DO NOT allow the rope or hook to be touched by a live welding electrode.
ak. DO NOT remove or obscure the warnings on the hoist.
al. DO NOT adjust or repair a hoist unless qualified to perform hoist maintenance.
am. DO NOT attempt to lengthen the load rope or repair damaged load rope.
an. Personnel not physically fit or properly qualified, shall not operate hoist.
ao. Do not operate hoists unless hook moves in the same direction as indicated on the push button. If opposite direction occurs, see preoperation checks, Paragraph
2-4.b.
ap. Do not operate hoist unless limit switch is operating properly.
aq. Center hoist over load before operating. Avoid side pulls and swinging of load or load hook when travelling hoist.
11058LB
Figure 4-1. View of Hoist Showing Location of
Name Plates and Oil Plugs
WARNING
Do not operate the 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 proper 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.
ar. Observe recommended inspection and maintenance procedures.
as. Use common sense and best judgement whenever operating a hoist.
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 insure long life. Intervals of at least six (6) months, coinciding with spring and fall seasons, are recommended. The reason for this is that, on hoists installed out-of-doors and in unheated areas, a “cold test” oil 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.
b. Flush out hoisting using kerosene. Reinstall drain plug.
c. Remove oil level plug from front of gearcase cover.
Page 8 d. Refill thru filler hole to proper level (bottom of oil level plug hole) using Automatic Transmission Fluid DEXRON
III Type, suitable for all temperature ranges. The amount of oil required depends upon overall size of gearcase; two sizes are used for Series “700” hoists. To determine size and amount of oil to add, measure width of hoist at gearcase cover. If the width is 24-3/4 inches, add 6 quarts of oil; and if 34-1/4 inches, add 18 quarts.
4-3. LUBRICATE HOISTING CABLE. Hoists are shipped from the factory without an exterior coating of grease 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.
4-4. LUBRICATE UPPER SHEAVE AND LOWER BLOCK
ASSEMBLY
a. Some hoists are equipped with roller-type upper and lower sheave bearings and have grease fittings located in ends of sheave pins. If hoist is so equipped, apply (*) NLGI No.
2 grease, such as Shell Oil Company’s Alvania No. 2 or equivalent, for operating temperatures from +50°F to
+125°F For colder temperatures, (-20°F to +50°F) use
NLGI No. 1 such as Shell Oil Company’s Alvania No. 1 or its equivalent. Hoists not equipped with grease fittings in sheave pins have shielded ball bearings with lubricant sealed in and do not require additional lubrication.
b. On Low Headroom Models, apply a few drops of S.A.E.
No. 50 oil to thrust bearings at trolley brackets.
(*) National Lubricating Grease Institute.
4-5. LIMIT STOP LEVER LUBRICATION. Some hoists are equipped with a bar operated limit switch. Apply a few drops of
S.A.E. No. 50 oil to pivot points of limit rod.
4-6. LUBRICATE LIMIT SWITCH. Provide a light film of NLGI
No. 2 grease on bevel gear of limit switch.
SECTION V - INSPECTION AND PREVENTIVE
MAINTENANCE
5-1. GENERAL. All SHAW-BOX, Series “700,” 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 service 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.
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.
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 percent “on” time and the average loading not exceeding 65 percent 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 11 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 be used to record scheduled inspection and maintenance services required.
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.
As a matter of expedience, appointed maintenance personnel inspecting hoist can also take care of minor adjustments, repairs and cleaning, where required. Note 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 (
"
). Note
“during inspection” corrective action taken and date in space provided. In this manner, items requiring further attention will be checked (
"
) 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 hazard.
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 with anything wrong or apparently wrong.
Danger may be present that the hoist operator cannot see. Determine and correct cause of unusual conditions and make certain hoist can be operated safely.
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5-2. INSPECT LOWER BLOCK.
a. Check lubrication of all parts. Also lubricate the shank of the hook which passes through the crosshead. If thrust bearing is removed, apply NLGI No. 2 grease.
b. Check each sheave to insure 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.
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 regulations 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.
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.
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 is not bent, loose or otherwise distorted; guide must have close clearance to sheave flange to keep rope in sheave grooves.
d. Check hoist suspension bolts on lug suspended hoists; make certain that bolts are secure, properly tightened and free from damage.
e. Check hoist suspension bolts on trolley mounted hoists.
Make certain that bolts are secure, properly tightened and free from damage. On low headroom hoists, and other two trolley hoists, suspension bolts to both trolleys must be inspected.
WARNING
Do not operate hoists having worn or damaged suspension bolts.
12172
Figure 5-1. Method of measuring hook throat opening
RECOMMENDED INSPECTION AND MAINTENANCE SCHEDULE
TIME INTERVAL
Daily or start of each shift
(visual)
1 Month
1-3 Months
6 Months
INSPECTION OR MAINTENANCE
* 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.
* HOIST CABLE - Inspect and lubricate per Paragraph 5-8.
* ELECTRICAL CONTROLS - Inspect per Paragraph 5-4. Check hoist gearcase oil level - add oil as required per
Paragraph 4-2.d.
* LOWER BLOCK - Inspect per Paragraph 5-2.
UPPER BLOCK - Inspect per Paragraph 5-3.
Annually
6 Months or
500-750 hours
“on” time
5 Years elapsed time or 5000 hours “on” time
* Motor brake and actuating mechanisms. Inspect and adjust per Paragraph 5-5. Inspect hooks with crack detecting procedures per Paragraph 5-2. Drain and refill hoist gearcase per Paragraph 4-2.
* Inspect electrical controls per Paragraph 5-4. Change hoist gearcase oil - Fill with oil per Paragraph 4-2.d. 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.
* Complete inspection, disassembly, and maintenance required. It is recommended that your SHAW-BOX Repair
Station be contacted for this service.
Page 10
INSPECTION SCHEDULE AND MAINTENANCE REPORT
HOIST SERIAL NO. (MFGRS) _______________________ CUSTOMER CRANE IDENTITY NO. _______________________
RATED LOAD _________________
TYPE ________________________
VOLTAGE _____________________
LOCATION IN PLANT __________________________________
THIS INSPECTION IS MONTHLY
#
SEMI-ANNUAL
#
ANNUAL
#
INSPECTED BY: ________________ DATE _____________
COMPONENT, UNIT OR PART and location
*
mended
CONDITION
(Check column best indicating condition when
Inspection part or unit is inspected. Use note column to
Interval the right if condition is not listed below.)
CORRECTIVE ACTION
NOTES
COMPONENT,
UNIT OR
PART
(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
Gears, Shafts & Bearings
Upper Block
Lower Block
Hook & Throat Opening
Hoist Rope
Rope Drum
Guards
Limit Switch
X
Record Hook Throat Opening
Pushbutton
Wiring
Motor
Brake (when so equipped)
Couplings
Gears, Shafts & Bearings
Frame
Wheels
Bumpers
Guards
Conductors
Collectors
Hoist
Trolley
*
Monorail Joints
Monorail
Main Conductors
Main Collectors
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.
12375B
Page 11
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.
Note the location in the electrical compartment of the control circuit fuse, transformer, limit stop switches and the hoist contactors. Trolley contactors and optional hoist and trolley fuses may also be located in this compartment on certain models. (Note: The rope anchor on single reeved hoists is accessible from this compartment.)
Hoist and trolley fuses and trolley contactors may be located in electrical compartment located on trolley on certain models.
Use wiring diagram furnished with hoist to determine electrical components on your hoist; then determine component location and identity on your hoist.
WARNING
Be certain that main power switch is locked in open position before opening hinged access cover on side of hoist.
a. Open hinged access cover at side of hoist and inspect wiring and terminals. Terminals should be securely crimped to wires and insulation sound. Terminal screws should be tight.
b. Check condition of contactor assembly, transformer, and upper limit switches.
5-5. INSPECT MOTOR BRAKE AND ACTUATING
MECHANISM.
WARNING
Check to be certain main power switch is locked in open position before removing brake cover.
a. Remove one hex button head cap screw from brake cover and lift brake cover away from gearcase cover.
b. Unplug electrical leads and loosen set screw in gearcase cover (Ref. No. 1 in Figure 9-6). Turn actuating mechanism counterclockwise, by hand or with a plumber’s strap wrench, and remove from gearcase cover.
c. Check to see that brake plunger moves freely. Inspect for evidence of overheating or other damage.
d. Replace all worn or damaged parts. Operating spring on actuating mechanism is color coded for brake torque; when replacing spring use spring having same color code.
When replacing body assembly, also replace brake operating spring.
e. Reassemble brake and cover only if further disassembly to check friction surfaces and hub spline is not required at this time. Refer to “MOTOR BRAKE ADJUSTMENT’ paragraph 7-2 for adjusting instructions. For further disassembly proceed to step “f.” f. To check motor brake friction surfaces (Figure 5-3), drain oil from gearcase. Disconnect solenoid coil leads. Remove hex head cap screws securing gearcase cover to gearcase. Remove gearcase cover and attached motor brake actuating mechanism from gearcase.
Page 12
Figure 5-3. Motor Brake Friction Plates
g. Remove retaining rings from the brake pilot studs and lift off the compression plate. Lift off washer and lining assemblies, release springs, and motor brake plates. (Note for reassembly, that two of the washer and lining assemblies have friction surfaces on one side only and must be replaced at each end. Three washer and lining assemblies, with friction surfaces on both sides and release springs are replaced between the motor brake plates; see Figure 5-3). Check motor brake plates for warping, scoring or other signs of deterioration. Also check spline fit of motor brake plates to the brake hub for gouging, mushrooming of the plates or other signs of distress or wear. Replace plates if these conditions are found. Brake plates which are replaced because of spline wear should also receive a replacement brake hub. Check condition of friction material on the washer and lining assemblies, and replace assemblies if required. Reinstall brake plates, release springs, and friction washers in sequence as shown in Figure 5-3 and replace retaining rings. On the Size 3 hoist it is possible to get the lining assemblies misoriented. When installed properly the friction linings will be on a horizontal line (not vertical).
Clean and flush gearcase and replace gearcase cover using a new gasket. Refill with new lubricant.
5-6. INSPECT MECHANICAL LOAD BRAKE AND GEARING.
WARNING
11988
Check to be certain main power switch is locked in open position before removing brake cover.
a. To inspect hoist, drain oil from gearcase, remove motor brake actuating mechanism per Paragraphs 5-5.a and 5-
5.b, remove hex head cap screws from gearcase cover, and remove gearcase cover.
b. Remove compression plate, washer and lining assemblies, springs and brake plates as described in Paragraph 5-
5.g. Remove hex nuts and hex head bolts holding gearcase spider and remove spider. Inspect gearing for tooth wear or damage, (see Figure 5-4). If replacement parts are indicated, disassemble load brake and gearing as follows:
WARNING
Before disassembly prevent rope drum from free spinning by wedging drum in place with a block of wood, and resting lower block on work surface so all weight is off rope drum. Rope may also be removed from hoist drum.
(1) Pull out motor pinion shaft from gearcase, (see Figure
5-4).
(2) The complete load brake assembly can now be pulled out from the gearcase or removed part by part.
WARNING
The complete mechanical load brake assembly is heavy (approx. 150 lbs.). Provide adequate means to support weight of assembly before removal from gearcase, especially if brake assembly is removed with hoist suspended.
10028
Figure 5-4. View of Gearing - Spider Removed
c. To disassemble and inspect mechanical load brake without overload clutch, either in or removed from hoist, proceed as follows:
(1) Remove the two (three on larger models) selflocking screws from each of two retaining plates and remove plates from groove on splines of brake shaft (Figure
5-5).
(2) Pull off brake helix (Ref. No. 12, Figure 9-4).
(3) Pull off brake gear (Ref. No. 11, Figure 9-4).
Note: It may be necessary to apply some force to end of shaft when removing brake gear.
(4) Remove (1) friction washer, roller and ratchet assembly, and another friction washer. The roller and ratchet assembly should not be disassembled; replacement, if required, as an assembly is recommended.
(5) Remove brake shaft and flange assembly.
(6) Check condition of all parts for evidence of wear or damage. Replace worn or damaged parts.
(7) Reinstall in reverse procedure from disassembly making certain helix is seated and that retaining plates are properly seated in groove on shaft spline (Figure
5-5).
d. To disassemble and inspect mechanical load brake with overload clutch, either in or removed from hoist, proceed as follows:
(1) Remove the two (three on larger models) selflocking screws from each of two retaining plates and remove plates from groove on splines of brake shaft (Figure
5-5).
(2) Pull off brake helix. Surface of brake helix may be below brake adjusting collar (Ref. No. 24, Figure 9-4).
With some pressure on end of brake shaft, pull brake gear toward end of shaft about one inch. Then return gear to original position to expose outside of helix.
Grasp outside of brake helix and slide off from splined shaft.
(3) Do not remove the overload clutch adjusting screws unless clutch requires service. See Paragraph 5-6.e
below. Remove clutch and brake gear as one unit by pulling off from brake shaft while exerting some pressure on end of brake shaft.
(4) Remove (1) friction washer, roller and ratchet assembly, then the other friction washer. The roller and ratchet assembly should not be disassembled; replacement, if required, as an assembly is recommended.
(5) Remove brake shaft and flange assembly.
(6) Check condition of all parts for wear or damage.
Replace worn or damaged parts.
(7) Reinstall in reverse procedure from disassembly making certain helix is seated and that retaining plates are properly seated in groove on shaft spline (Figure
5-5).
e. Disassembly of overload clutch. It is recommended that disassembly, inspection, and reassembly of the overload clutch be performed by a factory approved SHAW-BOX
Repair Station. Fine adjustments can be made with clutch installed. (See OVERLOAD CLUTCH ADJUSTMENT,
Paragraph 7-5.)
Page 13
10024
11990
Figure 5-7. Installing Load Brake Shaft Ball Bearing in
Gearcase Spider (Size 2 Hoist Shown)
Figure 5-5. Installing Retainer Plates on Load Brake Shaft
f. To remove drum gear, remove spirolox retaining ring from end of drum shaft and pull drum gear from splined shaft
(Figure 5-6). This should be done after complete load brake shaft assembly has been removed.
10026
Figure 5-6. All Gearing Removed except Drum Gear
I. Before replacing brake cover, fine adjustment can be made to overload clutch if your hoist is so equipped. See
OVERLOAD CLUTCH ADJUSTMENT - Paragraph 7-5. If clutch adjustment is not required replace brake cover.
5-7. INSPECT ROPE DRUM AND SHAFT.
a. To remove rope drum, remove hoisting cable, gearcase cover, and remove load brake and gearing as outlined in
Paragraph 5-6.
b. Remove hinged side cover, hinge plate and cover bridge from hoist frame.
c. Take out four bolts holding gearcase to frame and remove gearcase. Drum and shaft will remain in frame.
d. Remove four bolts holding drum shaft bearing retainer to inside of gearcase and pull ball bearing and oil seal from bore in gearcase.
e. Pull drum and shaft from frame.
f. Check parts for wear and damage. Replace drum or shaft if there are any signs of cracks or other damage. Replace oil seal if the sealing edge appears worn or cracked.
g. Reinstall parts following a procedure in reverse of disassembly. Refill gearcase to proper level with correct grade of oil. (See SECTION IV - LUBRICATION.)
5-8. ROPE INSPECTION, MAINTENANCE AND
REPLACEMENT.
g. Replace motor pinion shaft.
h. Reinstall spider and motor brake plates on gearcase. Make certain motor pinion shaft bearing on a size 2 hoist and load brake shaft bearing (Figure 5-7) are installed with the external retainer firmly seated against the inside (hoist side) of the spider and retainer side of bearing toward hoist. On a size 3 hoist the motor pinion shaft bearing is caged to the spider.
j. Replace gearcase gasket and cover and refill gearcase to bottom of oil level plug.
k. Reconnect motor brake leads.
WARNING
Wire rope improperly handled or abused can create a
SAFETY HAZARD. Read and comply with Inspection, maintenance and replacement information given herein.
Page 14
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. Inspections revealing but not limited to the following conditions, should cause 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 birdcaging.
(4) Heat damage from any cause.
(5) Reductions from nominal diameter of more than
(a) 1/64" for 3/16", 1/4", and 5/16" diameter rope.
(b) 1/32" for 3/8" and 7/16" diameter rope.
(c) 3/64" for 9/16" 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.
Before replacing rope, check condition of grooves in sheaves and drums to determine if they are excessively worn.
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 stand with shaft thru center of reel so rope can be pulled straight out with reel rotating.
CAUTION
It is imperative that rope reel or coil rotate 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, Figure
5-8. 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 3 part double reeved, Figure 5-8,
$
) and refer to 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 “DOWN” to completely unwind all wire rope from drum. Stop hoist so drum anchor slot(s) is accessible. Remove live rope end socket(s) from drum.
(7) TURN OFF POWER TO HOIST.
(8) Open electrical compartment cover on single reeved hoists to remove dead end socket.
Remove cotter pin from socket, slide rope toward socket until rope end fitting clears socket. Lift out rope and end fitting through groove provided. Remove old rope. Close electrical compartment cover.
c. Installing new rope.
WARNING
Use only factory approved rope with swagged wire rope sockets.
When first using hoist after rope replacement, break in rope by operating under lighter loads to full travel before applying maximum load.
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.
Page 15
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 “UP,” 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"
(d) 8 part single reeved - about 56'-0".
(4) Proceed with reeving as described in appropriate paragraph below and the reeving diagram for your hoist.
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 “UP,” guiding rope into grooves at both ends of drum, until the distance from the drum to the loop is:
(a) 2 part double reeved - about 14'-0"
(b) 3 part double reeved - about 21'-0"
(c) 4 part double reeved - about 28'-0"
(d) 5 part double reeved - about 35'-0"
(e) 6 part double reeved - about 42'-0".
(4) Proceed with reeving as described in appropriate paragraph below and the reeving diagram for your hoist.
d. Reeving - 2 part single.
See Figure 5-8,
%
for diagram.
See Figure 9-14 for bottom block parts with 3/8" or 7/16" rope.
See Figure 9-15 for bottom block parts with 9/16" rope.
With new rope installed on drum as described in
Paragraph 5-9.c, single reeved above, proceed with rereeving following steps below:
(1) Thread the remaining cable end through limit switch weight, then pass it over partial sheave, inside hoist, and insert in anchor fitting at hoist frame. Be certain power is off before opening electrical compartment cover for access to anchor fitting. Properly seat rope end fitting in socket and replace cotter pin in end of socket.
(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.
e. Reeving - 4 part single.
See Figure 5-8,
&
for diagram.
See Figure 9-14 for bottom block parts with 1/4", 5/16",
3/8", 7/16" rope.
See Figure 9-15 for bottom block parts with 9/16" rope.
With new cable installed on drum as described in
Paragraph 5-9.c, 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.
(3) Thread rope end socket through limit switch weight; then, pass it over partial sheave, inside hoist, and insert in anchor fitting at hoist frame. Be certain power is off before opening electrical compartment cover for access to anchor fitting. With end fitting properly seated in anchor, replace cotter pin in end of socket.
Two loops have now been formed for bottom block sheaves.
(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 to install spacer washers 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.
Page 16
2
PART SINGLE
@
4
PART SINGLE
CD
6 PART SINGLE
0
2 PART DOUBLE
BALANCED REEVING
Gl
3
PART DOUBLE
BALANCED REEVING
®
4 PART DOUBLE
BALANCED REEVING
~
3 PART DOUBLE
®
4 PART DOUBLE (])
8 PART SINGLE
®
5 PART DOUBLE
6
PART
DOUBLE
Figure 5-8. Reeving Diagrams
Page 17
f. Reeving - 6 part single.
See Figure 5-8,
'
for diagram.
See Figure 9-15 for bottom block parts - 9/16" rope.
See Figure 9-19 for bottom block parts - 3/8" rope.
With new cable installed on drum as described in
Paragraph 5-9.c, single reeved above, proceed with rereeving following steps below:
(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 ca ble 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.
(3) Thread rope end socket through limit switch weight; then, pass it over partial sheave, inside hoist, and insert in anchor fitting at hoist frame. Be certain power is off before opening electrical compartment cover for access to anchor fitting. With end fitting properly seated in anchor, replace cotter pin in end of socket.
Three loops have now been formed for bottom block sheaves.
(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 to install spacer washers between sheaves, when 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.
(6) Replace sheave guard.
(7) Lubricate cable per Paragraph 4-3.
g. Reeving - 2 part double.
See Figure 5-8,
(
for diagram.
See Figure 9-16 for block parts.
With new rope installed on drum as described in Paragraph
5-9.c, double reeved above, proceed with rereeving following steps below:
(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.
(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.
(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.
Page 18
(5) Replace sheave guard.
(6) Lubricate rope per Paragraph 4-3.
h. Reevinq - 3 part double.
See Figure 5-8,
$
for diagram.
See Figure 9-17, for block parts.
With new rope installed on rope drum as described in
Paragraph 5-9.c, double reeved above, proceed with rereeving following steps below:
(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) Grasp remaining rope at midpoint loop and raise two rope parts up to the hoist. Carefully form two upper sheave loops and insert into upper sheave pockets.
Slide pipe or rod through sheave pin holes to hold the two ropes.
(3) Pull remaining rope down to the lower block equalizer sheave. Place equalizer sheave in loop and sheave with rope in sheave pocket. Insert sheave pin thru one washer, the sheave and the other washer.
(4) Push sheave pin thru side plates and install snap ring on each end of pin to secure pin.
(5) Insert lower sheave pin into bottom block thru washers and sheaves as shown on parts illustration, removing pipe as sheave pin is inserted.
(6) Install key plates and bolts to secure pin.
(7) Repeat steps 5 & 6 for upper block sheaves.
(8) Replace sheave guard.
(9) Lubricate rope per Paragraph 4-3.
j. Reevinq - 4 part double.
See Figure 5-8,
)
for diagram.
See Figure 9-18, for block parts.
With new rope installed on rope drum as described in
Paragraph 5-9.c, double reeved above, proceed with rereeving following steps below:
(1) Form loop in each rope coming from rope drum. Place these loops into outside sheave pockets in bottom block. Note position of ropes passing limit stop bar.
Slide pipe or rod thru sheave pin holes to hold the two ropes.
(2) Grasp remaining rope at midpoint loop and raise loop with two ropes up to the hoist. Carefully form two upper sheave loops and insert sheaves with rope into upper sheave pockets. Slide pipe thru upper sheave pin holes to hold the two ropes.
(3) Pull loop and two ropes down to the bottom block.
Pass ropes across bottom block between ropes placed there in step 1. Note position of ropes passing limit stop bar.
(4) Carefully remove pipe while holding first two ropes in bottom block and insert ropes in step 3 into outside block pockets between existing ropes.
(5) Pull remaining rope up to upper equalizer sheave.
Partially insert sheave pin thru yoke side plate and one washer. Place sheave in rope loop and insert sheave with rope into sheave pocket. Slide pin thru sheave and remaining washer into opposite side plate.
Secure pin by installing snap ring on each side of pin.
(6) Insert upper block sheave pin thru side plate and one washer. Place upper block sheaves in rope loop and insert into sheave pocket removing pipe or rod as pin is inserted. Make certain to install one washer on each side of upper sheaves.
(7) Install key plates and bolts to secure pin.
(8) Partially insert lower block sheave pin into block side plate opening and thru one washer removing pipe as pin is inserted. Place outside sheave into rope loop and insert sheave with rope into sheave pocket. Slide pin into sheave. Repeat this procedure installing sheaves and washers in both outside pockets of bottom block. Center pocket of bottom block is not used for sheaves.
(9) Replace key plates and bolts to secure sheave pin.
(10) Lubricate rope per Paragraph 4-3.
k. Reeving - 3 part double.
See Figure 5-8,
* for diagram.
See Figure 9-15, for block parts.
With new rope installed on rope drum as described in
Paragraph 5-9.c, double reeved above, proceed with rereeving following steps below:
(1) Form loops in the two ropes coming from rope drums.
Place these loops into bottom block pockets and slide pipe or rod through sheave pin holes.
(2) Grasp remaining rope at midpoint loop and raise loop and two ropes up to the hoist. Carefully form two upper sheave loops and insert into upper sheave pockets. Slide pipe or rod through sheave pin holes to hold the two ropes.
(3) Pull the remaining rope down to the lower block. Insert loop in between the two ropes already in lower block by partially removing pipe while holding original ropes in place. Note: This last loop must be rotated 90° as it is placed between existing ropes into lower block; refer to reeving diagram.
(4) Complete installation following steps 4 thru 9 in
Paragraph 5-9.h.
I. Reeving - 4 part double.
See Figure 5-8,
+ for diagram.
See Figure 9-15, for block parts.
With new rope installed on rope drum as described in
Paragraph 5-9.c, double reeved above, proceed with rereeving following steps below:
(1) Form loop in each rope coming from rope drum. Place these loops in sheave pockets in bottom block. Slide pipe or rod thru sheave pin holes to hold the two ropes.
(2) Grasp remaining rope at midpoint loop and raise loop with two ropes up to the hoist. Carefully form two upper sheave loops and insert into upper sheave pockets. Slide pipe or rod thru upper sheave pin holes to hold the two ropes.
(3) Pull loop and two ropes down to the bottom block.
Pass ropes across bottom block between ropes placed there in step 1.
(4) Carefully remove pipe while holding first two ropes in bottom block and insert second pair (step 3) of ropes in bottom block between existing ropes.
(5) Pull remaining rope up to upper equalizer sheave
(center sheave). Remove pipe while holding first two ropes in place far enough to insert last loop. Note:
This last loop must be rotated 90° as it is placed between existing ropes into upper block. Refer to reeving diagram.
(6) Complete installation following steps 6 thru 10 in
Paragraph 5-9.j.
m. Reeving - 8 part single.
See Figure 5-8,
,
for diagram.
See Figure 9-21, for block parts.
With new rope installed on drum as described in
Paragraph 5-9.c, single reeved above, proceed with rereeving following steps below:
(1) Grasp cable at a point one-fourth (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.
(3) Repeat (1) above and install third upper sheave with rope. Insert sheave pin and install key plates and bolts to secure sheave pin.
(4) Thread rope end socket through limit switch weight; then, pass it over partial sheave, inside hoist, and insert in anchor fitting at hoist frame. Be certain power is off before opening electrical compartment cover for access to anchor fitting. With end fitting properly seated in anchor, replace cotter pin in end of socket.
Four loops have now been formed for bottom block sheaves.
(5) 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 to install spacer washers between sheaves, when shown on parts illustration.
Page 19
(6) Repeat step 5 for remaining bottom block sheaves.
Install sheave pin through sheaves. Replace key plates and bolts securing sheave pin.
(7) Replace sheave guard.
(8) Lubricate cable per Paragraph 4-3.
n. Reeving - 5 part double.
See Figure 5-8,
-
for diagram.
See Figure 9-20a, for block parts.
Reeve similar to Paragraph 5-9.1.
o. Reeving - 6 part double.
See Figure 5-8,
.
for diagram.
See Figure 9-22, for block parts.
Reeve similar to Paragraph 5-9.1.
p. 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.
(1) To remove rope twist in single reeved hoists.
(a) Observe direction block tends to rotate.
(b) Lower the block to a low position and turn off power.
(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.
(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.
(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.
a. General. Before placing hoist in service, hoist should be tested to insure safe operation when hoist has been disassembled and reassembled. 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 175 percent rated load and the weight of the hoist - see OVERLOAD
CLUTCH ADJUSTMENT - Paragraph 7-5. 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 rated load.
(1) Attach rated load to lower hook
(2) Depress “UP” push button and raise load. When push button is released, hoist should immediately stop and hold load at that level.
(3) Depress “DOWN” 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 VII - Paragraph 7-2.
Trouble
6-1. Hoist Will Not Operate.
SECTION Vl - TROUBLE SHOOTING
Probable Cause
a. No power to hoist.
b. Wrong voltage or frequency c. Loose or broken wire connections in hoist electrical system.
Possible Remedy
a. Check switches, circuit breakers or fuses and connections in power supply lines.
b. Check current rating on motor data plate against power supply.
c. Shut off power supply, open hinged cover on hoist and check wiring connections. Also check connections in push button station and limit switches.
Page 20
Trouble
6-1. Hoist Will Not Operate
(Continued).
SECTION Vl - TROUBLE SHOOTING (continued)
Probable Cause Possible Remedy
d. Contactor assembly not functioning.
e. No control voltage.
f. Motor burned out.
a. Reverse phasing on threephase hoists.
d. Check contact points. Replace if excessively burned or pitted. Check for burned out contactor coils. See that necessary jumper wires are properly installed.
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. Replace motor. Check input power supply.
Check hoist motor connections.
a. Interchange any two power supply line leads. Refer to SECTION II.
6-2. Hook Moves in Wrong
Direction.
b. Hoist or push button wired wrong.
6-3. Hook Will Raise But Not Lower.
a. Lower electrical circuit open.
6-4. Hook Will Lower But Not Raise.
a. Excessive load.
6-5. Hoist Will Not Lift Rated Load.
b. Contactor not functioning.
b. Hoist circuit open.
c. Contactor not functioning.
a. Low voltage b. Check wiring connections with appropriate wiring diagram.
a. Check for loose connections. See that necessary jumper wires are properly installed on contactor.
b. Check for burned or pitted contact points or burned out contactor coil.
a. Reduce loading to rated load of hoist, as shown on nameplate.
b. Check for loose connections. See that necessary jumper wires are properly installed on contactor.
c. Check for burned or pitted contact points or burned out contactor coil.
a. See that power supply current is same voltage listed on motor data plate. Check size of power supply lines.
b. See SECTION VII, Paragraph 7-5.
6-6. Load Drifts Excessively When
Hoist Is Stopped.
b. Overload Clutch not properly adjusted.
a. Excessive load.
b. Motor brake not holding.
c. Load brake not holding.
a. Reduce loading to rated load, as shown on nameplate.
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. (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).
Page 21
Trouble
6-7. Hoist Motor Overheats
SECTION Vl - TROUBLE SHOOTING (continued)
Probable Cause Possible Remedy
6-8. Hoist Operates Intermittently.
a. Excessive load.
b. Excessive duty-cycle c. Wrong voltage or frequency.
a. Reduce loading to rated load of hoist, shown on nameplate.
b. Reduce frequency of lifts or amount of jogging.
c. Check current rating on motor data plate against power supply.
d. Disassemble hoist and inspect for defective, worn or damaged parts.
d. Defective motor or worn bearings in hoist frame.
e. Overload clutch slipping without lifting load.
f. Motor brake actuating mechanism sticking.
e. Adjust clutch per SECTION VII, Paragraph
7-5.
f. (1) Disassemble actuating mechanism and inspect for defective work or damaged parts. (2) Check voltage to brake coil at brake controller. Brake control with solenoid connected provides a 100 volt DC pulse to the solenoid for 1 /10 of a second, after which time this voltage drops to 10 volts
DC ± 5 volts.
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 VII - ADJUSTMENTS
7-1. MECHANICAL LOAD BRAKE. The mechanical load brake on SHAW-BOX hoists is a roller 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 ADJUSTMENT. These brakes are designed so that adjustment is seldom required. If, after a period of service, the load hooks “drifts” downward more than usual for your hoist before coming to a stop, the motor brake may require adjustment to compensate for brake disc wear.
In addition to the adjustment instructions below motor brake adjustment instructions may also be found inside the brake cover. Refer to Figure 9-6 and proceed as follows: a. Remove one hex socket button head cap screw from brake cover and then remove brake cover.
b. Loosen set screw at gearcase cover (Ref. No. 1 in Figure
9-6).
c. Turn brake actuating assembly, by hand, until brake adjustment indicator pin (Ref. No. 10) is flush with the end of the body assembly (Ref. No. 9).
d. Retighten set screw.
Note: Do not overtighten set screw. Damage to actuator or gearcase cover threads may occur.
e. Replace brake cover.
f. Operate hoist and brake to assure brake is free when disengaged. If brake is dragging, loosen brake actuating assembly by 1/8 turns until brake action is proper.
g. If, after above adjustment, the load hook continues to
“drift” downward more than normal for this hoist, make a complete inspection of motor brake mechanism including friction surfaces. See SECTION V, Paragraph 5-5.
7-3. BLOCK OPERATED LIMIT SWITCH. The block operated limit stop, furnished as standard equipment, is nonadjustable and designed to stop lower block at safest high point of travel to eliminate any possibility of doubleblocking. When the safest high point is reached, the limit switch automatically stops hook travel.
WARNING
Some hoists are shipped with the electrical controls loose (disconnected) and will not have the upper and lower limit switches connected. DO NOT
OPERATE HOIST UNTIL LIMIT SWITCHES ARE
PROPERLY CONNECTED AND ADJUSTED. Failure to do so may allow hoist to be operated beyond proper travel limits which can cause load to drop, resulting in damage to equipment or injury.
Page 22
7-4. GEARED ROTARY LIMIT SWITCH ADJUSTMENT.
The geared rotary type limit switch is optional equipment and when furnished is located at the motor end of the hoist.
a. This limit switch consists of two adjustable cams driven thru gear reduction by a worm gear shaft which flexibly couples to end of drum shaft. Each cam operates the contacts of separate switches; one for hoisting circuit and one for lowering circuit. The switch assembly must be wired in accordance with appropriate wiring diagram which is shipped with the hoist. Adjustment of the rotary limit switch is accomplished as follows: (Refer to Figure 7-1.)
(7) Retighten cam clamping screws, fold down insulating shields and replace cover.
b. 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 shipped with the hoist. Instructions for adjusting limit switch are inside switch cover and are repeated below (see
Figure 7-2).
11991
Figure 7-1. Geared Rotary Limit Switch Adjustment
(Early Model Hoists)
(1) Remove four cover screws and lift off enclosure cover.
(2) Operate hoist to raise lower block to upper limit of desired travel. Allow about 2" for drift.
(3) Loosen the two cam clamping screws on top of cam assembly one half turn each.
(4) Locate cam adjusting pinion “A” (upper) by referring to the indicating arrow on insulation shield. Depress this screw with a screwdriver until pinion teeth mesh with gear teeth on top cam. Rotate cam in direction cam turns when hoisting by turning screwdriver until cam operates switch. White marker on gear teeth is directly over nylon roller that trips switch. When top operating cam has been adjusted so the roller has tripped switch, adjustment of upper limit is complete.
(5) Operate hoist and run lower block to lower limit of desired travel. Allow approximately 6" for drift. Make certain that at the lowest point of hook travel a minimum of 1 turn of wire rope remains on rope drum.
(6) Locate cam adjusting pinion “B” (lower) by referring to the indicating arrow on insulation shield. Depress this screw with a screwdriver until pinion teeth mesh with gear teeth on lower cam. Rotate cam in direction cam turns when lowering by turning screwdriver until cam operates switch. White marker on gear teeth of lower cam will be directly over nylon roller that trips switch and adjustment is complete.
Figure 7-2. Screw-Type Limit Switch Adjustment
1. Remove four screws and lift off switch cover.
2. Loosen locking plate screws. Slide locking plate away from adjustment discs.
3. Turn proper adjustment disc (right for up, left for down) toward switch to reduce hook travel or away from switch to increase hook travel.
4. Slide locking plate back into position ensuring slots on adjustment discs are fully engaged, tighten locking plate screws to 4 in-lbs.
5. Replace cover.
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 complete wrap of rope on drum with hook in lowest position.
Provide a light film of NLGI No. 2 grease on gear of both limit switches.
7-5. OVERLOAD CLUTCH ADJUSTMENT AND TESTING.
a. When hoist is equipped with an overload clutch, minor clutch adjustments can be made with your hoist suspended. Clutch adjustment shall be supervised by an authorized person familiar with the hoist and the purpose of the adjustment and test. (See Paragraph 5-6.e for disassembly, inspection and readjustment.) To test clutch operation and make minor adjustments, proceed as follows:
Page 23
WARNING
Before attempting to adjust and test an overload clutch, an appointed person shall determine that the trolley and/or other supporting structure is capable of safely supporting a load equal to 175 percent of the hoist rated load plus the weight of the hoist.
Failure to provide adequate support could cause injury to equipment and personnel.
With the hoist in position for testing as determined by an appointed person, attach a known load, equal to the rated load of the hoist, to the lower hook. Adequate and proper rigging shall be provided to insure test loads are securely attached, properly balanced and lifted level.
b. Energize hoist to lift rated load. Raise this load just high enough to be certain hoist is lifting entire load. Clutch should not slip with this rated load. Lower load to rest position. If hoist will not lift rated load, clutch adjustment is required - proceed with step c.
j. Insert T-type allen wrench thru opening in gearcase and spider into clutch bolt socket. (See Figure 9-4 for part number of adjusting wrench.) k. Rotate each clutch adjusting bolt clockwise 1/4 turn. Be certain each bolt is rotated an equal amount for every adjustment.
I. Replace lower pipe plug finger tight.
m. Replace motor brake actuating mechanism and adjust per Paragraphs 7-2.a through 7-2.f.
n. Make certain all workmen are clear of hoist and plumber’s strap wrench has been removed from motor shaft. Turn on power and energize hoist to raise rated load. Only one adjustment should be required; however, if further adjustment is required repeat steps f through n making certain POWER IS OFF for each adjustment.
With clutch adjusted to lift rated load, your hoist can now be tested for maximum load at which clutch slips. This load should not be greater than 175 percent of rated load
(Rated load multiplied by 1.75).
!
WARNING
Never lift more than hoist rated load except for clutch adjustment and testing as described In this paragraph.
12512
Figure 7-3. View Showing Clutch Adjustment
Plug Locations
c. Lock main power switch in open position.
d. Provide an adequate and safe means to support workmen who are to make adjustments.
e. Remove brake cover.
f. Remove two pipe plugs from gearcase (see Figure 7-3).
g. Remove motor brake actuating mechanism per
Paragraphs 5-5.a and 5-5.b, and rotate motor shaft.
Note: On some hoists motor shaft can be rotated by hand; others may require the use of a plumber’s strap wrench to rotate motor shaft. (DO NOT USE REGULAR
PIPE WRENCH WHICH COULD SCAR SHAFT SURFACE
AND REDUCE SHAFT STRENGTH.) h. Rotate motor shaft until the two hex socket head bolts on clutch are visible through pipe plug openings in gearcase.
A small flashlight may be helpful to see hex socket head bolts.
To determine load at which clutch slips proceed as follows: p. Increase load in steps from rated load to a maximum of
175 percent of rated load, lifting load with each increase in weight. Hoist should slip and refuse to lift load before
175 percent of rated load is reached. Should hoist lift 175 percent of rated load - STOP TEST - clutch adjustment is required.
r. Repeat steps c through j above. Rotate each clutch adjusting bolt counterclockwise approximately 1/16 turn
(22-1/20).
s. Repeat step n with less than 175 percent of load. Clutch should slip. Readjust as described in step r until clutch slips before reaching 175 percent of load.
t. Run hoist with load causing clutch to slip (hoist refusing load) ten cycles of approximately 1 second each, to insure that hoist will not lift 175 percent of load.
u. Remove weight added in step p and return to rated load.
Lift rated load one final time. Clutch should not slip.
v. Replace pipe plugs in gearcase. Replace brake cover.
Remove ladders or other equipment used to reinforce hoist support and used by workmen.
Page 24
7-6. SHORTENING OF PUSH BUTTON CABLE.
WARNING
Be certain that electrical power supply is OFF and locked in the open position before attempting shortening of push button cable.
a. Loosen screws at cable connectors and clamps.
b. Adjust steel support cable to proper length and tighten screws.
c. Loosen upper cable grip and pull excess cable into connection box at hoist.
d. Tighten cable grip and cut off excess cable.
e. Strip cable sheath and connect wires with same type of terminals previously furnished (care must be exercised to match previous wire color coding with wire markers in accordance with wiring diagram furnished with hoist.)
SECTION IX - PARTS LIST
9-1. GENERAL. The parts lists and illustrations in this section of the manual cover parts for all standard and low head room models Series “700” 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 Capacity of Hoist when ordering parts.
SHAW-BOX Series “700” Hoists are built in two basic sizes,
Size 2, and Size 3. To determine the size of your hoist measure the width of your hoist at the gearcase cover. Size 2 hoists measure 24-3/4 inches and Size 3 hoists measure 34-1/4 inches. Select part numbers and quantities in the column corresponding to the size of your hoist.
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 (t) symbol at the side of the parts reference numbers.
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 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.
The numbers assigned to the parts of our various assemblies in our parts list are not the part numbers used in manufacturing the par t. 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.
LIST OF PARTS ILLUSTRATIONS
Title
Figure Page
No.
No.
Frame, Gearcase, Motor and
External Covers .....................................
Suspension Parts for Low Headroom
9-1
Hoists .....................................................
9-2
Drum, Shaft, Gear and Bearings .............
9-3
Mechanical Load Brake Parts
(Includes Overload Clutch Parts) .........
Motor Pinion Shaft, Coupling and
9-4
Motor Brake Parts .................................
9-5
Motor Brake Actuating Mechanism ..........
9-6
Upper Limit Switch Parts -
Block Operated:
Single Reeved Hoists ........................
Double Reeved Hoists .......................
Low Headroom Hoists .......................
Upper and Lower Limit Switch:
Geared Rotary Type ..............................
Geared Rotary Type ..............................
9-7
9-7a
9-8
9-9
9-9a
26
28
29
30
31
32
33
34
35
36
37
Title
Figure Page
No.
No.
Electrical Control Equipment:
Size 2 Hoists .........................................
9-10
Size 3 Hoists Thru 15 Tons Only ..........
9-10a
Size 3 Hoists, 20 and 25 Tons ..............
9-10b
Size 2 Hoists (Later Models) ................
9-10c
Size 3 Hoists (Later Models) ................
9-10d
Push Button Station and Conductor
Cord Assembly ......................................
9-11
Upper and Lower Block Parts
Including Hoist Rope:
Standard Headroom Hoists:
2 thru 7-1/2 Ton - Single Reeved
- 1/4", 5/16", 3/8", 7/16" Rope ........
9-14
2 thru 5 Ton - Double Reeved
- 3/8" Rope ......................................
9-16
5 thru 15 Ton - Single Reeved
- 9/16" Rope ....................................
9-15
38
39
40
42
44
46
48
52
50
Page 25
LIST OF PARTS ILLUSTRATIONS
(Continued)
Title
Figure Page
No.
No.
Upper and Lower Block Parts: (Continued)
Standard Headroom Hoists: (Continued)
6 thru 10 Ton - Double Reeved
- 5/16" & 3/8" Rope ............................
9-15
7-1/2 Ton -Single Reeved
- 3/8" Rope .........................................
9-19
10 Ton - Single Reeved
- 7/16" Rope .......................................
9-20
10 Ton - Double Reeved
- 5/16" Rope .......................................
9-20a
15 and 20 Ton - Double Reeved
- 7/16" Rope .......................................
9-22
50
58
59
60
64
Title
Upper and Lower Block Parts: (Continued)
Standard Headroom Hoists: (Continued)
20 and 25 Ton - Single Reeved
- 1/2" & 9/16" Rope ...............................
Low Headroom Hoists:
2 thru 5 Ton - 2 PD Reeved
- 5/16" & 3/8" Rope ...............................
2 thru 7-1/2 Ton - 3 PD Reeved
- 5/16" & 3/8" Rope ...............................
10 Ton - 4 PD Reeved
3/8" Rope ...............................................
PD = Part Double
Figure Page
No.
No.
9-21
9-16
9-17
9-18
62
52
54
56
9953LD
Figure 9-1. Frame, Gearcase, Motor and External Covers
Ref.
No.
1
4
5
2
3
6
7
8
9
10
11
12
Page 26
Part
Number
700-101
700-150
700-112
700-113
700-114
700-115
700-151
700-116
700-117
700-179
700-118
700-178
700-120
700-119
Description
Motor Assembly (includes key)
Spacer - Motor (not used on all models)
Screw - Round Head, Self-tapping
Lockwasher
Gasket - Cover Bridge
Bridge Assembly - Cover
Fit Bolt - Hex Head
Frame - Hoist (typical frame shown)
Gearcase - Hoist
Gearcase - Hoist
Spider - Gearcase
Spider - Gearcase
Washer - "0" Ring Type
Nut - Hex, Self-locking
Quantity Required
Size 2
Hoist
Size 3
Hoist
-
2
2
1
-
2
1
1
1
4
1
-
4
1
1
2
2
-
1
2
1
-
1
6
1
1
6
1
Figure 9-1. Frame, Gearcase, Motor and External Covers (Continued)
Part
Number
700-152
700-153
700-180
700-154
700-131
700-181
700-126
700-182
700-183
700-184
700-185
700-129
700-157
700-158
700-134
700-159
700-136
700-160
700-161
700-162
700-163
700-164
700-165
700-166
700-167
700-168
700-169
700-170
700-171
700-148
700-186
Ref.
No.
27
28
29
30
31
22
23
24
25
26
17
18
19
20
21
13
14
15
16
37
38
39
40
41
32
33
34
35
36
42
48
* These parts are used only on hoists with swivel trolleys.
Description
Lockwasher
Bolt - Hex Head
Cover - Oil Hole
Plug - Pipe (functional with overload clutch only)
Gasket - Gearcase Cover
Cover - Gearcase
Lockwasher
Screw - Hex Head Cap
Screw - Hex Socket Head Cap
Cover - Brake
Gasket - Brake Cover
Plug - Pipe
Nut - Hex
Lockwasher
Stud - Spider
Rod - Hinge
Plug - Pipe, Oil Drain
Nut - Hex, Self-locking
Nut - Hex
Lockwasher
Cover Assembly - Electrical
Screw - Sheet Metal
Screw - Round Head, Self-tapping
Lockwasher
Hinge
Bolt - Hex Head
Bolt - Hex Head
Lockwasher
Pin - Cotter (single reeved only)
Gasket - Cover Assembly
Washer - Flat
NOTES
Quantity Required
Size 2
Hoist
Size 3
Hoist
1
3
3
1
2
1
3
1
1
3
1
1
17
17
1
1
2
1
1
4
4
2
2
1
2
2
2
2
2
1
2
1
2
2
1
2
1
2
1
1
2
1
1
24
24
1
1
2
2
2
3
2
4 or 8
4 or 8
1
2
2
3
3
2
1
3
Page 27
10012L
Figure 9-2. Suspension Parts for Low Headroom Hoists
Ref.
No.
13
14
15
16
17
8
9
10
11
12
18
19
20
5
6
3
4
7
1
2
Part
Number
700-232
700-233
700-234
700-235
700-236
700-237
700-238
700-239
700-224
700-240
700-241
700-242
700-243
700-244
700-245
700-201
700-204
700-246
700-247
700-213
Description
*Crossbar - Redundant Support
Wire Rope Assembly - Redundant Support
Rope Sleeve Pocket
Bolt - Hex Head, Self-locking
Nut - Hex, Slotted
Pin - Drive
Machinery Bushing
Bearing - Thrust
Crosshead - Trailer
Bearing - Thrust
Machinery Bushing
Nut - Hex, Slotted
Pin - Drive
Bearing Race
Bearing - Thrust
Crosshead - Driver
Loadbolt - Driver
Plate - Retainer
Screw - Round Head, Self-locking
Loadbolt - Trailer
* Correct monorail beam size must be given when ordering this part.
Page 28
Quantity Required
Size 2
Hoist
Size 3
Hoist
1
1
1
2
1
-
-
1
1
1
1
2
1
1
1
2
8
1
1
2
-
1
1
-
1
1
1
1
1
1
1
2
1
1
1
2
8
1
1
2
9977L
Figure 9-3. Drum, Shaft, Gear and Bearings
Ref.
No.
1
4
5
2
3
6
7
8
9
10
11
Part
Number
700-314
700-304
700-305
700-306
700-307
700-308
700-309
700-313
700-312
700-310
700-311
Ring - Retaining, External
Bearing - Drum Shaft
*Drum
*Shaft - Drum
Seal - Oil, Drum Shaft
Bearing - Drum Shaft
Description
Retainer - Bearing, Drum Shaft
Lockwasher
Bolt - Hex Head
Gear - Drum
Ring - Retaining, External
Quantity Required
Size 2
Hoist
1
1
1
1
1
1
8
1
1
8
1
Size 3
Hoist
1
1
1
1
1
1
4
1
1
4
1
*Drums on some models have drum shaft integral (Ref. No. 4). Drums for low headroom models and some longer lift models, have right and left hand grooves.
NOTES
Page 29
9979LC
Figure 9-4. Mechanical Load Brake Parts (Includes Overhead Clutch Parts)
Ref.
No.
3
4
1
2
6
7
8
9
10
11
12
13
14
Part
Number Description
Quantity Required
Size 2
Hoist
Size 3
Hoist
5
27
28
29
30
31
22
23
24
25
26
15
16
17
18
19
20
21
32
33
34
700-420
700-421
700-422
700-423
700-424
700-425
700-426
700-427
700-428
700-429
700-430
700-431
700-432
700-433
700-434
700-435
700-436
700-437
700-401
700-402
700-403
700-404
700-405
700-406
700-417
700-407
700-408
700-409
700-410
700-411
700-412
700-413
700-414
700-415
700-418
700-416
700-419
Plug - Expansion (not used on later models)
Bearing
Shaft and Flange Assembly, Brake
Washer - Friction
*Roller and Ratchet Assembly Brake (includes Ref. Nos. 5 through 10)
Rivet - Flat Head
Bolt - Hex Head (with nut)
Plate - Roller Retaining
Race - Roller
Ratchet -Roller
Roller
Bushing - Bronze
Gear - Brake
Helix - Brake
Plate - Retaining
Screw - Flat Head Socket, Self-locking
Screw - Socket Head Cap, Self-locking
****Bearing
Ring - Retaining, External
Cap - Retaining, Bearing
Lockwasher
Bolt - Hex Head
**Center Assembly - Gear
**Helix - Brake
**Gear - Brake
**Spring - Belleville
**Collar - Adjusting
**Screw - Socket Head, Self-locking
**Pin - Groove
Tool - Clutch Adjusting
***Ring.- Retaining
***Bearing
***Cage - Bearing
***Washer - Support
***Ring - Retaining
***Lockwasher
***Screw - Socket Head Cap
* When Ref. Nos. 5 through 10 require replacement, the factory recommends use of above assembly instead of individual parts. On some models Ref. Nos. 8 and 10 are integral.
** Ref. Nos. 20 through 26 are used only on hoists equipped with overload clutch.
*** For 20 & 25 ton rated loads only, Ref. Nos. 28 through 34 replace Ref. Nos. 15 through 19.
**** Size 2 shown. On Size 3 rotate bearing 180° and install from outside of spider.
-
-
-
-
-
1
-
-
1
2
1
1
2
-
1
-
-
1
-
1
2
4
-
1
1
1
6
1
-
2
1
4
1
1
2
1
1
1
6
6
1
1
1
1
1
1
2
1
1
2
6
1
1
6
1
6
1
2
-
1
1
1
1
6
1
6
2
1
-
1
1
2
-
1
Page 30
9978LA
Figure 9-5. Motor Pinion Shaft, Coupling and Motor Brake Parts
Ref.
No.
1
2
3
4
5
6
7
8
9
†
10
†
25
26
27
28
20
21
22
23
24
11 †
12 †
13
†
14
†
15
16**
17 †
18
19
Part
Number
700-556
700-514
700-515
700-516
700-518
700-521
700-522
700-523
700-524
700-525
700-526
700-527
700-528
700-529
700-501
700-530
700-531
700-502
700-503
700-504
700-505
700-506
700-519
700-507
700-508
700-509
700-510
700-520
700-551
700-553
700-552
700-555
Description
Coupling - Motor
Ring - Retaining (not shown)
Pin - Drive (not shown)
Gasket - "0" Ring
Cage - Bearing
Seal - Oil
Bearing
Shaft - Motor Pinion (with keyway)
Shaft - Motor Pinion (with spline)
Key 1
Ring - Retaining, External
Bearing
Hub - Motor Brake (with keyway)
Hub - Motor Brake (with spline)
Washer & Lining Assembly - Spider End
Plate - Motor Brake
Washer & Lining Assembly - Intermediate
Washer & Lining Assembly - Pressure Plate End
Plate - Compression
Ring - Retainer, External
Spring - Release
Stud - Pilot
Nut - Hex, Self-locking
*Coupling - Shaft, Intermediate
*Pin - Drive
*Shaft - Intermediate
*Nut - Hex
*Lockwasher
*Pillow Block - Intermediate Shaft
*Bolt - Hex Head
*Bolt - Hex Head
*Plate - Mounting, Pillow Block
Quantity Required
Size 2
Hoist
Size 3
Hoist
1
4
1
1
4
8
2
1
2
2
3
1
1
1
4
3
-
1
1
1
1
-
-
1
1
1
1
1
1
1
1
-
1
4
1
-
4
8
2
1
2
2
1***
1
3
1
4
3
1
1
1
1
1
1
-
-
1
1
1
1
-
1
-
1
* Ref. Nos. 20 through 22 are used only on models with extended frames. Ref. Nos. 23 through 28 are used only on models with the longest frame extension.
** Spacers may occur between Ref. Nos. 15 and 16.
*** For hoists with 227' lift there are 2 pillow blocks and the quantity of associated hardware is twice that shown.
†
Recommended spares.
Page 31
12502A
Figure 9-6. Motor Brake Actuating Mechanism
Ref.
No.
1
2
3
4
5
6
7
†
†
8
9
10**
11**
Plunger
Body Assembly
Spring - Brake Pin
Description
Screw - Hex Socket Head Set
Rod - Brass
Seal - "0" Ring
*Brake Actuating Assembly (includes Ref. Nos. 4, 5, 8 and 9)
Screw - Hex Socket Button Head Cap
Washer - Spring Stop
Spring
Natural Color
White
Red
Green
Washer - Spacer (used with red and green springs only)
Used with Red Spring Only
Used with Green Spring Only
Indicator Pin - Brake Adjustment
Part Quan.
Size 3 Hoist
Quan.
Number Req'd Number Req'd
700-673
700-674
700-675
700-677
700-679
700-680
700-682
-
-
-
Size 2 Hoist
-
-
700-687
700-689
700-691
700-693
1
1
1
1
1
1
1
-
-
-
-
-
1
1
1
1
Part
700-673
700-674
700-676
700-678
700-679
700-681
-
700-683
700-684
700-685
700-686
700-686
700-688
700-690
700-692
700-693
* When Ref. Nos. 4, 5, 8 and 9 require replacement, the factory recommends use of the above assembly instead of individual parts.
** Not shown (Inside Ref. No. 9)
†
Recommended spares.
1
1
1
1
1
1
-
1
1
1
1
1
1
2
1
1
Page 32
9984LA
Figure 9-7. Upper Limit Switch Parts - Block Operated - Single Reeved Hoists
Ref.
No.
Part
Number
700-732
700-703
700-704
700-707
700-709
700-708
700-705
*
700-712
700-702
700-710
700-711
700-725
700-722
700-726
700-718
700-719
700-720
700-717
700-721
700-716
700-714
700-727
700-728
700-729
700-730
700-731
700-724
700-723
700-701
Actuator Assembly - Limit Switch (includes Ref. Nos. 1 through 12 and 16 thru 18)
Weight Actuator
Pin - Drive
Rod - Actuator
Pin - Drive
Spring - Actuator
Insert - Spring
Washer - Actuator
Clevis - Actuator
Pin - Cotter
Cap Screw - Hex Socket Head
Rod End - Actuator
Pin - Actuator
Nut - Standard Hex
Lockwasher
Bracket - Limit Switch (R.H.)
Nut - Hex Cap (Optional)
Nut - Standard Hex
Lockwasher
Switch Assembly - Upper Limit
Lockwasher
Screw - Round Head Machine
Spring - Lever
Lever Assembly - Limit Switch
Spacer - Limit Switch Lever
Screw - Flat Head Machine
Bracket - Limit Switch (L.H.)
Screw - Round Head Machine
Lockwasher
Nut - Standard Hex
Description
16
17
18
19
†
20
11
12
13
14
15
8
9
6
7
10
3
4
1
2
5
26
27
28
29
21
22
23
24
25
*Replacement for Lever Assembly is Lever (Part Number 700-736) plus Hub (Part Number 700-737).
†
Recommended spares.
Qty.
Req’d
1
1
4
2
2
1
2
1
1
4
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
Page 33
12943
Figure 9-7a. Upper Limit Switch Parts - Block Operated - Double Reeved Hoists
Ref.
No.
Part
Number
1
2
3
8
†
9
10
11
6
7
4
5
12
13
14
15
700-2700
700-2701
700-2702
700-2703
700-2704
700-2705
700-2706
700-2707
700-2708
700-2709
700-2710
700-2711
700-2712
700-2713
700-2714
700-2715
700-2716
700-2717
700-2718
†
Recommended spares.
Page 34
Description
Limit Switch Assembly
For 3, 4 and 6 Part Double Reeving (Includes Ref. Nos. 1 thru 11)
For 2 Part Double Reeving (Includes Ref. Nos. 1 thru 15)
Mounting Block
Heavy Hex Nut (1/4-20)
Fillister Head Machine Screw (1/4-20 x 2-3/4)
Flat Head Machine Screw (5/16-18 x 1)
Self-Locking Hex Socket Head Cap Screw - Plated (1/4-20 x 1/2)
Lockwasher (#10)
Phillips Pan Head Machine Screw (#10-24 x 1-1/4)
Limit Switch
Actuator Arm
Limit Switch Lever Arm
Lever Arm Pin
Tube
Lockwasher (5/16)
Heavy Hex Nut (5/16)
Hex Head Machine Bolt (5/16-18 x 3/4)
Not Shown - On Lower Block For 700-2700 Only:
Striker Plate
Self-Tapping Screw With Phillips Recessed Pan Head - Plated (1/4-20 x 7/8)
Qty.
Req’d
1
1
1
1
1
4
2
2
2
2
2
1
1
1
1
1
1
2
10015LA
Figure 9-8. Upper Limit Switch Parts - Block Operated - Low Headroom Hoists
Ref.
No.
7
8
9
10
11
12
1
4
5
2
3
6
Part
Number
700-751
700-752
700-753
700-754
700-755
700-756
700-757
700-758
700-759
700-760
700-761
700-762
Pin - Cotter
Washer
Washer
Connecting Rod Assembly
Lockwasher
Nut - Hex
Pin - Cotter
Rod End
Washer
Pin - Cotter
Actuator
Spring
Description
For limit switch catalog numbers, see Figure 9-7, Ref. No. 13 through 15 and 19 through 29.
NOTES
Qty.
Req’d
2
1
2
1
1
1
2
1
1
2
2
1
Page 35
9988L
Figure 9-9. Upper and Lower Limit Switch - Geared Rotary Type. (Early Model Hoists)
Ref.
No.
6
7
4
5
8
1
2
3
9
10
Part
Number
700-916
700-917
700-918
700-919
700-920
700-921
700-922
700-923
700-924
700-925
Nut - Hex, Jam
Lockwasher - Spring Type
Switch - Geared, Rotary
Rollpin - Drum Shaft
Crank
Rollpin - Crank
Plate - Switch Mounting
Screw - Round Head, Slotted
Lockwasher
Bolt - Hex Head
Description
NOTES
Qty.
Req’d
1
1
1
1
3
2
2
3
3
1
Page 36
12757
Figure 9-9a. Upper and Lower Limit Switch - Geared Rotary Type. (Later Model Hoists)
Ref.
No.
1
2
3
4
Part
Number
700-950
700-951
700-953
Description
Limit Switch Assembly - Geared Rotary (Includes Ref. Nos. 2, 3 and 4)
Cap Screw - Hex Socket Head (#10-24 x 3/4 Pltd.)
Sealing Washer
Drum Shaft Insert
NOTES
Qty.
Req’d
1
3
3
1
Page 37
12199LB
Figure 9-10. Electrical Control Equipment
Ref.
No.
1
2
3 †
4
†
5
†
6
7 †
8 †
9
†
10
11
12 †
13
†
14
15 †
16 †
17 †
Part
Number
700-1088
700-1026
700-1027
700-1028
700-1086
700-1030
700-1031
700-1032
700-1033
700-1035
700-1036
700-1087
700-1038
700-1039
700-1040
700-1084
700-1091
Description
Plate - Mounting, Contactor
Terminal Board
Contactor - two speed only
Contactor
*`Transformer
Terminal Board - single speed only (not shown)
*Contact Kit - single speed (not shown)
*Contact Kit - two speed
Coil - single speed (not shown)
Coil - two speed
Plate - Mounting, Contactor (10 ton - two speed only)
Terminal Board (10 ton - two speed only)
**Transformer (10 ton - two speed only)
Contactor (10 ton - two speed only)
Relay - Timing
*Contactor Kit (10 ton - two speed only)
Controller - Brake
Fuse, Fuse Holder and Wire Assembly (not shown)
* Order one (1) contact kit per contactor.
** Furnish complete nameplate data from old transformer.
† Recommended spares.
Note: When ordering coils, contactors, contactor kits, or brake controllers, specify voltage.
Page 38
Qty.
Req’d
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
9983LC
Figure 9-10a. Electrical Control Equipment
Ref.
No.
1 †
2
3
8 †
9 †
10
†
11
†
4
5
†
6
†
7
Part
Number
700-1084
700-1085
700-1086
700-1087
700-1022
700-1011
700-1003
700-1019
700-1023
700-1024
700-1034
700-1092
Controller - Brake
Plate - Contactor Mounting
*Transformer
Single speed Hoist
Two speed Hoist
Terminal Board
**Contactor - Accelerating
Contactor
Block Assembly - Terminal (not shown)
***Contact Kit - 3-Pole (not shown)
***Coil (not shown)
Description
***Interlock - electrical contactor - replace in pairs (not shown)
Fuse, Fuse Holder and Wire Assembly (not shown)
* Furnish complete nameplate data from old transformer.
** Parts used on two-speed hoists only.
*** Order one (1) per contactor.
† Recommended spares.
Note: When ordering relay, contactors, contact kits, coils or brake controller, specify voltage.
2
1
1
1
2
1
1
2
Qty.
Req’d
1
1
1
Page 39
12467A
Ref.
No.
1
Part
Number
700-1050
700-1051
700-1052
700-1053
700-1054
700-1055
700-1056
700-1057
700-1058
700-1059
700-1060
700-1061
700-1062
700-1063
700-1060
700-1064
700-1065
700-1063
Page 40
Figure 9-10b. Electrical Control Equipment
One
Speed
Quantity Required
Two
Speed
3 Speed
Points
1 1 1
Description
Kit - Hoist Motor Fuse (Optional)
15 HP, 208/230V
15 HP, 460V
15 HP, 575V
20 HP, 208/230V
20 HP, 460V
20 HP, 575V
25 HP, 208/230V
25 HP, 460V
25 HP, 575V
Replacement Fuses
15 HP, 208/230V
15 HP, 460V
15 HP, 575V
20 HP, 208/230V
20 HP, 460V
20 HP, 575V
25 HP, 208/230V
25 HP, 460V
25 HP, 575V
3 3 3
Ref.
No.
5
6
7
8
2
3
4
9
10
†
†
†
†
11
†
12 †
Part
Number
700-1087
700-1089
700-1090
700-1091
700-1070
700-1071
700-1072
700-1073
700-1074
700-1075
700-1073
700-1074
700-1075
700-1076
700-1077
700-1074
700-1075
700-1073
700-1074
700-1075
700-1078
700-1074
700-1079
700-1077
700-1074
700-1075
700-1078
700-1074
700-1079
700-1077
700-1074
700-1075
700-1080
700-1084
700-1081
700-1082
700-1083
700-1092
20 HP Only
25 HP Only
Description
Transformer
230/460V
208V
575V
Transformer Fuse
Terminal Board - Motor
Terminal Board - Motor
Terminal Board - Control
Contactor - Reversing (Double)
Replacement Coil
Contact Kit
Contactor - Reversing (Double)
All except 25 HP, 230V
Replacement Coil
Contact Kit.
25 HP, 230V Only
Contactor - Accelerating (Single)
Replacement Coil
Contact Kit
Contactor - Reversing (Double)
Replacement Coil
Contact Kit
Contactor - Accelerating (Single)
15 and 20 HP Only
Replacement Coil
Contact Kit
25 HP Only
Replacement Coil
Contact Kit
Contactor - Accelerating (Single)
15 and 20 HP Only
Replacement Coil
Contact Kit
25 HP Only
Replacement Coil
Contact Kit
Relay - Time Delay
Controller - Brake
Resistor - Secondary (not shown - located outside of control panel)
15 HP Only
Fuse, Fuse Holder and Wire Assembly (not shown)
One
Speed
1
1
1
2
1
2
2
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
1
-
-
-
1
Quantity Required
Two
Speed
1
1
-
1
2
1
2
2
1
1
1
1
2
-
-
-
-
-
-
-
-
-
-
2
-
-
-
-
-
-
1
1
-
-
-
1
3 Speed
Points
1
1
1
2
-
-
-
-
1
1
1
1
1
1
1
1
1
1
1
1
† Recommended spares.
Note: When ordering contactors, coils, contact kits or brake controller, specify voltage. When ordering transformer, furnish complete nameplate data from old transformer.
1
1
1
1
1
1
-
-
-
-
-
2
1
1
2
-
NOTES
Page 41
Figure 9-10c. Electrical Control Equipment, Size 2 Hoists (Later Models)
4
5
2
3
6*
Ref.
No.
1
Part
Number
700-2300
700-2301
700-2302
700-2303
700-2304
700-2305
700-2306
700-2307
700-2308
700-2309
700-2310
700-2311
700-2326
700-2327
700-2328
Description
Mounting Plate
For All Except 208V & 230V Hoists with 10 HP Motor or True Vertical Lift
Hoist with Plate Width of 21-3/8"
For 208V & 230V Hoists with 10 HP Motor Only
For True Vertical Lift Hoist with Plate Width of 21-3/8" Only
Pan Head Machine Screws (#8-32 x 5/8)
Terminal Board
Ground Lug
Pan Head Machine Screws (#10-32 x 1/4)
Transformer
230/460V Except with 10 HP Motor
208V Except with 10 HP Motor
575V
230/460V with 10 HP Motor
208V with 10 HP Motor
New Transformers
For 230V 7.5 HP Motor
Fuse (1 A)
Fuse (6/10A)
Page 42
12873
Qty.
Req’d
1
1
1
2
1
1
1
2
1
Figure 9-10c. Electrical Control Equipment. (Continued)
Ref.
No.
7
8
9
10
Part
Number
700-2326
700-2329
700-2328
700-2330
700-2327
700-2328
700-2331
700-2332
700-2328
700-2333
700-2334
700-2335
700-2336
700-2334
700-2335
700-2306
700-2312
700-2337
700-2306
11
12
13
14*
700-2313
700-2314
700-2315
700-2316
700-2317
700-2318
700-2319
700-2320
700-2321
700-2322
700-2323
700-2324
700-2325
Description
For 460V 5 and 10 HP Motor
Fuse (1/2A)
Fuse (6/1 OA)
For 208V 7.5 HP Motor
Fuse (1 A)
Fuse (6/10A)
For 575V 5 and 10 HP Motor
Fuse (1/4A)
Fuse (6/1 OA)
For 230V 10 HP Motor
Fuse (2A)
Fuse (1-4/10A)
For 208V 10 HP Motor
Fuse (2A)
Fuse (1-4/1OA)
Pan Head Machine Screws (#10-32 x 1/4)
DIN Rail Except for 208V and 230V 10 HP Motor
DIN Rail For 208V and 230V 10 HP Motor
Pan Head Machine Screws (#10-32 x 1/4)
Contactor
460V & 575V with 5 HP Motor
460V & 575V with 10 HP Motor
208V & 230V with 7.5 HP Motor
208V & 230V with 10 HP Motor
Contactor - Two Speed Only
460V & 575V with 5 HP Motor
460V & 575V with 10 HP Motor and 208V & 230V with 7.5 HP Motor
208V & 230V with 10 HP Motor
Brake Controller
Pan Head Machine Screws (#8-32 x 7/8)
Fuse, Fuse Holder and Wire Assembly
For 208V & 230V with 10 HP Motor Only
Fuse Only (2A, 300V)
For All Others
Fuse Only (1A, 300V)
1
1
2
1
*Fuse Assembly, Ref. No. 14, has been eliminated and Transformers, Part Numbers 700-2307 thru 700-2310, have been replaced by Transformers with Fuses mounted on the top of the transformer on the latest hoists.
Qty.
Req’d
1
3
4
1
1
1
2
2
1
1
2
1
1
1
1
1
1
1
2
2
NOTES
Page 43
Figure 9-10d. Electrical Control Equipment, Size 3 Hoists (Later Models)
Ref.
No.
3
4
1
2
5
6*
Part
Number
700-2400
700-2401
700-2402
700-2403
700-2404
700-2405
700-2406
700-2407
700-2420
700-2421
700-2422
700-2420
700-2423
700-2422
700-2424
700-2421
700-2422
Page 44
Description
Mounting Plate
Pan Head Machine Screws (#8-32 x 5/8)
Terminal Board
Ground Lug
Pan Head Machine Screws (#10-32 x 1/4)
Transformer
230/460V
208V
575V
New Transformers
For 230V 7.5 and 15 HP Motor
Fuse (2A) '
Fuse (1-4/10A)
For 460V 10 and 20 HP Motor
Fuse (1 A)
Fuse (1-4/1OA)
For 208V 7.5 and 15 HP Motor
Fuse (2A)
Fuse (1-4/1OA)
12874
Qty.
Req’d
1
1
1
2
1
1
1
2
2
1
1
1
1
1
2
Figure 9-10d. Electrical Control Equipment. (Continued)
Ref.
No.
7
8
9
10
11
Part
Number
700-2425
700-2426
700-2422
700-2404
700-2408
700-2409
700-2404
700-2410
700-2411
700-2412
For 575V 15 and 20 HP Motor
Fuse (1/2A)
Fuse (1-4/10A)
Pan Head Machine Screws (#10-32 x 1/4)
DIN Rail
208V & 230V with 7.5 HP Motor and 208V & 230V with 15 HP Motor and
460V & 575V with 20 HP Motor
460V with 10 HP Motor and 575V with 15 HP Motor
Pan Head Machine Screws (#10-32 x 1/4)
Contactor
460V with 10 HP Motor and 575V with 15 HP Motor
208V & 230V with 7.5 HP Motor and 460V & 575V with 20 HP Motor
208V & 230V with 15 HP Motor
Contactor - Two Speed
460V with 10 HP Motor and 575V with 15 HP Motor
208V & 230V with 7.5 HP Motor and 460V & 575V with 20 HP Motor
208V & 230V with 15 HP Motor
Brake Controller
Pan Head Machine Screws (#8-32 x 7/8)
Fuse, Fuse Holder and Wire Assembly
Fuse Only (2A, 300V)
Description
Qty.
Req’d
1
2
1
4
1
4
1
1
12
13
14*
700-2413
700-2414
700-2415
700-2416
700-2417
700-2418
700-2419
1
2
1
*Fuse Assembly, Ref. No. 14, has been eliminated and Transformers, Part Numbers 700-2405 thru 700-2407, have been replaced by Transformers with Fuses mounted on the top of the transformer on the latest hoists.
NOTES
Page 45
12675
Figure 9-11. Push Button Station and Conductor Cord Assembly
Ref.
No.
1
Part
Number
2
3
4
5
Page 46
700-3100
700-3101
700-3102
700-3103
700-3104
700-3105
700-3106
700-3107
700-3108
700-3109
700-3110
700-3111
700-3112
700-3113
700-3114
700-3115
Grip Assembly - Conductor
For 4 Conductor Cable
For 5 Conductor Cable
For 6 Conductor Cable
For 7 and 8 Conductor Cable
For 10, 12 and 16 Conductor Cable
Cable - Flexible Conductor*
4 Conductor
5 Conductor
6 Conductor
7 Conductor
8 Conductor
10 Conductor
12 Conductor
16 Conductor
Thimble - Strain Cable
Connector - Strain Cable
Connector - Conductor to Strain Cable
Description
Qty.
Req’d
1
1
2
1
1
Figure 9-11. Push Button Station and Conductor Cord Assembly (Continued)
Ref.
No.
6
7
8
15
16
17
18
19
20
9
10
11
12
13
14
21
22
23
24
25
Part
Number
700-3116
700-3117
700-3118
700-3119
700-3120
700-3121
700-3122
700-3123
700-3124
700-3125
700-3126
700-3127
700-3128
700-3129
700-3130
700-3131
**
**
**
**
700-3132
**
**
**
**
**
**
**
**
700-3133
700-3134
700-3135
700-3136
700-3137
700-3138
700-3139
700-3140
700-3141
Description
Clamp - Conductor
For 4 Conductor Cable
For 5 and 6 Conductor Cable
For 7 Conductor Cable
For 8 and 10 Conductor Cable
For 12 Conductor Cable
For 16 Conductor Cable
Cable - Strain*
Sleeve - Pressure
Push Button Assembly (Includes Ref. Nos. 9 thru 24)
2 Buttons
4 Buttons
6 Buttons
8 Buttons
Enclosure Assembly (Includes Ref. Nos. 9 thru 21)
2 Buttons
4 Buttons
6 Buttons
8 Buttons
Clamp - Conductor
Screw - Slotted Head
Lockwasher
Support - Strain Cable
Sleeve - Conductor
Nut - Hex
Screw - Slotted Head
Clamp - Conductor
Enclosure Body
Enclosure Front
Enclosure Rear
Screw - Slotted Head
2 Button Station
4 Button Station
6 Button Station
8 Button Station
Lockwasher
2 Button Station
4 Button Station
6 Button Station
8 Button Station
Block - Contact
2 Button Station
4 Button Station
6 Button Station
8 Button Station
Push Button Assembly
2 Button Station
4 Button Station
6 Button Station
8 Button Station
Nameplate
Stop
Start
Up
Down
Right
Left
Operator Warning Label
* Specify length required.
** Not available separately. Order Enclosure Assembly.
Qty.
Req’d
1
6
8
2
4
6
8
2
4
1
1
2
2
2
3
3
3
3
1
1
1
2
1
1
3
3
3
3
1
1
1
1
6
8
2
4
1
6
8
2
4
1
Page 47
10014LA
Ref.
No.
13
14
15
16
17
8
9
10
11
12
18
5
6
3
4
7
1
2
19
†
20
21
22
23
24
25
Page 48
Part
Number
700-1430
700-1431
700-1432
700-1433
700-1434
700-1435
700-1436
700-1437
700-1438
700-1439
700-1443
700-1444
700-1402
700-1403
700-1404
700-1445
700-1446
700-1447
700-1448
700-1449
700-1429
700-1450
700-1451
700-1452
700-1453
700-1413
Figure 9-14. Upper and Lower Block Parts Including Hoist Rope.
(2 through 7½ ton - single reeved standard headroom hoist with 1/4" through 7/16" rope)
Description
Fitting - Grease
Screw - Hex Head Cap
Lockwasher
Key Plate
Pin - Upper Sheave
Spacer
Bearing (includes outer race)
Sheave - Upper
Bolt - Rope Guide
Lockwasher
Pin - Upper Sheave
Fitting - Grease
Screw - Hex Head Cap
Lockwasher
Key Plate
Bushing - Spacer
Bearing - Upper Sheave (includes inner race, not shown)
Sheave - Upper
Block Assembly - Lower (Complete)
Block Assembly - Lower (Complete)
**Rope Assembly - Wire
Bushing - Spacer
Bearing - Lower Sheave (no inner race)
Guard - Sheave
Sheave - Lower
Nut- Hook
Pin - Roll
Quantity Required
Reeving
2PS 4PS
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
1
1
1
1
1
1
1
-
-
2
1
2
2
2
1
2
1
1
2
1
1
2
1
1
1
1
1
2
1
2
1
1
-
1
1
1
4
Figure 9-14. Upper and Lower Block Parts Including Hoist Rope. (Continued)
Ref.
No.
37
38
39
40
41
32
33
34
35
36
26
27
28
29
30
31
Part
Number
700-1440
700-1414
700-1415
700-1427
700-1428
700-1454
700-1455
700-1456
700-1424
700-1419
700-1418
700-1444
700-1457
700-1410
700-1441
700-1442
Description
Shield - Thrust Bearing
Washer - Thrust
Bearing - Thrust
Lockwasher
Nut - Hex
Ring - Retaining, External
Body - Lower Block
Hook Assembly (includes nut and latch)
Plate Capacity
Lockwasher
Screw - Round Head, Self-tapping
Fitting - Grease
Pin - Lower Sheave
Bolt - Hex Head
**Adapter - Rope Fitting (not shown)
**Screw - Socket Set (not shown)
Quantity Required
2PS
1
2
-
1
1
-
2
4
1
1
4
2
2
2
1
2
Reeving
4PS
* Hook nuts are not interchangeable; available only with hook as an assembly.
** CAUTION: Only factory approved wire rope assembly of proper length having swagged fittings, one at each end, should be used for replacement. Do not use substitutes. Ref. Nos. 40 and 41 above are not used on all hoists.
†
Recommended spares.
2
2
1
1
2
2
4
1
1
4
1
2
2
2
1
2
NOTES
Page 49
10011L
Figure 9-15. Upper and Lower Block Parts Including Hoist Rope.
(5 through 15 ton hoists with 9/16" rope and 6 through 10 ton double reeved standard headroom hoists)
Ref.
No.
1
4
5
2
3
6
7
8
9
10
11
17
18
19
20
21
12
13
14
15
16
22
23
Page 50
Part
Number Description
700-1501 Screw - Hex Head Cap
700-1502 Lockwasher
700-1503 Key Plate
700-1504 Fitting - Grease
700-1505 Pin - Upper Sheave
700-1508 Spacer - Upper Sheave
700-1506 Bearing - Upper Sheave
700-1507 Sheave - Upper
700-1531 Spacer - Upper Sheave (not shown)
700-1532 Bolt - Rope Guide
700-1533 Lockwasher
700-1511 Block Assembly - Lower, 2PS (includes Ref. Nos. 12 thru 28)
700-1512 Block Assembly - Lower, 4PS (includes Ref. Nos. 12 thru 28)
700-1513 Block Assembly - Lower, 6PS (includes Ref. Nos. 12 thru 28)
700-1534 Block Assembly - Lower, 3PD (includes Ref. Nos. 12 thru 28)
700-1535 Block Assembly - Lower, 4PD (includes Ref. Nos. 12 thru 28)
700-1529 Spacer - Lower Sheave
700-1530 Bearing Assembly (includes outer race)
700-1515 Sheave - Lower
700-1514 Guard - Sheave
700-1516 Pin - Roll
** Nut - Hook
700-1517 Bearing - Thrust
700-1518 Body - Lower Block
700-1519 Hook - Assembly (includes nut and latch)
700-1527 Plate - Capacity
700-1536 Screw - Round Head, Self-tapping
700-1524 Lockwasher
2PS
-
-
1
-
-
-
-
-
-
-
-
-
-
-
-
-
1
1
1
1
2
4
4
1
1
2
1
1
Quantity Required
4PS
Reeving
6PS 3PD
-
-
-
1
-
-
2
1
1
2
1
1
1
1
1
2
1
1
1
1
2
4
4
2
1
3
2
1
1
-
-
-
-
-
2
2
2
2
1
1
1
1
1
4
1
1
1
1
2
4
4
3
1
4
3
1
-
1
-
-
-
2
-
2
2
-
4
1
1
4
2
3
1
1
1
1
1
2
2
3
1
3
3
1
4PD
-
-
-
-
1
-
-
3
3
-
4
1
1
4
2
4
1
1
1
1
1
2
2
4
1
4
4
1
Figure 9-15. Upper and Lower Block Parts Including Hoist Rope. (Continued)
Ref.
No.
Part
Number Description
24
25
26
27
700-1523 Screw - Hex Head Cap
700-1522 Key Plate
700-1525 Fitting - Grease
700-1526 Pin - Lower Sheave
28 700-1528 Screw - Button Head, Cap, Self-locking
700-1537 Screw - Round Head, Self-tapping
29 † 700-1510 *Rope Assembly - Wire
30 700-1538 Adapter - Rope Assembly (not shown)
31 700-1539 Screw - Rope Adapter (not shown)
2PS
1
-
4
-
-
1
1
4
2
Quantity Required
4PS
2
1
1
4
-
1
-
-
Reeving
6PS
1
-
4
-
1
1
4
2
-
3PD
2
1
1
1
-
4
1
2
2
* CAUTION: Only factory approved wire rope assembly of proper length, having swagged fittings, one at each end, should be used for replacement. Do not use substitutes.
** Hook nuts are not interchangeable; available only as an assembly.
†
Recommended spares.
4PD
1
2
-
4
2
1
1
2
1
NOTES
Page 51
10010LA
18
19
20
21
22
23
24
25
10
11
12
13
14
15
16
17
Ref.
No.
6
7
4
5
8
1
2
3
9
26
27
Page 52
Part
Number
700-1602
700-1623
700-1624
700-1603
700-1625
700-1604
700-1607
700-1606
700-1605
700-1608
700-1626
700-1627
700-1628
700-1621
700-1609
**
700-1619
700-1615
700-1638
700-1614
700-1617
700-1629
700-1630
700-1632
700-1633
700-1634
700-1645
700-1635
700-1616
Figure 9-16. Upper and Lower Block Parts Including Hoist Rope.
(2 through 5 ton - standard and low headroom hoists 2PD reeved)
Description
Pin - Upper Sheave Yoke
Ring - Retaining
Spacer
Yoke - Upper Sheave
Pin - Drive
Pin - Upper Sheave
Bearing
Sheave - Upper
Pin - Cotter
Block Assembly - Lower (includes Ref. Nos. 10 through 27)
Screw - Round Head, Self-tapping
Guard - Sheave
Spacer
Bearing - Sheave
Sheave - Lower
Nut - Hook
Pin - Drive
Bearing Assembly - Thrust
Body - Lower Block
Hook Assembly (includes nut and latch)
Plate - Capacity
Lockwasher
Screw - Self-tapping, Round Head
Screw - Hex Head
Lockwasher
Key Plate
Ring - Retaining (not shown)
Fitting - Grease
Pin - Lower Sheave
Quantity Required
Size 2
Hoist
Size 3
Hoist
1
1
4
2
1
4
1
2
1
-
1
1
1
2
1
1
2
-
2
2
-
-
-
2
4
1
1
4
1
1
1
2
2
1
4
1
2
1
4
1
1
1
-
1
1
2
4
1
-
2
2
2
1
2
1
1
2
1
Figure 9-16. Upper and Lower Block Parts Including Hoist Rope. (Continued)
Ref.
No.
28
†
29
30
31
32
33
34
35
36
Part
Number
700-1622
700-1636
700-1637
700-1639
700-1640
700-1641
700-1642
700-1643
700-1644
Description
*Rope Assembly - Wire (not shown)
Adapter - Wire Rope (not shown)
Screw - Socket Set (not shown)
Pin - Upper Sheave
Bearing
Sheave - Upper
Key Plate
Lockwasher
Bolt - Hex Head
Quantity Required
Size 2
Hoist
1
1
-
1
1
1
-
2
2
Size 3
Hoist
* CAUTION: Only factory approved wire rope assembly of proper length, having swagged fittings, one at each end, should be used for replacement. Do not use substitutes.
** Hook nuts are not interchangeable; available only as an assembly.
†
Recommended spares.
1
1
1
1
1
1
2
2
2
NOTES
Page 53
10013L
Figure 9-17. Upper and Lower Block Parts Including Hoist Rope.
(2 through 7½ ton low headroom hoists 3PD reeved)
21
22
23
24
25
26
16
17
18
19
20
12
13
14
15
27
28
29
30
Ref.
No.
1
4
5
2
3
6
7
8
9
10
11
Page 54
Part
Number
700-1707
**
700-1722
700-1718
700-1746
700-1716
700-1720
700-1734
700-1721
700-1737
700-1735
700-1736
700-1738
700-1739
700-1719
700-1740
700-1728
700-1725
700-1726
700-1727
700-1702
700-1729
700-1730
700-1731
700-1703
700-1704
700-1701
700-1742
700-1732
700-1708
700-1733
700-1706
Description
Fitting - Grease
Screw - Hex Head
Lockwasher
Key Plate
Pin - Upper Sheave
Pin - Cotter
Pin - Rope Guide
Space - Upper Sheave
Bearing - Upper Sheave
Sheave - Upper
Pin - Cotter
Block Assembly (includes Ref. Nos. 12 through 34)
Ring - Retaining, External
Pin - Idler Sheave
Spacer - Idler Sheave
Sheave - Idler
Bearing - Idler Sheave
Nut - Hook
Pin - Drive
Bearing - Thrust
Body Assembly - Lower Block
Hook Assembly (includes nut and hook latch)
Plate - Capacity
Lockwasher
Screw - Round Head, Self-tapping
Key Plate
Screw - Round Head, Machine
Screw - Hex Head Cap
Lockwasher
Fitting - Grease
Pin - Lower Sheave
Screw - Round Head, Self-tapping
Quantity Required
Size 2
Hoist
Size 3
Hoist
4
-
4
-
1
4
4
4
1
2
2
1
1
1
1
1
1
-
1
2
1
4
2
2
-
2
-
-
1
-
-
4
2
2
-
2
1
4
2
2
1
1
1
1
1
1
1
1
1
2
1
2
1
2
2
2
4
-
2
1
1
2
2
4
Figure 9-17. Upper and Lower Block Parts Including Hoist Rope. (Continued)
Ref.
No.
31
32
33
34
35
†
36
37
Part
Number
700-1741
700-1743
700-1710
700-1711
700-1724
700-1744
700-1745
Guard - Sheave
Spacer - Lower Sheave
Description
Bearing - Lower Sheave
Sheave - Lower
*Rope Assembly - Wire (not shown)
Screw - Socket Set (not shown)
Adapter - Wire Rope (not shown)
Quantity Required
Size 2
Hoist
1
-
4
2
-
1
-
Size 3
Hoist
* CAUTION: Only factory approved wire rope assembly of proper length, having swagged fittings, one at each end, should be used for replacement. Do not use substitutes.
** Hook nuts are not interchangeable; available only as an assembly.
† Recommended spares.
1
2
2
2
2
1
4
NOTES
Page 55
11983L
Figure 9-18. Upper and Lower Block Parts Including Hoist Rope.
(10 ton low headroom hoists)
Ref.
No.
15
16
17
18
19
10
11
12
13
14
7
8
5
6
9
3
4
1
2
24
25
26
27
28
20
21
22
23
29
Page 56
Part
Number
700-1801
700-1802
700-1803
700-1804
700-1805
700-1906
700-1807
700-1808
700-1909
700-1810
700-1811
700-1812
700-1813
700-1814
700-1815
700-1816
700-1817
700-1818
700-1819
700-1820
700-1821
700-1822
700-1823
700-1824
**
700-1825
700-1826
700-1827
700-1828
700-1829
Description
Fitting - Grease
Screw - Hex Head Cap
Lockwasher
Key Plate
Pin - Upper Sheave
Pin - Cotter
Pin - Rope Guide
Spacer - Upper Sheave
Bearing - Upper Sheave
Sheave - Upper
Yoke Assembly - Equalizer
Spacer - Equalizer Yoke Pin
Pin - Equalizer Sheave
Ring - Retaining
Spacer - Equalizer Sheave
Bearing - Equalizer Sheave
Sheave - Equalizer Yoke
Pin - Equalizer Yoke
Pin - Cotter
Lower Block Assembly (includes Ref. Nos. 20 through 37)
Guard - Sheave
Spacer - Lower Sheave
Sheave - Lower
Bearing - Lower Sheave
Nut- Hook
Pin - Drive
Bearing - Thrust
Body Assembly - Lower Block
Hook Assembly (includes nut and hook latch)
Plate - Capacity
Qty.
Req’d
1
1
2
1
2
2
1
2
1
2
2
4
1
4
2
2
1
2
2
1
1
1
1
1
6
4
1
1
4
1
Figure 9-18. Upper and Lower Block Parts Including Hoist Rope. (Continued)
Ref.
No.
35
36
37
38
†
39
30
31
32
33
34
40
Part
Number
700-1830
700-1831
700-1832
700-1833
700-1834
700-1835
700-1836
700-1837
700-1838
700-1839
700-1840
Lockwasher
Screw - Round Head, Self-tapping
Key Plate
Lockwasher
Screw - Hex Head Cap
Fitting - Grease
Pin - Lower Sheave
Screw - Round Head, Self-tapping
*Rope Assembly - Wire (not shown)
Adapter - Wire Rope (not shown)
Screw - Socket Set (not shown)
Description
* CAUTION: Only factory approved wire rope assembly of proper length, having swagged fittings, one at each end, should be used for replacement. Do not use substitutes.
** Hook nuts are not interchangeable; available only as an assembly.
† Recommended spares.
Qty.
Req’d
4
1
2
1
2
1
2
2
2
2
2
NOTES
Page 57
11984L
Figure 9-19. Upper and Lower Block Parts Including Hoist Rope.
(7½ ton standard headroom hoists)
Ref.
No.
1
4
5
2
3
6
7
8
9
Part
Number
**
700-1917
700-1918
700-1919
700-1920
700-1921
700-1922
700-1923
700-1924
700-1925
700-1926
700-1927
700-1928
700-1929
700-1930
700-1931
700-1932
700-1933
700-1910
700-1902
700-1903
700-1904
700-1905
700-1906
700-1907
700-1908
700-1909
700-1910
700-1911
700-1912
700-1913
700-1914
700-1915
700-1916
Screw - Hex Head Cap
Lockwasher
Key Plate
Pin - Upper Sheave
Spacer - Upper Sheave
Screw - Flat Head Socket, Self-locking
Plate - Retainer, Bearing
Bearing - Upper Sheave
Sheave
Lower Block Assembly (includes Ref. Nos. 10 through 32)
Screw - Flat Head Socket, Self-locking
Spacer - Lower Sheave
Plate - Retaining Bearing
Bearing - Lower Sheave
Sheave - Lower
Guard - Sheave
Nut - Hook
Pin - Drive
Shield - Bearing
Washer - Thrust
Nut - Hex
Lockwasher
Bearing - Thrust
Body Assembly - Lower Block
Hook Assembly (includes nut and hook latch)
Plate - Capacity
Lockwasher
Screw - Round Head, Self-tapping
***Key Plate
***Lockwasher
***Screw - Hex Head Cap
***Pin - Lower Sheave
Bolt - Hex Head
*Rope Assembly - Wire (not shown)
Description
21
22
23
24
25
16
17
18
19
20
10
11
12
13
14
15
26
27
28
29
30
31
32
33
†
* CAUTION: Only factory approved wire rope assembly of proper length, having swagged fittings, one at each end, should be used for replacement. Do not use substitutes.
** Hook nuts are not interchangeable; available only as an assembly.
*** Later Model hoists use pin (700-1935) with two retaining rings (700-1934).
†
Recommended spares.
Page 58
Qty.
Req’d
1
2
1
2
4
4
4
4
1
1
2
1
2
1
2
1
1
2
3
3
4
3
1
2
1
2
2
12
2
1
3
2
1
8
12198LA
Figure 9-20. Upper and Lower Block Parts Including Hoist Rope.
(10 ton size 2, 6 part single reeved standard headroom hoists)
Ref.
No.
1
4
5
2
3
6
7
8
23
24
25
26
27
18
19
20
21
22
28
29t
9
10
11
12
13
14
17
Part
Number
700-2001
700-2002
700-2003
700-2004
700-2005
700-2006
700-2007
700-2008
700-2000
700-2009
700-2010
700-2011
700-2012
**
700-2014
700-2017
700-2018
700-2019
700-2020
700-2021
700-2022
700-2023
700-2024
700-2025
700-2026
700-2027
700-2028
700-2013
Description
Fitting - Grease
Screw - Hex Head Cap
Lockwasher
Key Plate
Pin - Upper Sheave
Washer - Spacer, Upper Sheave
Bearing- Upper Sheave
Sheave - Upper
Block Assembly - Lower (includes Ref. Nos. 9 through 28)
Washer - Spacer, Lower Sheave
Bearing - Lower Sheave
Sheave - Lower
Guard - Lower Sheave
Nut - Hook
Roll Pin - Hook Nut
Nut - Hex (sheave guard)
Lockwasher (sheave guard)
Bearing - Thrust
Retaining Ring - External (sheave pin)
Body - Lower Block
Hook Assembly (includes nut, roll pin, hook and safety latch)
Plate - Capacity
Lockwasher
Screw - Round Head, Self-tapping
Fitting - Grease
Pin - Lower Sheave
Bolt - Hex Head
*Rope Assembly - Wire (not shown)
Qty.
Req’d
1
1
3
1
2
1
6
2
2
3
1
1
1
1
1
4
4
1
2
4
1
2
1
2
1
2
1
1
* CAUTION: Only factory approved wire rope assembly of proper length, having swagged fittings, one at each end, should be used for replacement. Do not use substitutes.
** Hook nuts are not interchangeable; available only as an assembly.
†
Recommended spares.
Page 59
10
-1
I
I
I
___ -.J
I
I
~
16
1
12944
Page 60
Figure 9-20a. Upper and Lower Block Parts Including Hoist Rope.
(10 ton size 2, 5 part double reeved standard headroom hoists)
Figure 9-20a. Upper and Lower Block Parts Including Hoist Rope. (Continued)
7
8
5
6
9
3
4
1
2
10
11
12
13
14
23
24
25
26
27
28
29 †
15
16
17
18
19
20
21
22
Part
Number
700-2051
700-2052
700-2053
700-2054
700-2055
700-2056
700-2057
700-2058
700-2059
700-2060
700-2061
700-2062
700-2063
700-2064
700-2065
700-2066
700-2067
700-2068
**
700-2069
700-2070
**
700-2071
700-2072
700-2073
700-2052
700-2053
700-2054
700-2074
700-2075
700-2076
Ref.
No.
Description
Block Assembly - Upper (Includes Ref. Nos. 1 through 9)
Bolt - Hex Head (3/8-16 x 5/8)
Lockwasher (3/8)
Key Plate
Pin - Upper Sheave
Spacer - Upper Sheave
Bearing - Upper Sheave
Sheave - Upper
Spacer - Upper Sheave
Fitting - Grease
Block Assembly - Lower (Includes Ref. Nos. 10 through 28)
Guard - Lower Sheave
Screw - Round Head, Self-tapping (1/4-20 x 1/2)
Spacer - Lower Sheave
Bearing - Lower Sheave
Sheave - Lower
Hook Assembly (Includes nut, roll pin, hook and safety latch)
Roll Pin - Hook Nut
Nut - Hook
Bearing - Thrust
Hook Latch
Hook - Lower Block
Screw - Round Head, Self-tapping (#10-24 x 1/2)
Lockwasher (#10)
Plate - Capacity
Bolt - Hex Head (3/8-16 x 5/8)
Lockwasher (3/8)
Key Plate
Fitting - Grease
Pin - Lower Sheave
Body - Lower Block
*Rope Assembly - Wire (Not Shown)
16' Lift
18' Lift
700-2077
700-2078
* CAUTION: Only factory approved wire rope assembly of proper length, having swagged fittings, one at each end, should be used for replacement. Do not use substitutes.
** Hook nuts are not interchangeable; available only as an assembly.
† Recommended spares.
Qty.
Req’d
1
1
5
1
1
4
6
1
1
5
4
3
2
4
2
2
1
1
2
1
1
2
2
2
1
1
1
2
2
1
1
1
NOTES
Page 61
12466A
Ref.
No.
1
2
3
4
7
8
5
6
9
10
Page 62
Part
Number
700-2100
700-2101
700-2102
700-2103
700-2104
700-2105
700-2106
700-2107
700-2108
700-2109
700-2110
700-2111
700-2112
Figure 9-21. Upper and Lower Block Parts Including Hoist Rope.
(20 and 25 ton - single reeved standard headroom hoist with 1/2" and 9/16" rope)
Lower Block Assembly (includes Ref. Nos. 1 through 16)
Lower Block Assembly (includes Ref. Nos. 1 through 16)
Body - Lower Block
Guard - Sheave
Cap Screw - Hex Socket Head
Sheave - Lower
Sheave - Lower
Spacer - Lower Sheave
Bearing - Lower Sheave
Pin - Lower Sheave
Fitting - Grease
Key Plate
Screw - Hex Head Cap
Description
Quantity Required
For
20 Ton
For
25 Ton
1
2
5
4
1
2
4
4
1
1
-
1
-
1
2
5
4
1
2
4
-
1
1
4
-
1
Figure 9-21. Upper and Lower Block Parts Including Hoist Rope. (Continued)
13
14
15
16
17
18
Ref.
No.
11
12
19
20
21
22
23
24
25
26
27 †
Part
Number
700-2113
700-2114
700-2115
700-2116
700-2117
700-2118
700-2119
700-2120
700-2105
700-2106
700-2111
700-2112
700-2113
700-2110
700-2107
700-2108
700-2121
700-2113
700-2122
700-2123
700-2124
700-2125
700-2126
700-2127
Lockwasher
Plate - Capacity
Plate - Capacity
Screw - Round Head, Self-tapping
Bearing - Thrust
Hook Assembly (includes hook, nut, roll pin and latch)
Pin - Drive
Pin - Upper Sheave
Sheave - Upper
Sheave - Upper
Key Plate
Screw - Hex Head Cap
Lockwasher
Fitting - Grease
Spacer - Upper Sheave
Bearing - Upper Sheave
Bolt - Hex Head (for rope guide)
Lockwasher
*Rope Assembly - Wire
20' Lift
27' Lift
34' Lift
17'-6" Lift
24' Lift
30' Lift
Description
Quantity Required
For
20 Ton
3
2
1
4
2
1
2
1
-
2
1
1
4
1
1
2
2
-
1
1
1
-
-
-
For
25 Ton
* CAUTION: Only factory approved wire rope assembly of proper length, having swagged fittings, one at each end, should be used for replacement. Do not use substitutes.
†
Recommended spares.
Note: Hook nuts are not interchangeable; available only as an assembly.
3
2
1
4
2
1
2
-
1
2
1
1
4
1
1
2
-
2
-
1
-
-
1
1
NOTES
Page 63
12825
Page 64
Figure 9-22. Upper and Lower Block Parts Including Hoist Rope.
(15 and 20 ton - double reeved hoist with 7/16" rope)
Figure 9-22. Upper and Lower Block Parts Including Hoist Rope. (Continued)
19
20
21
22
23
24
25
26
27
28 †
8
9
6
7
10
4
5
2
3
11
12
13
Part
Number
700-2218
700-2219
700-2220
700-2221
700-2222
700-2223
700-2224
700-2225
700-2226
700-2227
700-2228
700-2229
700-2230
700-2231
700-2232
700-2233
700-2200
700-2201
700-2202
700-2203
700-2204
700-2205
700-2206
700-2207
700-2208
700-2209
700-2210
700-2211
700-2212
700-2213
700-2214
700-2215
700-2216
700-2217
Ref.
No.
1
14
15
16
17
18
Spacer
Key Plate
Lockwasher
Bolt - Hex Head
Fitting - Grease
Pin - Sheave
*Rope Assembly - Wire
16' Lift
26' Lift
36' Lift
56' Lift
20' Lift
27' Lift
Description
Lower Block Assembly (includes Ref. Nos. 1 thru 18)
Lower Block Assembly (includes Ref. Nos. 1 thru 18)
Body - Lower Block
Body - Lower Block
Guard - Sheave
Lockwasher
Bolt - Hex Head
Spacer
Sheave
Bearing
Pin - Sheave
Fitting - Grease
Bolt - Hex Head
Lockwasher
Key Plate
Plate - Capacity
Plate - Capacity
Machine Screw - Round Head
Lockwasher
Hook Assembly (includes hook, nut, roll pin & latch)
Hook Assembly (includes hook, nut, roll pin & latch)
Roll Pin
Roll Pin
Bearing - Thrust
Bearing - Thrust
Spacer
Sheave
Bearing
700-2234
700-2235
700-2236
700-2237
700-2238
700-2239
1
1
1
1
-
-
* CAUTION: Only factory approved wire rope assembly of proper length, having swagged fittings, one at each end, should be used for replacement. Do not use substitutes.
†
Recommended spares.
Note: Hook nuts are not interchangeable; available only as an assembly.
-
1
1
-
-
-
Quantity Required
For
20 Ton
For
25 Ton
4
4
4
2
1
1
2
5
1
-
5
-
1
2
1
-
1
-
2
1
2
1
2
6
6
2
4
4
-
1
7
1
-
1
4
4
4
2
1
1
2
5
-
1
5
1
-
2
-
1
-
1
2
1
2
1
2
6
6
2
4
4
1
1
7
-
1
-
NOTES
Page 65
NOTES
NOTES
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 set of load brake fiction washers
One set of motor brake washer and lining assemblies
One set of motor brake plates
One set of motor brake release springs
One motor brake actuator spring
One brake controller
One gearcase cover gasket
One brake cover gasket
One set of contactors
One transformer
One wire rope assembly
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
Yale
!!!!!
Lift-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 WHATSO-
EVER, EXPRESS, IMPLIED AND STATUTORY, INCLUDING, WITH-
OUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANT-
ABILITY 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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Key features
- Wide-faced helical gearing made of heat-treated steel for durability
- Ball bearings throughout for smooth operation
- Large diameter grooved rope drum for better rope life
- Large lower block rope sheave for increased lifting capacity
- Hinged side cover for quick access to electrical components
- Removable lightweight aluminum end covers for easy servicing
- Weight Watcher overload clutch for protection against overloading
- Easy accessibility to all working parts for maintenance
- ANSI B30.16 safety code compliant