SHAW-BOX World Series Wire Rope Hoist Operation, Service & Parts Manual

OPERATION, SERVICE & PARTS MANUAL
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WORLD SERI ES 70
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FORWARD
This book contains important information to help you install, operate, maintain and service your
new SHAW-BOX electric hoist. We recommend that you study its contents thoroughly before
putting the hoist into use. We also recommend that you read Section IX – Series Lifting
Equipment of the European Federation of Materials Handling and Storage Equipment (FEM) and
the applicable performance and safety standards referenced therein. Then, through proper
installation, application of correct operating procedures, and by practicing the recommended
maintenance procedures, you can expect maximum lifting service from the hoist.
It will likely be a long time before parts information found in the Parts List is needed. Therefore,
after the hoist is installed and you have completely familiarized yourself with operation and
preventative 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 and Model Number that are found on the nameplate attached to
the hoist as shown in 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.
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.
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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.
INDEX
SECTION I: GENERAL DESCRIPTION
PAGE
Paragraph 1-1. General………………………………………………………………………………………………. 4
Paragraph 1-2. Basic Construction………………………………………………………………………………….. 4
SECTION II: INSTALLATION
Paragraph 2-1. General……………………………………………………………………………………………….
Paragraph 2-2. Installing Hoist….…………….……………………………………………………………………..
Paragraph 2-3. Connecting Hoist to Electrical Service……………..……………………………………………..
Paragraph 2-4. Pre-Operation Checks…………….………………………………………………………………..
4
4
5
5
SECTION III: OPERATION
Paragraph 3-1. General……………………………………………………………………………………………….
Paragraph 3-2. Push Button Operation……………..……………………………………………………….………
Paragraph 3-3. Operating Precautions…………….………………………………………………………………..
7
7
7
SECTION IV: LUBRICATION
Paragraph 4-1 General……………………………………………………………………………………………….. 9
Paragraph 4-2 Changing Gearcase Oil……………………………………………………………………………... 9
Paragraph 4-3 Lubrication of Hoist Cable…………………………………………………………………………... 9
Paragraph 4-4 Lubrication of Limit Switch………..………………………………………………………………… 9
Paragraph 4-5 Lubrication of Geared Trolley Wheels and Pinions….…………………………………………… 9
Paragraph 4-6 Lubrication of Rope Guide………………..………………………………………………………… 9
Paragraph 4-7 Lubricant Specifications……………..……………………………………………………………… 11
SECTION V: INSPECTION AND PREVENTATIVE MAINTENANCE
Paragraph 5-1 General……………………………………………………………………………………………….
Paragraph 5-2 Inspection of Lower Block…………………………………………………………………………..
Paragraph 5-3 Inspection of Upper Block……………..……………………………………………………………
Paragraph 5-4 Inspection of Electrical Controls……………….…………………………………………………..
Paragraph 5-5 Inspection of Rope Guide……………..……………………………………………………………
Paragraph 5-6 Rope Inspection, Replacement & Maintenance……………..…………………………………..
Paragraph 5-7 Rope Reeving……………..…………………………………………………………………………
Paragraph 5-8 Inspection of Rope Drum & Shaft……………..…………………………………………………..
Paragraph 5-9 Inspection of Hoist Gearing……………….………………………………………………………..
Paragraph 5-10 Inspection of Motor Brake and Actuating Mechanism……………..…………………………..
Paragraph 5-11 Inspection of Traverse Drive……………..……………………………………………………….
Paragraph 5-12 Testing Block Operated Limit Switch……..……………..……………………………………….
Paragraph 5-13 Testing Over-Capacity Limit Switch………………………………………………………………
Paragraph 5-14 Testing Hoist………………………………………………………………………………………..
13
16
16
16
17
17
18
20
21
22
24
25
26
26
SECTION VI: TROUBLESHOOTING CHART…………………..……………………………………………………… 27
SECTION VII: ADJUSTMENTS
Paragraph 7-1 Motor Brake Adjustment……………..………………………………………………………………
Paragraph 7-2 Block Operated Limit Switch Adjustment……………..……………………………………………
Paragraph 7-3 Geared Rotary Limit Switch Adjustment……………………………………………………………
Paragraph 7-4 Over-Capacity Limit Switch Adjustment……………………………………………………………
Paragraph 7-5 Shortening of Push Button Cable……………..……………………………………………………
28
28
29
29
30
SECTION VIII: WIRING DIAGRAMS…………….………………………………………………………………………. 30
SECTION IX: PARTS LIST
Paragraph 9-1 General………………………………………………………………………………………………. 33
Paragraph 9-2 List of Parts Illustrations…………….……………………………………………………………… 33
SECTION I – GENERAL DESCRIPTION
SECTION II – INSTALLATION
1-1. GENERAL. SHAW-BOX “World Series” electric
hoists are wire rope and drum type hoists that are
manufactured with an integral trolley. These hoists
are all low headroom models with the rope drum and
upper block supported on opposite sides of the
beam, by the trolley frame. There are two basic
frame sizes each with two standard lifts: the “B”
frame handles capacities up to 5 tonne; and the “C”
frame handles capacities up to 10 tonne. The “B”
frame has an integral trolley with three different
flange width ranges available: 4-5/8” through 8”, 81/8” through 14”, and 14-1/8” through 20” wide with
a maximum flange thickness of 1-3/4”. The “C” frame
integral trolley has a flange range of 6” through 20”,
with the same flange ranges as the “B” frame above,
with a maximum flange thickness of 1-3/4”. The hoist
motor is 2-speed with a 4:1 ratio between high and
low speeds, as standard. The motor driven trolley
has two available speeds with 1-speed, 2-speed, or
variable frequency control.
Throughout this manual, you will see references to
the “B” or “C” frame hoists. If you are unsure about
which frame size you have, see Section IV,
Paragraph 4-2 for a simple gearcase measurement
to easily determine the size of your hoist.
1-2. BASIC CONSTRUCTION. SHAW-BOX “World
Series” hoists consist of a rugged steel frame, made
from structural tubing, which houses a lifting drum
and serves as the suspension means for the rated
hoist load. An aluminum gearcase, attached to one
end of the drum frame, houses a triple-reduction,
helical gear train. Applying power to the gearcase is
a 2-speed, AC hoisting motor with a 4:1 speed ratio
coupled with a 250% torque DC brake. High strength
wire rope and a covered lower sheave block act as
the load carrying means. Standard equipment
includes a rope guide, a rotary-geared limit switch to
limit hook travel in both up and down directions and
an overload capacity limit switch. An optional block
operated limit switch can be used to limit the upward
travel of the lower block. An integral trolley,
consisting of a 2-speed AC motor and a sealed
worm reducer, applies torque to the trolley wheels
through a cross-shaft and pinion arrangement, which
provides traverse motion to the hoist. A single NEMA
4/12 control enclosure houses both the hoist and
trolley electrical system controls. A push button
control station (purchased separately) for operating
the hoist is suspended on a wire strain cable
attached to the hoist.
2-1. GENERAL. SHAW-BOX “World Series” electric
hoists are lubricated and tested before being
shipped from the factory. To place a hoist in service,
install onto beam by adjusting appropriately for the
flange width, connect to electrical service and
perform pre-operation tests and checks.
WARNING
Only qualified personnel with proper
supervision shall install the hoist on the
monorail and perform the final preoperation inspection.
WARNING
Working in or near exposed energized
electrical equipment presents the danger
of electric shock.
TO AVOID INJURY:
DISCONNECT POWER AND IMPLEMENT
LOCKOUT/TAGOUT PROCEDURE BEFORE
REMOVING COVER OR SERVICING THIS
EQUIPMENT.
2-2. INSTALLING HOIST.
FIGURE 2-1. Trolley Wheel Spacing.
OPEN-END BEAM: If the trolley can be installed
directly from the end of the supporting beam, adjust
the spacing between the trolley wheel flanges to be
3/16”-1/4” greater than the exact width of the beam
flange (See Figure 2-1). Before adjusting the width
of the trolley frame, make sure to loosen the pinion
set screws nearest the traverse drive on the keyed
cross shaft and those on the traverse reducer. Do
not lose the keys for the pinion and reducer during
adjustment. Also, the electrical conduit/cable must
NOTICE
Loosen all electrical cable or conduit
attached to the frame and alignment bars
before adjusting trolley width. Ensure
that the electrical cable is not stretched,
pinched, twisted or otherwise damaged
when adjusting trolley width.
not be constrained when attempting to adjust the
trolley sides, in or out. The trolley width is adjusted
by loosening the jam nuts on the traverse drive side
of the threaded rods at each end of the hoist. If
necessary, lubricate the frame alignment bars with
penetrating oil before attempting to adjust trolley
width. The trolley side may then be pushed or driven
into position by turning the adjusting nuts on the
threaded rods. Adjust nuts on each side of the hoist
simultaneously, to avoid binding. After adjusting the
trolley to the proper width, tighten all adjusting nuts
and setscrews, and re-secure the electrical
conduit/cable. Verify that the geared wheels mesh
properly with the traverse drive pinions. Using proper
equipment, carefully lift the hoist and install on the
end of the beam. Lubricate the wheel gear and
pinion (WG, Section IV, Paragraph 4-3).
CLOSED-END BEAM: For trolleys which are to be
mounted along the span of a beam not having open
ends, the trolley must be adjusted in the same
manner as described above to a width that allows
clearance between the axle ends and the beam
flange. Using proper lifting equipment, the trolley and
hoist must then be lifted to the beam where it is to
be installed. Once in position, adjust the spacing
between the trolley wheel flanges to be 3/16”-1/4””
greater than the exact width of the beam flange (See
Figure 2-1). After tightening all adjusting bolts, set
screws, and all electrical conduit/cable clamps,
carefully set the trolley on the beam. Lubricate the
wheel gear and pinion (WG, Section IV, Paragraph
4-3).
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.
Follow ANSI/NFPA 70, state, and local electrical
codes including the grounding provisions thereof
when providing electrical service to the hoist.
Make electrical connections using the appropriate
wiring diagrams furnished with the hoist. Only
qualified journeyman electricians shall make any
electrical connections, including connections to
collectors or power cord.
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 ANSI/NFPA
70, or other applicable codes. If the
grounding method used is through the
trolley wheels, then each section of track
must be grounded by metal-to-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.
CAUTION
Power supply to hoist and trolley must
be the same voltage, frequency, and
phase that are specified on the hoist and
trolley nameplate.
2-4. PRE-OPERATION CHECKS.
a) Check Oil Level. (Figure 2-1) The gearcase
has been filled with oil to the proper level.
However, this should be re-checked before
operating the hoist.
Check oil level by removing the plug
indicated in Figure 2-1. When properly filled,
oil should be level with the bottom of the
tapped hole. Fill to this level with oil as
specified in Paragraph 4-2.e.
b) Check Push Button Operation and Phasing.
To properly check the phase of the hoist,
follow these steps:
(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.
low limits of lower block travel. Refer to
SECTION VII, Paragraph 7-3.
(2) Connect hoist to power source.
Operate “UP” button briefly to determine
direction of hook travel.
(4) If hook raises when “UP” button is
depressed, phasing is correct.
(2) A block operated upper limit switch can be
furnished as optional equipment on
SHAW-BOX “World Series” hoists. This
limit stop is factory set to stop the lower
block at the safest high position, guarding
against over travel and possible damage
to hoist. Minimal adjustments can be
made. When equipped with this option, the
hoist should be tested by jogging the lower
block against the limit switch actuator arm
to assure the switch is functioning
properly. When the lower block lifts the
actuator, the hoist will automatically stop.
If the lower block coasts through the limit
switch when lifting, a reversing switch will
automatically close and reverse direction
of motion to lowering.
(3)
(5) If hook lowers when “UP” button is
depressed, hoist is “Reverse Phased.”
TURN AND LOCK POWER OFF and
check the pushbutton wiring. If the
pushbutton was wired properly, correct the
problem by interchanging any two leads at
power source connection. Do not change
internal wiring of hoist.
WARNING
On three phase hoists, it is possible to
have “Reverse Phasing” causing the
block to lower when the “UP” button is
depressed. When this condition exists,
the automatic limit switch is inoperative
and hoist operation will be dangerous.
c) 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. Also
check to see that the lower block and rope
do not twist excessively. If it does twist to
the extent that two ropes rub against each
other, disengage the swaged rope end from
the frame anchor and twist the rope four or
five turns in a direction opposite to that
which the block turns. Reconnect rope to the
frame anchor, holding firmly to eliminate
rope twisting back to its original position.
Operate hoist up and down a few times. If
lower block still rotates excessively, repeat
process until twisting is corrected.
d) Lubricate Hoisting Cable. For longer cable
life, it is recommended that the cable be
lubricated at time of installation by applying
a heavy coating of lubricant CL (Paragraph
4-7) as outlined in SECTION IV, Paragraph
4-3.
e) Check Limit Switch Operation.
(1) A geared rotary type upper and lower limit
switch is provided as standard equipment
on SHAW-BOX “World Series” hoists. This
switch is adjustable and although preset
by the factory, it should be adjusted at
time of installation to the desired high and
f)
An over-capacity limit switch is provided as
standard equipment on SHAW-BOX “World
Series” hoists. This switch is adjustable and
although preset by the factory, it should be
adjusted at the time of installation to the
desired setting. Refer to SECTION VII,
Paragraph 7-4.
g) When first using the hoist and trolley,
operate with lighter loads through full travel
before applying maximum load.
WARNING
Damage to the hoist, a dropped load, and
injury may result if limit switches fail due
to improper use.
TO AVOID INJURY:
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 may be 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.
WARNING
SECTION III – OPERATION
3-1. GENERAL. Operation of SHAW-BOX “World
Series” 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 the load in small
increments, providing accurate positioning capability.
The push button station has a built-in interlock to
prevent
depressing
opposing
buttons
simultaneously.
Equipment covered herein is not
designed or suitable as a power source
for lifting or lowering persons.
a)
DO read applicable sections of FEM Section
IX, Series Lifting Equipment 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 the controls. If
opposite direction occurs, see Pre-Operation
Checks, Section II, Paragraph 2-4.b.
d)
DO make sure hoist limit switches function
properly.
e)
DO maintain firm footing when operating
hoist.
f)
DO make sure that the load slings or other
approved single attachments are properly
sized and seated in the hook saddle.
b) Depress push button marked “DOWN” to
lower load.
g)
DO make sure that the hook latch is closed
and not supporting the load.
c) Depress push button marked “RIGHT” to
traverse one direction.
h)
DO make sure that load is free to move and
will clear all obstructions.
d) Depress push button marked “LEFT” to
traverse in the opposite direction.
i)
DO take up slack carefully, check load
balance, lift a few inches and check load’s
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.
When first using the 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.
e) On two-speed hoist or trolley motions, partial
depression of a button operates hoist or
trolley at slow speed; depressing button
completely operates hoist or trolley at full
speed.
CAUTION
Excessive
“jogging”
will
cause
premature burning of contact tips, motor
overheating, and premature brake wear.
3-3. OPERATING PRECAUTIONS. 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.
q)
DO use hook latches.
kk)
DO NOT remove or obscure the warnings
on the hoist.
r)
DO apply lubricant to the wire rope as
recommended.
ll)
DO NOT adjust or repair a hoist unless
qualified to perform hoist maintenance.
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 properly.
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 wire 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)
aa)
bb)
cc)
nn)
DO NOT allow personnel not physically fit or
properly qualified, to operate hoist.
oo)
DO NOT operate hoists unless hook moves
in the same direction as indicated on the
push button. If opposite direction occurs,
see pre-operation checks, Section II
Paragraph 2-4.b.
pp)
DO NOT operate hoist unless limit switches
are operating properly.
qq)
DO avoid operating hoist when hook is not
centered under hoist. Avoid side pulls and
swinging of load or load hook when traveling
hoist.
DO NOT apply the load to the tip of the
hook.
rr)
DO operate hoist within recommended duty
cycle and DO NOT “jog” unnecessarily.
DO NOT operate unless load is centered
under hoist.
ss)
DO conduct regular visual inspections for
signs of damage and wear.
DO NOT allow your attention to be diverted
from operating the hoist.
tt)
DO NOT operate hoist with hooks that have
opened up. See Section V, Paragraph 5-2.f.
DO NOT operate the hoist beyond limits of
wire rope travel.
uu)
DO provide supporting structure that has an
appropriate design factor based on the load
rating and dead weight of the hoist. If in
doubt of the supporting structure’s strength,
consult a structural engineer.
dd)
DO NOT use limit switches as routine
operating stops unless recommended. They
are emergency devices only.
ee)
DO NOT use hoist to lift, support, or
transport people.
ff)
DO NOT lift loads over people.
gg)
DO NOT leave a suspended load unattended unless specific precautions have
been taken.
hh)
DO NOT allow sharp contact between two
hoists or between hoist and obstructions.
ii)
DO NOT allow the rope or hook to be used
as a ground for welding.
jj)
DO NOT allow the rope or hook to be
touched by a live welding electrode.
mm) DO NOT attempt to lengthen the wire rope
or repair damaged wire rope.
WARNING
DO NOT operate hoist with the hoisting
rope out of the drum grooves. Such
operation may result in damage to the
rope guide and rope and could result in
the rope breaking. This may result in
dropping the load that can cause damage
to equipment and injury to operator or
other personnel. Hoist rope will remain in
the drum grooves during operation under
normal operating conditions, however,
slack or kinked rope, excessive side
pulls, swinging or jerking of load, or
similar abuse, may cause damage to the
rope guide causing the rope to leave the
grooves.
vv)
DO NOT use hoist in location that will not
allow operator movement to be free of the
load.
ww) DO, when starting to lift, move the load a
few inches at which time the hoist should be
checked for proper load holding action. The
operation shall be continued only after the
operator is assured that the hoist is
operating properly and that the load is
supported
in
the
center
of
the
base/bowl/saddle of the hook.
xx)
DO observe recommended inspection and
maintenance procedures.
yy)
DO use common sense and best judgment
whenever operating a hoist.
WARNING
Avoid skin contact with Mobilsol A. In
case of skin contact: dry wipe the skin,
cleanse the area with a waterless hand
cleaner
and
follow
by
washing
thoroughly with soap and water.
c)
d)
Reinstall drain plug.
Remove oil level plug from front of gearcase
cover.
SECTION IV – LUBRICATION
4-1. GENERAL. The lubrication services outlined in
Paragraphs 4-3 thru 4-6 should be performed before
initial operation of the hoist. The lubrication services
outlined in Paragraphs 4-2 thru 4-6 should be
performed at regular intervals at least every six (6)
months, coinciding with spring and fall seasons is
recommended. The reason for this is that on hoists
installed outside or in unheated areas a “cold test” oil
is required in such (below freezing) climates making
seasonal changes necessary.
4-2. CHANGING GEARCASE OIL.
FIGURE 4-2. Gearcase Width Illustration.
e)
Refill through filler hole to proper level
(bottom of oil level plug hole) using GCOH
(Paragraph 4-7). The amount of oil required
depends on overall size of gearcase; two
sizes are used for “World Series” hoists. To
determine size and amount of oil to add,
measure width of hoist gearcase (see Figure
4-2). The “B” Frame measures 9-3/4” and
requires approximately 5 quarts of oil. The
“C” Frame’s width is 12-1/2” and requires
approximately 11 quarts of oil.
4-3. LUBRICATION OF 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 CL (Paragraph 4-7).
4-4. LUBRICATION OF LIMIT SWITCH. Provide a
light film of grease MPG (Paragraph 4-7) on bevel
gear of rotary geared limit switch.
FIGURE 4-1. View of Hoist Showing Location of
Name Plates and Oil Plugs.
a)
Add 5% solution of Mobilsol A (or
equivalent) to the oil and run for a short
time. This will clean components and hold
particles in suspension for draining.
b)
Remove oil drain plug from bottom of
gearcase and drain oil out. Dispose of oil in
accordance with local environmental codes.
4-5. LUBRICATION OF GEARED TROLLEY
WHEELS AND PINIONS. At installation and
periodically, apply grease WG (Paragraph 4-7) to the
traverse drive pinions and the gears of the trolley
wheels.
4-6. LUBRICATION OF ROPE GUIDE
a) Maintenance. The rope guide is made of a
molded self-lubricated reinforced nylon
material. It is lubricated prior to installation
at the factory and requires only periodic
inspection.
(1) Periodically
re-grease
with
MPG
(Paragraph 4-7) by applying grease to the
leading edge of the guide and rope drum.
(2) Every 6 months, the rope guide should be
removed per Section V, Paragraph 5-5,
cleaned and inspected. When reassembled, the rope guide should be thoroughly
greased with MPG (Paragraph 4-7) and
the hoist run up and down to lubricate both
the drum and the wire rope.
NOTES
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4-7. LUBRICANT SPECIFICATIONS.
GCOH
Gear Case Oil.
Hoist Gear Case.
SG
Spline Grease
AGMA Lubricant
Viscosity @ 100° F
Viscosity Index
Pour Point
Mobil  Oil Corp.
Shell  Oil Co.
Texaco  Inc.
AMBIENT TEMPERATURE
-20q to 50qF
50q to 125qF
125q to 250qF
(-29q to +10qC)
(10q to 52qC)
(52q to 121qC)
No. 6
1335 - 1632 SUS
154
-40°F
Mobil  SHC 632
Omala RL 320
Pinnacle 320
No. 7 EP
1919 - 2346 SUS
95
20°F
Mobilgear  634
Omala  460
Meropa  460
No. 7
1919 - 2346 SUS
158
-37°F
Mobil SHC 634
Omala RL 460
Pinnacle 460
NLGI Grease
ASTM D217 Worked
Penetration
Dropping Point
Base
Mobil  Oil Corp.
320°F (160°C)
Lithium
---------------------------Mobilux  EP 111--------------------------
WG
Wheel Gear and
Pinion Grease
Viscosity @ 100° F
Mobil  Oil Corp.
Texaco  Inc.
25,000 SUS (contains diluent)
---------------------------Mobiltac  375 NC----------------------------------------------------Crater H  --------------------------
CL
Cable Lubricant.
No Specification
Amoco  Oil Co.
Mobil  Oil Corp.
Sun  Oil Co.
Texaco  Inc.
----------------------------Amovis  5-X -----------------------------------------------------Mobilarma  798----------------------------------------------Sunoco  Wire Rope Lubricant----------------Crater A
Texclad  2
AGMA Lubricant
Viscosity @ 100° F
Viscosity Index
Pour Point
Amoco  Oil Co.
Mobil  Oil Corp.
Shell  Oil Co.
Sun  Oil Co.
Texaco  Inc.
No. 1
No. 2
193 - 235 SUS
284 - 347 SUS
60 Min.
60 Min.
-20°F (-29°C)
10°F (-12°C)
Rykon  Oil 46
American Industrial Oil  68
----------------------Mobil  DTE Oil Heavy------------------------Rotella  10W
Rotella  10W-30
Sunvis  932
Sunvis  968
Rando  Oil 46
Rando  Oil 68
Wire Rope
Lubricant
GO
General Oil.
General Oiling to
Prevent Rusting
and Provide
Limited Lubrication
for Points Not
Considered Normal
Wear Points.
MPG
Multipurpose
Grease.
Grease Lubricated
Wear Points
Provided with
Fittings and Grid or
Gear Type Flexible
Couplings.
NLGI Grease
6ASTM Worked
Penetration
Dropping Point
Base
Amoco Oil  Co.
Mobil Oil  Corp.
Shell  Oil Co.
Sun  Oil Co.
Texaco  Inc.
No. 1
310 - 340
No. 1
310 - 340
No. 2
265 – 295
360°F (182°C)
360°F (182°C)
Lithium
Lithium
Amolith  Grease 1 EP
Amolith  Grease No. 2 EP
Mobilith  AW 1
Mobilith  AW 2
-------------------------Retinax LC----------------------------------Prestige  741 EP
Sunoco  Multipurpose 2 EP
Multifak  EP 1
Multifak  EP 2
4-7. LUBRICANT SPECIFICATIONS
(CONTINUED).
GCOT
Gear Case
Oil.
Traverse
Gear Case.
AGMA Lubricant
ISO Viscosity Grade
Amoco  Oil Corp.
Mobil  Oil Corp.
Shell  Oil Co.
Texaco  Inc.
AMBIENT TEMPERATURE
15q to 60qF
(-9q to +16qC)
50q to 125qF
(10q to 52qC)
125q to 250qF
(52q to 121qC)
No. 7 or 7C
(Compounded)
460
Worm Gear Oil
Mobil SHC 634
Synthetic,
Mobil  600W
Valvata  J460
Meropa  460
No. 8 or 8C
(Compounded)
680
Cylinder Oil #680
Mobil SHC 634
Synthetic,
Extra Hecla Super
Valvata J680
Meropa  680
Refer to SHAW-BOX
Hoist Field Service
Department for
Gearcase Operating
Temperatures above
125qF.
NOTES
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SECTION V – INSPECTION AND
PREVENTATIVE MAINTENANCE
5-1. GENERAL. All SHAW-BOX “World Series”
hoists are inspected and tested at the factory.
Regular in-service inspection and preventative
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
preventative 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
a 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 630 total 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 63 percent of rated load. For
more details regarding hoist duty cycles, please
reference FEM Section IX, Series Lifting Equipment.
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 the factory’s Field Service
Department for advice regarding 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 15 of this manual is a recommended
Inspection Schedule and Maintenance Report form
that 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 on page 14 of this
manual 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 that may exist. However,
written, dated and signed inspection reports should
be maintained particularly on critical items such as
hoist hooks, hoisting rope, 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 person responsible for hoist operation and
safety, or whoever reviews the inspection reports,
that deficiencies exist. The designated person will
check all deficiencies as listed and re-examine 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.
All SHAW-BOX “World Series” hoists are equipped
with a Hoist Monitor card, which is wired into the
control circuit in the control enclosure. This
equipment consists of a circuit board, a serial
communications port, and onboard memory, which
will retain data even when hoist is removed from
power. The Hoist Monitor records the most recent
hoist activities including all normal operation events,
motor starts, over-capacity lifts and thermal overload
events. In addition, the Hoist Monitor records the
total cumulative operating time and motor starts for
the life of the equipment. Each monitor card is
programmed with the equipment serial number at
the factory.
Data may be downloaded from the monitor, via the
serial communications link, by a certified technician.
Monitor card data may be used in determining
equipment usage, application assessment and
troubleshooting, as well as an aid in determining the
useful life of the equipment.
RECOMMENDED INSPECTION AND MAINTENANCE SCHEDULE
TIME INTERVAL
Daily or start of
*
each shift (visual)
1 Month
1-3 Months
*
*
6 Months
*
*
*
*
*
*
Annually
*
10 years elapsed
time or 6300
hours “on” time
*
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 per Paragraph 5-6 and lubricate per Paragraph 4-3.
ELECTRICAL CONTROLS – Inspect per Paragraph 5-4. Check hoist gearcase oil level
– add oil as required per Paragraph 4-2.e.
LOWER BLOCK –Inspect per Paragraph 5-2.
UPPER BLOCK –Inspect per Paragraph 5-3.
ROPE GUIDE-Inspect per Paragraph 5-5.
OVER-CAPACITY LIMIT SWITCH-Inspect per Paragraph 5-13.
BLOCK OPERATED LIMIT SWITCH (if equipped)-Inspect per Paragraph 5-12.
Lubricate hoist cable per Paragraph 4-3. Lubricate upper and lower hook block,
Lubricate outboard bearing cartridge at grease fitting, Add a light film of MPG grease to
the bevel gear in the screw type limit switch per Paragraph 4-7.
Complete inspection. Motor brake and actuating mechanisms inspected and adjusted
per Paragraph 5-10. Inspect hooks with crack detecting procedures per Paragraph 5-2.
Complete inspection, disassembly, and maintenance required. It is recommended that
your SHAW-BOX repair Station be contacted for this service.
NOTES
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INSPECTION SCHEDULE AND MAINTENANCE REPORT
HOIST SERIAL NO. (Manufacturer’s) ____________________
RATED LOAD ____________________
TYPE ___________________________
VOLTAGE _______________________
Motor
Motor Brake
Couplings
Gears, Shafts, & Bearings
HOIST
Upper Block
Lower Block
Hook & Throat Opening
Hoist Rope
{
{
{
{
{
{
§
§
Rope Drum
Rope Guide
Guards
CONTROL
STATION OR
PUSHBUTTON
Limit Switches
Wiring
Motor
Brake (when so equipped)
Couplings
TROLLEY
{
Pushbutton
Gears, Shafts, & Bearings
{
{
{
{
Frame
Wheels
Bumpers
Guards
Conductors
RESISTORS
Hoist
RUNWAYS
Collectors
Monorail Joints
Trolley
Monorail
Main Conductors
Main Collectors
MISC.
General Condition
Load Attachment Chains
Rope Slings & Connections
Change Gearcase Lubricant
Grounding Faults
*
{
{
{
{
{
§
§
CLEANING OR
PAINTING REQUIRED
LUBRICATION
REQUIRED
(Low Oil or Grease,
Rust or Corrosion)
REPLACEMENT
REQUIRED
(Worn or Damaged)
REPAIR REQUIRED
(Loose Parts or Wires)
GOOD
ADJUSTMENT
REQUIRED
ANNUAL
MONTHLY
COMPONENT,
UNIT OR PART
…
…
CONDITION
*Recommended (Check column best indicating condition when part or
Inspection
unit is inspected. Use note column to the right if
Interval
condition is not listed below.)
SEMI-ANNUAL
LOCATION
COMPONENT, UNIT OR PART
and location
CUSTOMER CRANE IDENTITY NO. __________________________
LOCATION IN PLANT
ANNUAL
THIS INSPECTION IS: MONTHLY
SEMI-ANNUAL
INSPECTED BY:______________________________DATE:__________
…
CORRECTIVE ACTION NOTES
(Indicate corrective action taken during inspection and
note date. For corrective action to be done after
inspection, a designated person must determine that
the existing deficiency does not constitute a safety
hazard before allowing unit to operate. When
corrective action is completed, describe and note date
in this column.)
DATE
Record Hook Throat Opening:
X
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
See text for DAILY & WEEKLY REQUIREMENTS.
INSPECTION INTERVAL.
Typical Inspection Schedule and Maintenance Report form.
§SIGNED & DATED REPORT - OSHA.
X
MAGNETIC PARTICLE OR EQUIVALENT EXAMINATION REQUIRED.
User must adjust Inspection Interval and components to suit his individual conditions and usage.
12375gwr
WARNING
Do not operate a hoist having unusual
vibrations, sounds, or with anything
visibly or otherwise wrong. Danger may
be present that the hoist operator
cannot see. Determine and correct the
cause of unusual conditions and make
certain hoist can be operated safely.
5-2. INSPECTION OF LOWER BLOCK.
Refer to the Section IX, Figure 9-4.
Lower Block Assembly.
a) Check lubrication of all parts. Also lubricate
the shank of the hook that passes through
the crosshead. If the thrust bearing is
removed, apply MPG grease (Section IV,
Paragraph 4-7).
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 the spring pin holding the
hook nut to the hook is securely in position.
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 nondestructive test methods.
h) Check wear of the hook, especially at the
saddle and replace if worn more than 10%
of original dimensions.
5-3. INSPECTION OF UPPER BLOCK.
Refer to the Section IX, Figure 9-5.
Upper Block Assembly.
a) Check upper block sheaves 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, bearing and
hanger pins are free of foreign material.
Bearings without grease fittings are
lubricated for the life of the bearing and
require no further lubrication.
c) Make certain that the rope retention bolts
are not bent, loose or otherwise distorted;
bolts must have close clearance to sheave
flange to keep rope in sheave grooves.
e) If hook is equipped with a hook latch or
rotational lock, check to determine that they
are in good operating condition.
5-4. INSPECTION OF ELECTRICAL CONTROLS.
f)
Arrangement of electrical control equipment varies
with the type of control, physical space and the
optional control features ordered with the hoist.
Check throat opening of the hook. (Refer to
Figure 5-2.) 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. We
suggest that a gage block properly
identified to the hoist, similar to the one
shown in Figure 5-2, be made for each
hook for use in these measurements.
Note the location in the electrical enclosure of the
control circuit fuse, transformer, limit stop switches
and the hoist contactors. Trolley contactors and
optional hoist and trolley fuses are also located in
this enclosure.
Use wiring diagrams 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 (OFF) before
opening hinged control enclosure cover
mounted to the counterweight.
FIGURE 5-2 Gage Block.
a) Open hinged control panel enclosure cover
mounted to the counterweight 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. INSPECTION OF ROPE GUIDE.
a) General. The rope guide is intended to help
prevent the rope from “back-winding” and to
hold the rope in the proper groove. Side pulling
and excessive load swing will severely damage
the rope guide and must be avoided.
WARNING
Side pulling and excessive load swing
will severely damage the rope and rope
guide. Failure of these components may
result in injury.
parts list in Section IX.
(1) Remove socket head cap screws and lock
washers (Items 6 and 7). Remove drum
frame rod (Item 8).
(2) Remove shoulder bolts (Item 3) and
compression springs (Item 4). The two
halves of the rope guide body (Item 1) can
now be pulled off the drum separately.
When reassembling be sure that the half
with the rope slot is on the top half of the
drum.
WARNING
Once shoulder bolts are removed, the
halves will separate and, if not properly
supported, the halves could fall.
(3) Carefully unhook the rope tensioning spring
(Item 5), which is under tension.
WARNING
The rope tensioning spring is under
considerable tension; use caution when
unhooking to avoid injury.
(4) Remove the split plastic shroud (Item 2)
from the drum. When reassembling the
rope guide, be sure the plastic shroud (Item
2) fits snugly in the rope guide body
groove.
(5) Thoroughly
clean
components.
and
inspect
all
(6) Follow steps in reverse to reassemble. Be
sure to re-grease the rope guide with MPG
(Paragraph 4-7), after assembling.
5-6. ROPE INSPECTION, MAINTENANCE AND
REPLACEMENT.
WARNING
Wire Rope improperly handled or
abused can create a SAFETY HAZARD.
Read and comply with inspection,
maintenance
and
replacement
information given herein.
Figure 5-3. Rope Guide Assembly.
b) Disassembly. Refer to Figure 5-3. For further
assistance in locating components, refer to the
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.
Inspections should take place at the most
active sections of the rope, which may be
identifiable through visual inspection of
rope color. Ropes will wear more quickly in
areas that are more frequently in contact
with the running sheaves and drum.
(1) Replace wire rope if the number of visible
broken wires exceeds 13 over a length of
6 times the nominal diameter (6d) or
exceeds 26 wires over a length of 30d.
(2) Replace wire rope, if a complete strand
has broken.
(3) Replace wire rope, if rope exhibits
swelling, bruises, permanent bends,
kinks, crushing, bird-caging or especially
heavy wear.
(4) Replace wire rope, if rope has suffered
heat damage from any cause.
Special attention should be exercised when
inspecting rope normally hidden during
inspecting procedures.
Please refer to FEM Section IX, Series Lifting
Equipment,
namely
Section
9.661,
“Dimensions and Design of Rope Reeving
Components” and ISO 4309, “Wire Ropes Care, Maintenance, Installation, Examination
and Discard”, for illustrations and definitions
when following the above guidelines for rope
inspection.
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 that will scrape, nick, crush,
or induce sharp bends in the rope.
WARNING
Use only factory-approved rope with
swaged wire rope socket.
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.
Figure 5-4. Correct Method of Measuring Rope.
(5) Rope corrosion and/or rust formation,
internal or external.
(6) Effects from improper lubrication.
When first using hoist after rope
replacement, break in rope by operating
under lighter loads to full travel before
applying maximum load.
5-7. ROPE REEVING.
a) General. Place reel on stand with shaft
through the center of reel so rope can be
pulled straight out with reel rotating.
(7) Rope being idle for one month or more
due to shutdown or inactivity.
CAUTION
It is imperative that rope reel or coil
rotates as rope unwinds. If coil or reel
does not rotate the wire will be twisted
as it is uncoiled and kinking will result.
A kinked rope may be damaged and
unsafe for maximum service.
b) Before removing the old rope, refer to
reeving diagram, Figure 5-5. To assist with
re-reeving your hoist, refer to the reeving
diagram and corresponding paragraph that
describes the reeving procedure.
'580
833(5
%/2&.
(5) Remove two (2) rope retention bolts and
nuts from upper block yoke.
(6) Remove one retaining ring on upper
block to allow removal of upper block
sheave pin.
(7) Securely grasp the upper block sheave
before carefully sliding the sheave pin
out. Note that two spacers will also be
released as the pin is removed.
(8) Remove wire rope from sheave.
(9) Remove cotter pin from dead end anchor
pin. Securely grasp the swaged wire rope
before removing the pin.
(10) Remove rope guide per Section V,
Paragraph 5-5.
/2:(5
%/2&.
FIGURE 5-5. Reeving Diagram – 4 Part SingleReeved. (Note: Arrow on Drum Indicates
Direction of Drum when Lowering.)
c) Removing old rope. Please refer to Section
IX to assist in locating components referred
to in the following paragraphs.
(1) Lower the lower block to a scaffold 6 to 7
feet below hoist to relieve tension on wire
rope. (Lower block may be lowered to the
floor if desired; however, to handle less
weight and for ease of reeving, adequate
scaffold
below
the
hoist
is
recommended.)
CAUTION
Be certain all personnel are clear of
hoist as components, hardware, and
wire rope are removed from hoist.
(2) Remove the cap screws and hex nuts
that retain the lower block sheave covers.
Remove covers.
(3) Remove retaining rings from lower block
sheave pin.
(4) Slide out lower block sheaves and
remove wire rope.
(11) Make certain all personnel are clear of
hoist and operate hoist “DOWN” to
completely unwind all wire rope from
drum. Stop hoist so all (3) rope clamps
are accessible. Remove rope clamps and
wire rope from drum.
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.
d) Installing new rope.
(1) Thread rope to drum from trolley frame
side then secure with rope clamps as
follows:
(a) Make sure that the rope clamp
groove size utilized as marked
directly above the groove matches
the rope size for your hoist (9mm on
the “B” Frame and 12mm on the “C”
Frame).
(b) With the rope lying in the bottom of
the drum groove, begin by tightening
the rope clamp at the tail end of the
rope. Torque to 25-30 ft-lbs.
(c) With tension on the rope keeping it
properly seated in the drum groove,
torque the remaining two (2) rope
clamps in sequence to 25-30 ft-lbs.
(2) With all personnel clear of hoist – TURN
ON POWER.
(3) Operate hoist “UP” guiding six (6) wraps
of new rope into drum grooves with
gloved hand.
WARNING
The hoist must be removed from service
and placed on the ground for any
maintenance that requires removal of
the output shaft assembly or drum.
(4) Re-install rope guide over rope in rope
drum grooves as shown in Figure 5-3.
and outlined in Section V, Paragraph 5-5.
Continue lubricating as rope is spooled
onto the drum until about 28’-0” remain
unwound.
(5) With outer lower block covers removed,
thread the wire rope through the sheaves
of the upper and lower block as shown in
Figure 5-6.
(6) Attach swaged rope end to the dead end
anchor pin and fasten with the new cotter
pin provided with the rope.
(7) Replace the lower block sheave covers.
(8) Lubricate cable per Paragraph 4-3.
e) Checking for and removal of rope twisting.
(1) To remove rope twist in four part single
reeved hoists:
(a) Observe direction block tends to
rotate.
(b) Lower the block to a low position
and TURN OFF (lock out) POWER.
(c) Remove swaged fitting from anchor
pin and rotate rope several turns in
a direction tending to correct block
rotation.
(d) TURN ON POWER; raise and
lower the block several times to
feed the correcting twist in the rope
through the reeving.
5-8. INSPECTION OF ROPE DRUM AND SHAFT.
a) To remove the rope drum, remove the rope
guide and hoisting cable, as outlined in
Section V, Paragraphs 5-5. and 5-7.c.,
respectively.
Figure 5-6. Drum Frame & Geared Limit Switch.
b) Remove the geared limit switch or
disconnect the wires so that the electrical
cable will not inhibit removal of the drum.
(see Figure 5-6).
c) Remove the unit from the beam, place it on
the ground, and provide adequate means
to support the drum before removing the
frame rod nut and stiffener plate hardware
at the outboard drum frame end (see
Figure 5-6).
d) Remove the retaining ring securing the
outboard end trolley wheel to the axle.
Remove wheel to gain access to drum
mounting hardware.
e) The hardware attaching the drum frame to
the hoist and trolley frame may then be
removed.
f)
Keeping the drum level, remove the drum
from the splined output shaft at the gear
case end.
g) Inspect the gearcase output shaft and drum
splines for wear.
h) Before re-assembling, by reversing above
instructions, make sure to apply a liberal
amount of SG (Paragraph 4-7) spline
grease to both the output shaft and drum
splines. Torque “B” frame drum mounting
bolts to 170 ft-lbs. and “C” frame drum
mounting bolts to 325 ft-lbs.
5-9. INSPECTION OF HOIST GEARING.
(3) Drain the oil from the gear case per
Section IV, Paragraph 4-2.
(4) Check to make sure that the two (2) hex
bolts securing the gear case to the drum
frame bracket are in place and tightened
securely. These bolts will be supporting
the gear case after the cover is removed.
Figure 5-7. Hoist Gear Case Assembly.
a) General. The hoist gear case is a triplereduction, splash lubricated, vertically split,
cast aluminum case and cover. A helical
gear train provides smooth and quiet
hoisting operation. The gear shafts are
supported with ball and roller bearings
housed in the back of the case and in the
cover. The input pinion is integrated onto
the motor shaft. An oil seal housed in the
gear case at the motor input seals the
motor shaft as it passes into the gear case.
Since the entire motor shaft is submerged
in oil, anytime the motor is removed, the oil
must be drained from the gear case. All
pinions are integral with their shafts while
the gears are keyed and pressed onto their
shafts, with exception of the integral output
shaft. The output shaft passes through an
oil seal in the back of the gear case and
drives the drum by means of a crowned
spline. One end of the rope drum is
supported on this output shaft.
b) Inspection and Disassembly.
Gearcase. (See Figure 5-7.)
(1) Lower hook block to the floor and relieve all
load from ropes.
(2) Make sure power to hoist is off and locked
out.
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.
(5) Provide adequate means to support the
gearcase cover. Once the cover is
supported, remove the four (4) socket
head cap screws that protrude through
the cover and gearcase. Remove the
smaller socket head cap screws and lock
washers holding the cover to the
gearcase. Carefully draw the cover
directly away from the gear case, as
damage to this surface will prevent the
gasket from sealing properly. If needed,
lightly tap on the top and bottom cover
tabs to release. As the cover is removed,
ensure that all gear and shaft assemblies
remain in the case and are fully
supported by the gear case bearings.
WARNING
If output shaft assembly is pulled out of
the gear case with the cover, it will
disengage from the drum allowing the
drum to drop. Be certain all shaft
assemblies stay in the case.
(6) If it is necessary to remove the output
shaft assembly from the gear case, the
rope drum must first be removed from the
hoist. See Section V, Paragraph 5-8.
WARNING
The hoist must be removed from service
and repaired on the ground for any
maintenance that requires removal of
the output shaft assembly or drum.
Only once the output shaft is free of the
rope drum, can the output shaft assembly
be safely removed from the gear case.
Provide an adequate means to support
this shaft and gear assembly before
removing, as it weighs approximately 55
lbs. (“C” Frame Hoist).
(7) The pinion shaft and gear assemblies
may be removed as necessary.
(8) Inspect all gears, pinions, bearings, and
the output shaft spline for wear, pitting, or
mechanical
damage.
Replace
as
necessary. See Section IX, Figure 9-2 for
replacement parts. It is recommended
that gears and pinions only be replaced
as sets. Thoroughly clean the output
shaft external spline teeth before
reassembly.
(9) Assembly is opposite of removal. Use a
new gasket. Do not attempt to assemble
the cover to the gear case without a
gasket, as the spacing between bearings
will be reduced. Severe damage to the
hoist will occur if no gasket or the wrong
gasket is used. Refill gear case with new
lubricant per Section IV, Paragraph 4-2
before use. Using SG (Paragraph 4-7),
grease the spline teeth on the output
shaft before reinstalling rope drum.
(10)Test hoist per Section V, Paragraph 5-13
to ensure proper lubrication.
Hoist Motor.
(1) Lower hook block to the floor and relieve all
load from ropes.
(2) Make sure power to hoist is off and locked
out.
(3) Drain the oil from the gear case per
Section IV, Paragraph 4-2.
(4) Disconnect the wiring and conduit from
the motor junction box.
(5) Provide a means to support the hoist
motor. The hoist motor weighs approximately 175 lbs. and must be held
horizontal while removing and installing.
(6) Once the motor is properly supported,
remove the hardware fastening it to the
gear case. Carefully withdraw the motor
horizontally straight out from the gear
case. Do not tip or move the motor from
side to side.
(7) Replace the motor shaft seal using an
appropriate
seal
driver.
It
is
recommended that a new seal be
installed each time the motor is removed
from the case.
IMPORTANT!
(8) Before reinstalling the motor, pack the
gear teeth with MPG grease (Paragraph
4-7) and wrap the gear teeth with a
number of layers of Teflon tape to protect
the seal lip from being damaged by the
gear teeth. Coat the seal lip and the
motor shaft with MPG grease.
NOTICE
Failure to use a factory replacement
seal will cause premature seal failure
due to specific lip material requirements
that must be met.
(9) Install the motor to the gear case. The
motor shaft must be in line with the seal
bore and perpendicular to the mounting
surface before attempting to insert the
shaft through the seal. The motor shaft
must remain horizontal and not rock up
and down or side-to-side while installing
the motor or seal damage will occur. It
may be necessary to rotate the rope
drum slightly to align the gear teeth to
mesh with the teeth on the motor shaft.
Ensure that the motor seats properly into
the rabbet fit machined in the gear case.
Fasten the motor to the gear case.
(10) Reconnect the conduit and power
leads to the motor. See Section VIII
and refer to the specific wiring
diagrams shipped with your hoist.
(11) Refill gear case with lubricant per
Section IV, Paragraph 4-2.
(12) Test hoist to ensure proper operation
per Section V, Paragraph 5-13.
5-10. INSPECTION OF MOTOR BRAKE AND
ACTUATING MECHANISM.
a) General Operation. The hoist brake is an
electro-magnetically released, spring set nonadjustable brake. Torque is generated by
compressing a friction disk between the
stationary motor end bell and the spring loaded
brake armature. The friction disk is fixed to and
rotates with the motor shaft. When the magnet
coil is energized, the armature plate is pulled
across the air gap. The friction disk is carried
by a splined hub that permits axial movement
when the brake is released. This axial
movement releases both sides of the friction
disk from their mating stationary surfaces and
allows the friction disk to rotate freely when the
brake is energized. When power is removed
from the magnetic coil, the compression
springs push the armature against the friction
disk and the other side of the friction disk
against the motor end bell generating the
torque necessary to stop the hoist machinery
and hold the load.
It will be necessary to compensate for the
friction disk wear when a greater amount of
hook movement (drift) is noticed when
stopping. There is no torque adjustment of the
brake. Friction disk wear can only be
compensated for by resetting air gap.
must be reset.
(6) To measure the thickness of the friction
disk, it is necessary to remove the brake
body from the motor end bell. Remove
the three (3) brake mounting bolts and
draw the brake body away from the
friction disk. Carefully set the brake body
down on the motor shaft directly in front
of the fan. Draw the friction disk away
from the end bell and measure the
thickness across the friction surfaces. If
the friction disk thickness is less than the
minimum shown in Table 1, it must be
replaced. See Section IX, Figure 9-8. If
the friction disk thickness is within the
allowable, reassemble the brake body to
the motor end bell and torque the
mounting bolts to the value shown in
Table 5-1. Whenever the friction disk is
replaced, it is necessary to reset the air
gap.
Hoist
Mounting Bolt
Torque
Nominal Air Gap
Figure 5-8. Motor Brake.
b) Friction Disk
Adjustment.
Inspection
and
Air
Gap
(1) Lower hook block to the floor and relieve
all load from ropes.
(2) Make sure power to the hoist is off and
locked out.
WARNING
Check to be certain main power switch
is locked in open position (OFF), before
removing fan shroud.
(3) Remove the four (4) bolts attaching the
fan shroud to the motor and remove the
fan shroud. See Figure 5-8.
(4) Carefully roll the large O-ring from the
groove over the air gap back toward the
magnet body. Do not excessively stretch
this O-ring.
(5) Measure the air gap using feeler gages.
If the air gap exceeds the maximum
value shown in Table 5-1, the air gap
"B" Frame "C" Frame
7.5 ft-lbs. 18 ft-lbs.
(10 Nm)
(25 Nm)
0.016 in. 0.016 in.
(0.4 mm) (0.4 mm)
Maximum Air Gap 0.027 in. 0.035 in.
(0.7 mm) (0.9 mm)
Minimum Brake
0.374 in. 0.472 in.
Disk Thickness
(9.5 mm) (12.0 mm)
Table 5-1. Motor Brake Data.
(7) To reset the air gap, begin by releasing
the (3) mounting bolts 1/2 turn. Turn the
hollow spacer bolts into the magnet body
approximately 1/4 turn. Retighten all
three mounting screws. Measure the air
gap at a minimum of three places around
the circumference. Threading the hollow
spacer bolts into the magnet body will
decrease the air gap, while backing these
spacer bolts out of the magnet body will
increase the air gap. Repeat this step, as
necessary, until the required air gap is
achieved. The air gap must be the same
all the way around the brake. Once the
air gap is correct, torque the mounting
bolts to the value shown in Table 5-1.
(8) Replace the large O-ring over the air gap
and reassemble the fan shroud to the
motor.
(9) Test hoist per Section V, Paragraph 5-13
to ensure proper brake operation.
c) Brake Disassembly.
(1) Lower hook block to the floor and relieve
all load from ropes.
(2) Make sure power to the hoist is off and
locked out.
(3) Remove the four (4) bolts attaching the
fan shroud to the motor and remove the
fan shroud. See Figure 5-9.
5-11. INSPECTION
DRIVE.
OF
HOIST
TRAVERSE
(4) Remove the snap ring behind the plastic
fan. Carefully remove the fan and key
from the motor shaft. Remove the snap
ring in front of where the fan was
mounted.
(5) Disconnect the two wires from the
terminal block on the magnetic body.
(6) Remove the three mounting bolts that
attach the brake body to the motor end
bell and remove the brake body from the
motor. Remove the friction disk from the
motor shaft.
(7) Clean and inspect all components and
working surfaces. Replace all damaged
or worn components as necessary.
Measure friction disk thickness and
replace if less than the minimum
thickness shown in Table 5-1.
d)
Brake Re-assembly.
(1) Install the friction disk on the splined hub.
The friction disk must slide on the splined
hub and seat against the end bell of the
motor.
(2) Install the brake body to the motor end
bell using the three (3) mounting bolts.
The air gap must be reset as described in
Section V, Paragraph 5-10.b. Torque the
mounting bolts to the values shown in
Table 5-1. Install the large O-ring in the
groove over the air gap. Ensure this Oring is not pinched in the air gap.
(3) Connect the brake leads to the terminal
block on the brake body.
(4) Install the forward fan mounting retaining
ring and install the fan. Install the rear
retaining ring. Install the fan shroud and
bolts.
(5) Test hoist per Section V, Paragraph 5-13.
Figure 5-9. Traverse Drive Arrangement.
a) General. The traverse drive consists of four
single flange wheels, two on each side of
the beam, carried directly by the hoist
frame. These wheels rotate on sealed ball
bearings supported by fixed pins. Pinions
drive two opposing wheels with gear teeth
cut into the flange. Both pinions are
mounted on a keyed drive shaft supported
by sealed ball bearings at each hoist side.
The pinions are held in place by means of
locking setscrews. The drive shaft passes
through one hoist side and is keyed to and
driven by a single reduction hollow shaft
gear reducer.
b) Ensure that the hoist is properly fitted to the
beam. The hoist must be centered on the
beam with clearance between the sides of
the bottom of the beam flange and the
inside faces of the wheel flanges. Proper
clearance must exist along the entire length
of beam that the hoist can traverse. An
amount of 3/32 to 1/8 inch clearance per
side is recommended for a total of 3/16 to
1/4 inch wider than the beam flange. If too
little or too much clearance is determined,
adjust trolley per Section II, Paragraph 2-2.
c) Inspect wheel treads, flanges, and gear
teeth for wear. Check for adequate
lubrication (WG, Section IV, Paragraph 4-7)
on the wheel gear and pinion mesh. Check
wheel bearings for any signs of wear,
including rough rotation and signs of
lubricant leakage. Replace all damaged or
missing items. Wheels must always be
changed in opposing pairs and drive
wheels should be changed when the drive
pinions are replaced.
CAUTION
Ensure that the cross shaft is properly
positioned and locked into place by
means of the setscrews. Failure to do so
may allow the drive shaft to contact the
hoist gearcase.
CAUTION
d) Examine the drive pinions, cross shaft, and
cross shaft bearings. Check pinions for
gear tooth wear and proper alignment with
wheel gear. A spacer washer between the
cross shaft bearings and the pinion aligns
the gear mesh. Setscrews hold the pinions
and spacer washers tight against the
bearings. Verify that the setscrews are tight
on the cross shaft. If it is necessary to
adjust or reset the pinions, verify that the
cross shaft surface is free of mechanical
damage and oil before tightening the
setscrews. Drive pinions must be replaced
as sets and should be replaced along with
the drive wheels. The cross shaft bearings
are sealed for life and should be replaced
at any sign of mechanical wear or lubricant
leakage.
e) Inspect the traverse gearbox and motor.
Look for signs of rough operation,
mechanical damage or lubricant leaks.
Inspect the hollow bore and keyed cross
shaft for wear. Verify that all bolts that hold
the gearbox to the trolley frame (and torque
arm) and the four bolts that hold traverse
motor to the gearbox are all present and
tight. Replace and tighten as necessary.
The
factory
recommends
complete
replacement of the traverse gearbox.
However, gearbox service may be available
from your local authorized SHAW-BOX
repair center.
5-12. TESTING
SWITCH.
BLOCK
OPERATED
LIMIT
a) General. The optional block operated limit
switch is a secondary upper limit switch
actuated when the lower block contacts the
actuator rod. The rotary-geared limit switch
(screw type limit switch) is the primary
upper limit switch and must be temporarily
bypassed to allow the block operated limit
switch to be tested.
b) Procedure. Remove load from the hook. To
disconnect the geared limit switch, refer to
Figure 7-2. Remove the limit switch cover
then loosen the two (2) screws holding the
locking plate in place. Allow the locking
plate to slide down and disengage from the
adjustment discs. Do not rotate the
adjustment discs.
Damage to the hoist may occur if the
block operated limit switch fails during
testing.
Damage can be avoided by immediately
releasing the pushbutton once the lower
block has traveled through the limit
switch weight.
The block operated limit switch may now
be tested by slowly and carefully raising the
hook until the limit switch rod contacts the
lower block. If the hook does not stop when
the limit switch rod is lifted, immediately
release the pushbutton before damage to
your hoist occurs. If the block operated
switch functions properly, proceed by
testing in the same manner with rated load
on the hook. Once it has been determined
that the block operated limit switch is
functioning properly, the geared limit switch
must be reconnected and tested.
Position the lower block three inches (3”)
below the point where the block operated
limit switch is activated. The geared limit
switch shall be reconnected by sliding the
locking plate back into position ensuring
slots on adjustment discs are fully engaged
and tightening locking plate screws to 4 inlbs. (See Figure 7-2). The geared limit
switch must then be tested.
Test the geared limit switch by raising the
lower block until it stops. Ensure that the
geared limit switch stopped the hoist before
the block operated limit switch was
activated. If this is not the case, see
Section VII, Paragraph 7-3 for adjusting the
geared limit switch. Replace geared limit
switch cover when testing and adjusting is
complete.
b) Check hoist as outlined in PREOPERATION CHECKS, SECTION II,
Paragraph 2-4.
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 3” for hook drift
in both directions. Never allow less than
two (2) complete wraps of rope on drum
with hook in lowest position.
5-13. TESTING
SWITCH.
OVER-CAPACITY
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 stop immediately and hold
load at that level.
LIMIT
The over-capacity limit switch is provided as
standard equipment on SHAW-BOX “World
Series” hoists. This switch is integral to the
wire rope dead end assembly and is factory
preset to prevent over-capacity lifts. This
device is preset at the time of hoist inspection
to prevent the lifting of loads weighing 125150% of rated capacity.
To test the function of the over-capacity limit
switch, apply 125% of the rated capacity to
load hook. If hoist is capable of lifting the
load, then actual switch setting may be higher
than necessary and needs to be adjusted. If
hoist cannot lift load, then the switch setting
is correct. Refer to SECTION VII, Paragraph
7-4 for information regarding the adjustment
of the limit switch setting.
(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 7-1.
SECTION VI – TROUBLE SHOOTING
6-1. GENERAL. This section contains possible
causes and solutions to common hoist problems.
Please attempt to remedy your hoist problems by
following these steps, before contacting the factory.
Whenever servicing electrical components, be sure
to shut off and lock out power following proper
lockout/tagout procedures.
WARNING
5-14. TESTING HOIST.
a) General. Testing shall be performed in
accordance with FEM Section IX, Series
Lifting Equipment, namely Section 9.811
“Specification for rope and chain hoists”,
and this manual. 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.
Connect hoist to power supply as shown on
hoist nameplate and perform the checks
listed in b) and c) below.
Working in or near exposed energized
electrical equipment presents the
danger of electric shock.
TO AVOID INJURY:
DISCONNECT POWER AND IMPLEMENT
LOCKOUT/TAGOUT PROCEDURE BEFORE
REMOVING COVER OR SERVICING THIS
EQUIPMENT.
TROUBLE
6-1 Hoist Will Not
Operate.
6-2 Hook Moves in
Wrong Direction.
SECTION VI – TROUBLE SHOOTING
PROBABLE CAUSE
REMEDY
a. No power to hoist.
a. Check switches, circuit breakers or fuses and
connections in power supply lines. Check power
collectors.
b. Wrong voltage.
b. Check voltage required on motor data plate
against power supply.
c. Loose
or
broken
wire
connections in hoist electrical
system.
c. Shut off and lock out power supply; remove
electrical cover on hoist and check wiring
connections. Also check connections in push
button station and limit switches.
d. Contactor
assembly
functioning.
d. See that necessary jumper wires are properly
installed. Verify that the contactor armatures are
free to move. If binding occurs, replace
contactor. Check for burned out contactor coils.
not
e. No control voltage.
e. Check transformer fuse. If blown, check for
grounding and/or shorts in the push button
station. Check the transformer coil for signs of
overheating. Replace transformer if burned out.
Verify the transformer secondary is the same
voltage as the coils to which it is connected.
f. Motor burned out.
f. Replace motor. Check input power supply.
Check hoist motor connections.
g. Reverse phasing on threephase hoists
g. Check phase protection device (PPD), if amber
LED is steady; interchange any two power
supply line leads per Section II, Paragraph 4.b.
a. Check PPD, if green LED is steady; interchange
any two sets (each winding) of motor power
leads.
a. Reverse phasing on threephase hoists.
b. Hoist wired incorrectly.
6-3 Hook Will Raise
But Not Lower.
a. Lower electrical circuit open.
b. Contactor
functioning
assembly
c. Down,
push
inoperative.
button
not
is
b. Check wiring connections with appropriate
wiring diagram.
a. Check for loose connections. See that necessary
jumper wires are properly installed on contactor.
b. See that necessary jumper wires are properly
installed. Verify that the contactor armatures are
free to move. If binding occurs, replace contactor.
Check for burned out contactor coils.
c. Check push button contacts and wires.
TROUBLE
6-4 Hook Will Lower,
But Not Raise.
6-5 Hoist Will Not
Lift Rated Load.
6-6 Hoist Motor
Overheats.
6-7 Load Drifts
Excessively
When Hoist is
Stopped.
6-8 Hoist Operates
Intermittently.
SECTION VI – TROUBLE SHOOTING
PROBABLE CAUSE
REMEDY
a. Excessive load.
a. Reduce loading to rated load of hoist as shown on
nameplate.
b. Hoist electrical circuit open.
b. Check for loose connections. See that necessary
jumper wires are properly installed on contactor.
c. Contactor assembly not
functioning.
c. See that necessary jumper wires are properly
installed. Verify that the contactor armatures are
free to move. If binding occurs, replace contactor.
Check for burned out contactor coils.
d. Up, down button inoperative.
a. Low voltage.
d. Check push button contacts and wires.
a. See that the power supply current is the same
voltage listed on motor data plate. Check hoist
motor connections. Check size of power supply
lines.
a. Reduce loading to rated load as shown on
nameplate.
a. Excessive load.
b. Excessive duty-cycle.
b. Reduce frequency of lifts or amount of jogging.
c. Wrong voltage or frequency.
c. Check current rating on motor data plate against
power supply. Check hoist and inspect for
defective, worn or damaged parts.
d. Defective motor or worn
bearings in hoist frame.
d. Disassemble hoist and inspect for defective, worn
or damaged parts.
e. Brake not adjusted properly.
a. Excessive load.
e. Adjust brake per Section VII, Paragraph 7-1.
a. Reduce loading to rated load as shown on
nameplate.
b. Motor brake not holding.
b. With No Load, check hoist for drift. If drifting is
excessive, inspect motor brake (Section V,
Paragraph 5-10) and adjust as outlined in Section
VII, Paragraph 7-1.
a. Check collectors for free movement of spring arm,
weak spring or electrical connections.
a. Collectors make poor contact.
b. Loose connections.
SECTION VII – ADJUSTMENTS
7-1. MOTOR BRAKE ADJUSTMENT. These
brakes are designed so that adjustment is seldom
required. If, after a period of service, the load hook
“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.
b. Check all wiring for loose connections.
WARNING
Check to be certain main power switch
is locked in open position (OFF) before
removing brake cover.
Refer to Figure 5-9 and proceed as outlined in
Section V, Paragraph 5-10.
7-2. BLOCK
OPERATED
LIMIT
SWITCH
ADJUSTMENT. The block operated limit stop,
furnished as optional equipment, is minimally
adjustable and designed to stop the lower block at
the safest high point of travel to eliminate any
possibility of double-blocking. When the safest high
point is reached, the limit switch automatically stops
hook travel. If the block switch is not tripping after
contact with the lower block body, loosen the limit
switch hub retaining screw and rotate the hub and
rod downward to ensure earlier contact. Retighten
and test, repeat as needed until switch functions
properly.
d) Slide locking plate back into position
ensuring slots on adjustment discs are fully
engaged, tighten locking plate screws to 4
in-lbs.
e) Replace cover.
f)
7-3. GEARED
ROTARY
LIMIT
SWITCH
ADJUSTMENT. The geared rotary type limit switch
is standard equipment and is located on the drum
end opposite the gearcase end.
This limit switch has a rotary screw driven by a gear
reduction that 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
cover and are repeated below (see Figure 7-2).
Carefully check limit switch operation
without load before placing hoist in service.
If misadjusted, repeat steps above. Allow 3”
for hook drift in both directions. Never allow
less than two (2) complete wraps of rope
on drum with hook in lowest position.
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 3” for hook drift
in both directions. Never allow less than
two (2) complete wraps of rope on drum
with hook in lowest position.
Provide a light film of MPG grease (Paragraph 4-7)
on gear of both limit switches.
LOCKING ADJUSTMENT SWITCH
PLATE
DISC
Figure 7-2. Screw-Type Limit Switch Adjustment
(Wires Not Shown For Clarity.)
7-4.OVER-CAPACITY
LIMIT
SWITCH
ADJUSTMENT. The over-capacity limit switch is
standard equipment and is integrated into the wire
rope dead end assembly (see Figure 7-3). The
device is designed to prevent over-loading of the
equipment, but is not intended to be used as a
load-measuring device.
SWITCH
The limit switch is factory preset to prevent the
lifting of loads weighing 125-150% of rated
capacity. At times, it may be necessary to adjust
the limit switch setting.
WARNING
Be certain that electrical power supply
is OFF and locked in the open position
before removing limit switch cover.
a) Remove four screws and lift off switch
cover.
b) Loosen locking plate screws. Slide locking
plate away from adjustment disc.
c) Turn proper adjustment disc (right for up,
left for down) toward switch to reduce hook
travel or away from switch to increase hook
travel.
Figure 7-3. Over-capacity Limit Switch
To adjust the limit switch setting, simply loosen the
locking nut (see Figure 7-3) and then either loosen
or tighten the adjustment bolt into the overload
beam to achieve the desired setting. Loosening the
adjustment bolt will reduce the load required to trip
the limit switch plunger while tightening will
increase this setting. Only very small adjustment is
required.
7-5. SHORTENING OF PUSHBUTTON 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 at top of cable.
markers in accordance with the wiring
diagram furnished with the hoist).
SECTION VIII – WIRING DIAGRAMS
8-1. GENERAL. Comprehensive wiring diagrams for
SHAW-BOX electric hoists have been omitted from
this book because of the many possible variations.
This is due to different currents and types of
electrical components used in their construction.
Figures 8-1 and 8-2 are examples of typical twospeed hoist and trolley wiring diagrams
respectively. However, please consult the exact
wiring diagrams for your hoist. A print of the correct
wiring diagram for each hoist is furnished as a
separate insert and shipped with the hoist. We
suggest you carefully file the wiring diagram with
this book for future reference.
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
the same type of terminals previously
furnished (care must be taken to match
previous wire color coding with wire
Figure 8-1. Elementary Wiring Diagram for a Two-Speed Hoist and Trolley with Standard Features.
POWER SUPPLY
FROM M/lJNLlNE CONTACTOR
Ll l2 L3
ELEMENTARY DIAGRAM
II
l2
L3
II
L2
L3
CFU
HFU
PFU
Hl2
HU
CONNECT PER
NAMEPLATE FOR
PROPER VOLTAGE
PC
PU
PRIMARY
pee
H91
Cll Cl2 CL3
=HCPT
(~I )
Hll Hl2 HL3
F
SECONDARY
"
G
(n)
-,
-=rj
o CO2
HCFU
H91A
LCBI
I
L _C~®
A H02
C
TROL LEY BRAKE
A c. COil
(WHEN ORDERED)
Fe
~
co I CO2
eOJ
~t
CSOL
eT I CT2 CTJ
"
COil
COil
CFOLt
CTII
8~
H91
01 H02 HOJ
HSOL
t ~;~
T12
T2
TI
TJ
SLOW
/'"
Til
T13
F<3T
~J
~
HFDLS (
DOWN
1A
1H
I
I
92
92
T12
"''''
TJ
SLOW
Me
LSD
>Ii
HTII HT12 HT13
T2
TI
"'
HOl3
em em
TI HT2
/~
HOII
/'"
Til
2A
TDR
T13
F<3T
TROllEY MOTOR
92
H91
HOIST
BRAKE
RIGHT
40
>Ii
I
I
I
CTAS
4{JB
CSOL 40C CFOL
400
L 4DA
1,
+,
LE~
>Ii
41
R 41A
I
I
42
~~---------------------------------0FC
)
Figure 8-2. Component Diagram for a Two-Speed Hoist and Trolley with Standard Features.
WIRE
#
DEVICE CONNECTED
LI
HFU, CFU, PPD
HFU, CFU, PPD
HFU, CFU, PPD
HFU, U-D, PFU
HFU, U-D, PFU
HFU, U-D
CFU, R-L
CFU, R-L
CFU, R-L
PFU, HCPT
PFU, HCPT
U-D, F
U-D, F
R-L, FC
R-L, FC
F, HSOL
U-D, HSOL, HFOL
F, HSOL
F, HFOL
F, HFOL
FC, CSOL
R-L, CSOL, CFOL
FC, CSOL
FC, CFOL
FC, CFOL
HSOL
HSOL
HSOL
HFOL
HFOL
HFOL
CSOL
CSOL
CSOL
CFOL
CFOL
CFOL
~
~
HLI
H~
H~
CLI
CL2
CL3
PLI
PL2
A
C
D
F
HOI
H02
H03
HOII
H013
COl
CO,
C03
COil
COl3
HTI
HT2
HT3
HTII
HT12
HT13
C11
C12
C13
CTII
CTI2
CTI3
0
OA
DB
DC
00
DE
OH
I
IA
IH
,
2A
19
41l
41lA
41lB
41lC
4110
41
41A
42
H91
TIl
TIl
TIl
TIl
TIl
I,H9 IA
I
LI
A B C II 21
22 24
12 14
~
L3
LI
L2
HLI HL1 HL3
~,
8
00
C
~ ~ ~HFU ~ ~ ~CFU
RRO
lAO
' 7177'
979
1
CLI CL2 CL3
9,
iE
olB
~ ,~ ~ HI,
HOI HOZ HOJ
A
OW
HOII HOZ HOll
OD
19
L~~+I-~+J L~~+I-~+J
HTI HT2 HTJ
19
(X2) 4F
..
92
OE
00
Hrll Hl1Z Hrll
OE
Lrt
92
0
OH
92--OC
aru~ru.
I
12
~.A
R
L
I
I
0
910f- H91
OH0r-0H
IH0r-IH
}~~
'
'~6tf
L_
_ ____ J 'fuij-'
Lt
TOR
L, R
~BI
B20
TO HOIST HB2
D,C. BRME
SOLENOID
F
FC
I
_~J
TIl
TIl
TIl
HCPTG
SECONDARY
HCFU
HBI
CSOL
CSOL, CFOL
CFOL, L
CBI
=
(XI)
C
:;!~1Tl~ :;!~1Tl~ :li!ti:
TDR, F, MC
TIl
R;~lkj:~u
92 HOII HOI H03HOI3
U, D, MC
U, BCM
TIl
HL2
'1AJ~'
~tr+-~~j
HSOL
HSOL, HFOL
HFOL, OLC, Me
OLC, 0, BCM
OLC
TIl
TIl
HLI
H91A
2A
OLC
0, U, MC
MC
TIl
TIl
92
HBI
HB'
L1
TIl
H91A
CB2
CONNECT PER
NAMEPLATE FOR
PROPER VOLTAGE
R, L
FC
92
PPD, BCM, MC
HCFU, PPD
HCPT, OLC, U, 0, F,
BCM, MC, R, L, FC
D C02
COl C02 cm
F 41A
40A 9Z
40B
IXlII 0012 am
92 COil COl COJCOIJ
40C
r;-,s ~tt!t ~ [;,S ~tt!t ~
R-L
R-L
BCM
BCM
L~ ~+I-~ +J L~ ~+I-~ +J
CTI CTZ en
DANGER
(ppo) - PHASE REVERSAL/LOSS PROTECTION
DEVICE SHOWS A STEADY AMBER LED WHEN IN
PHASE REVERSAL CONDITION.
CORRECT IMPROPER PHASING BY INTERCHANGING INPUT POWER LEADS LlANO L2.
DO NOT CHANGE PUSHBUITON OR MOTOR
CIRCUIT WIRING.
WARNING
THIS EQUIPMENT MUST BE EFFECTIVELY GROUNDED
ACCORDING TO APPLICABLE CODES
AVERnSSEMENT
CIT EQUIPMENT DOlT ITRE MIS A'LA TERRE EN
ACCORDANCE AVEC LES NORMES EN VIGUEUR.
40C
eT11 em em
40D
SYMBOL DESIGNATIONS
PPD - PHASE REV./LOSS PROTECTION DEVICE
CFU - TROLLEY MOTOR CIRCUrT FUSING
HFU - HOIST MOTOR CIRCUrT FUSING
R - TROllEY RIGHT CONTACTOR
PFU - TRANSFORMER PRIMARY FUSING
L - TROLLEY LEFT CONTACTOR
HCPT - CONTROL CIRCUrT TRANSFORMER
FC - TROLLEY FAST CONTACTOR
HCFU - CONTROL CIRCUrT FUSING
CSOL - TROLLEY SLOW SPEED THERMAL OVERLOAD RELAY
U - HOIST UP CONTACTOR
CFOL - TROLLEY FAST SPEED THERMAL OVERLOAD RELAY
D - HOIST DOWN CONTACTOR
CTAS - TROLLfY MOTOR TEMPERATURE ACTIVATED SWITCH
F - HOIST FAST SPEED CONTACTOR
MC - MONITOR CARO
HSOL - HOIST SLOW SPEED THERMAL OVERLOAD RELAY
TB - TERMINAl BOARD
HFOL - HOIST FAST SPEED THERMAL OVERLOAD RELAY
G~ - FRAME GROUND
~~
~gl~ ~6~f~ g~ ~~f
~lli6~
::
blH:i
BCM - D.C. BRAKE CONTROL MODULE
TOR - TIMER DELAY MODULE
HTAS - HOIST MOTOR TEMPERATURE ACTUATED SWITCH
OLS - OVERLOAD LIMIT SWrTCH
OLC - OVERLOAD LIMIT SWITCH CONTACTOR
I
SECTION IX – PARTS LIST
9-1. GENERAL. The parts lists and illustrations in
this section of the manual cover parts for models of
SHAW-BOX “World Series” 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 “World Series” Hoists are built in two
basic frame sizes, “B” Frame and “C” Frame. To
determine the size of your hoist, measure the width
of the gearcase (see Figure 4-2.) The “B” Frame’s
gearcase has a width of 9 3/4” and the “C” Frame
has a gearcase width of 12 1/2”.
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
listed at the end of this manual.
The numbers assigned to parts of our various
assemblies in our Parts List are the part
numbers used in manufacturing. Some of these
itemized parts are not for individual sale, but
must be grouped with other related replacement
items.
WHEN ORDERING PARTS OR INFORMATION
ON THIS EQUIPMENT, ALWAYS INCLUDE
MODEL AND SERIAL NUMBER ON ORDER.
WARNING
Using “Commercial” or other manufacturer’s parts to repair World Series
Hoists may cause load loss.
TO AVOID INJURY:
Use only SHAW-BOX Hoist supplied parts.
Parts may look alike but SHAW-BOX Hoist
parts are made of specific materials or
processed to achieve specific properties.
LIST OF PART ILLUSTRATIONS
TITLE
Hoist Drum, Drum Frame, Gearcase, Motor, Rope Guide, and Limit Switch
Hoist Gearing
Motor Driven Trolley Frame and Drive
Lower Block Assembly
Upper Block Assembly
Wire Rope Dead End Assembly with Limit Switch
Rope Guide Assembly
Hoist Motor Brake – Standard Service
Hoist Motor Brake – Outdoor Service
FIGURE No.
9-1
9-2
9-3
9-4
9-5
9-6
9-7
9-8
9-9
PAGE No.
34
37
39
42
44
45
47
48
50
FIGURE 9-1. Hoist Drum, Drum Frame, Gearcase, Motor, Rope Guide, and Screw Type Limit Switch.
“B” Frame: Hoist Components for Figure 9-1.
Ref.
No.
Part
Number
1
33313801
33313802
33313803
33313804
11802602
11803103
11803003
44933001
11802706
11803103
11803003
11802603
11803401
11802504
11803501
11803004
11802707
11803203
23385901
23385902
44931501
44931502
23380301
11802705
11803202
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Description
7.5 HP Hoist Motor, 2-Speed with Brake and Fan (See Figure 9-8 for Parts)
208 volt, 3-phase, 60 Hertz
230 volt, 3-phase, 60 Hertz
460 volt, 3-phase, 60 Hertz
575 volt, 3-phase, 60 Hertz
Hex Head Bolt, M12
Flat Washer, M12
Locknut, M12
Hoist Gearcase (See Figure 9-2 for Parts)
Socket Head Cap Screw, M12
Flat Washer, M12
Locknut, M12
Hex Head Bolt, M12
Lockwasher, M12
Hex Head Bolt, M16
High Strength Flat Washer, M16
Locknut, M16
Socket Head Cap Screw, M10
Hi-Collar Lockwasher, M10
Drum Frame Rod
Frame Rod, 25’ Lift Model
Frame Rod, 40’ Lift Model
Rope Drum
Rope Drum, 25’ Lift Model
Rope Drum, 40’ Lift Model
Rope Clamp
Socket Head Cap Screw, M8
Hi-Collar Lockwasher, M8
Qty.
Req’d.
1
2
2
4
1
4
4
4
2
2
4
8
4
2
2
1
1
3
3
3
“B” Frame: Hoist Components for Figure 9-1.
Ref.
No.
Part
Number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
33291102
11801803
11802401
23383801
11802607
11802608
11803401
43981305
11593901
44930901
44930902
11802718
11803005
44931801
NO12283
44930801
Ref.
No.
Part
Number
1
33314001
33314002
33314003
33314004
11802602
11803103
11803003
44935501
11802712
11803104
11803004
11802603
11803401
11802516
11803502
11803006
11802707
11803203
23387601
23387602
44933501
44933502
23380301
11802705
11803202
33291702
11801802
10119421
23383801
11802609
11802610
Description
Drum Frame Bracket
Flanged Cartridge Ball Bearing
Heavy Duty External Retaining Ring
Limit Switch Bracket
Hex Head Bolt (Short), M12
Hex Head Bolt (Long), M12
Lockwasher, M12
Geared Limit Switch
Drum Shaft Insert for Geared Limit Switch
Stiffener Plate
Stiffener Plate, 25’ Lift Model
Stiffener Plate, 40’ Lift Model
Socket Head Cap Screw, M10
Locknut, M10
Rope Guide (See Figure 9-7 for Parts)
Hydraulic Fitting for Flanged Cartridge Ball Bearing (Not Shown)
SHAW-BOX Brand Label for Gearcase (Not Shown)
Qty.
Req’d.
2
1
1
1
2
2
4
1
1
2
8
8
1
1
1
“C” Frame: Hoist Components for Figure 9-1.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Description
15 HP Hoist Motor, 2-Speed with Brake and Fan (See Figure 9-8 for Parts)
208 volt, 3-phase, 60 Hertz
230 volt, 3-phase, 60 Hertz
460 volt, 3-phase, 60 Hertz
575 volt, 3-phase, 60 Hertz
Hex Head Bolt, M12
Flat Washer, M12
Locknut, M12
Hoist Gearcase (See Figure 9-2 for Parts)
Socket Head Cap Screw, M16
Flat Washer, M16
Locknut, M16
Hex Head Bolt, M12
Lockwasher, M12
Hex Head Bolt, M20
High Strength Flat Washer, M20
Locknut, M20
Socket Head Cap Screw, M10
Hi-Collar Lockwasher, M10
Drum Frame Rod
Frame Rod, 25’ Lift Model
Frame Rod, 40’ Lift Model
Rope Drum
Rope Drum, 25’ Lift Model
Rope Drum, 40’ Lift Model
Rope Clamp
Socket Head Cap Screw, M8
Hi-Collar Lockwasher, M8
Drum Frame Bracket
Flanged Cartridge Ball Bearing
External Retaining Ring
Limit Switch Bracket
Hex Head Bolt (Short), M16
Hex Head Bolt (Long), M16
Qty.
Req’d.
1
2
2
4
1
4
4
4
2
2
4
8
4
2
2
1
1
3
3
3
2
1
1
1
2
2
“C” Frame: Hoist Components for Figure 9-1.
Ref.
No.
Part
Number
27
28
29
30
11803402
43981305
11593901
44933401
44933402
11802719
11803005
44933801
NO410
44934201
31
32
33
34
35
Description
Lockwasher, M16
Geared Limit Switch
Drum Shaft Insert for Geared Limit Switch
Stiffener Plate
Stiffener Plate, 25’ Lift Model
Stiffener Plate, 40’ Lift Model
Socket Head Cap Screw, M10
Locknut, M10
Rope Guide (See Figure 9-7 for Parts)
Hydraulic Fitting for Flanged Cartridge Ball Bearing (Not Shown)
SHAW-BOX Brand Label for Gearcase (Not Shown)
Qty.
Req’d.
4
1
1
2
8
8
1
1
1
NOTES
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Figure 9-2. Hoist Gearing.
“B” Frame: Hoist Gearing for Figure 9-2.
Ref.
No.
Part
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
44933001
44932101
44932301
44933101
11802704
11803202
NO3751
10119402
23384701
23385201
11780905
NO3747
NO1560
23384601
11780901
23384501
NO1560
NO3751
23386201
10379710
11803301
10376276
10376275
10770006
11801301
Description
Complete 5t Hoist Gearcase Ass’y. - 80.57:1 Ratio (Excl. Ref. Nos. 25 & 26)
Gearcase
Cover
Gasket
Vent Plug
Drain/Fill Level Plug
Socket Head Cap Screw, M8
Hi-Collar Lockwasher, M8
Ball Bearing
External Retaining Ring
Intermediate Gear
Drum Pinion Shaft
Key
Ball Bearing
Ball Bearing
Intermediate Pinion Shaft
Key
Motor Gear
Ball Bearing
Ball Bearing
Output Shaft
Roller Bearing
Dowel Pin
Motor Shaft Oil Seal
Output Shaft Oil Seal
Torque Pin
Threaded Stud, M12
Qty.
Req’d.
1
1
1
1
1
2
12
12
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
2
“C” Frame: Hoist Gearing for Figure 9-2.
Ref.
No.
Part
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
44935501
44935501
44935101
44935301
44935401
11802711
11803204
NO9878
10119427
23388201
23389801
11780907
10377333
NO1670
23388101
11780901
23388001
NO3751
NO3751
23389901
10379711
11803302
10376276
10376274
10770006
11801301
Description
Complete 10t Hoist Gearcase Ass’y. – 103.8:1 Ratio (Excl. Ref. Nos. 25 & 26)
Complete 7.5t Hoist Gearcase Ass’y. – 103.8:1 Ratio (Excl. Ref. Nos. 25 & 26)
Gearcase
Cover
Gasket
Vent Plug
Drain/Fill Level Plug
Socket Head Cap Screw, M12
Hi-Collar Lockwasher, M12
Ball Bearing
External Retaining Ring
Intermediate Gear
Drum Pinion Shaft
Key
Ball Bearing
Ball Bearing
Intermediate Pinion Shaft
Key
Motor Gear
Ball Bearing
Ball Bearing
Output Shaft
Roller Bearing
Dowel Pin
Motor Shaft Oil Seal
Output Shaft Oil Seal
Torque Pin
Threaded Stud, M12
Qty.
Req’d.
1
1
1
1
1
1
2
12
12
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
2
NOTES
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Figure 9-3. Motor Driven Trolley Frame and Drive (“C” Frame Shown).
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
“B” Frame: Trolley Frame and Drive Components for Figure 9-3.
Part
Number
Description
44932401M
44932402M
44932501M
44932502M
44932620
44932621
23384201
23384202
23384203
31493324
11802707
11803203
10424754
10424755
10424756
11802902
11803402
23382201
23383702
Trolley Frame Side
Drum Side, 25’ Lift Model
Drum Side, 40’ Lift Model
Trolley Frame Side
Traverse Drive Side, 25’ Lift Model
Traverse Drive Side, 40’ Lift Model
Counterweight Plate
Counterweight, 25’ Lift Model
Counterweight, 40’ Lift Model
Hoist /Trolley Controls (Specify HP, Voltage, Frequency, No. of Speeds, Options)
Alignment Bar
Alignment Bar, 4” Thru 8” Trolley Beam Flange Width
Alignment Bar, 8 1/8” Thru 14” Trolley Beam Flange Width
Alignment Bar, 14 1/8” Thru 20” Trolley Beam Flange Width
Key Plate
Socket Head Cap Screw, M10
Lockwasher, M10
Threaded Rod, M16
Threaded Rod, 4” Thru 8” Trolley Beam Flange Width
Threaded Rod, 8 1/8” Thru 14” Trolley Beam Flange Width
Threaded Rod, 14 1/8” Thru 20” Trolley Beam Flange Width
Plain Hex Nut, M16
Lockwasher, M16
Wheel Axle
Plain Trolley Wheel
Qty.
Req’d
1
1
1
1
2
3
4
4
2
12
4
4
2
Ref.
No.
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
“B” Frame: Trolley Frame and Drive Components for Figure 9-3.
Part
Number
Description
23383701
NO8136
10008362
10119407
10119417
10378807
10235622
23384001
11781101
11802301
23382901
23382902
23382903
23383901
905378
905377
10392029
NO661
NO796
NO437
11802707
11803203
11803101
11802604
11803402
11802611
11802904
11803005
11680704
Geared Trolley Wheel
Ball Bearing
Internal Retaining Ring
External Retaining Ring
External Retaining Ring
Ball Bearing w/Retaining Ring
Flat Washer
Traverse Pinion
Key
Set Screw, M6
Traverse Cross Shaft
Cross Shaft, 4” Thru 8” Trolley Beam Flange Width
Cross Shaft, 8 1/8” Thru 14” Trolley Beam Flange Width
Cross Shaft, 14 1/8” Thru 20” Trolley Beam Flange Width
Torque Arm
Traverse Reducer
Traverse Reducer, 55 FPM
Traverse Reducer, 75 FPM
Socket Head Cap Screw, 5/16”-18
Lockwasher, 5/16”
Traverse Motor (Specify HP, Voltage, Frequency, No. of Speeds, Options)
Hex Head Bolt, 3/8”-16
Lockwasher, 3/8”
Socket Head Cap Screw, M10
Lockwasher, M10
Flat Washer, M10
Hex Head Bolt, M16
Lockwasher, M16
Hex Head Bolt, M10
Plain Hex Nut, M10
Locknut, M10
Bumper (Optional)
“C” Frame: Trolley Frame and Drive Components for Figure 9-3.
Part
Number
Description
44933901M
44933902M
44934001M
44934002M
44934120
44934121
23387301
23387302
23387303
31493324
11802707
11803203
10424757
10424758
10424759
11802903
11803403
Trolley Frame Side
Drum Side, 25’ Lift Model
Drum Side, 40’ Lift Model
Trolley Frame Side
Traverse Drive Side, 25’ Lift Model
Traverse Drive Side, 40’ Lift Model
Counterweight Plate
Counterweight, 25’ Lift Model
Counterweight, 40’ Lift Model
Hoist /Trolley Controls (Specify HP, Voltage, Frequency, No. of Speeds, Options)
Alignment Bar
Alignment Bar, 6” Thru 8” Trolley Beam Flange Width
Alignment Bar, 8 1/8” Thru 14” Trolley Beam Flange Width
Alignment Bar, 14 1/8” Thru 20” Trolley Beam Flange Width
Key Plate
Socket Head Cap Screw, M10
Lockwasher, M10
Threaded Rod, M20
Threaded Rod, 6” Thru 8” Trolley Beam Flange Width
Threaded Rod, 8 1/8” Thru 14” Trolley Beam Flange Width
Threaded Rod, 14 1/8” Thru 20” Trolley Beam Flange Width
Plain Hex Nut, M20
Lockwasher, M20
Qty.
Req’d
2
8
4
4
4
2
2
2
2
4
1
1
1
4
4
1
4
4
2
2
2
2
2
5
4
5
4
Qty.
Req’d
1
1
1
1
2
3
4
4
2
12
4
Ref.
No.
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
“C” Frame: Trolley Frame and Drive Components for Figure 9-3.
Part
Number
Description
23387501
23387702
23387701
10377711
10008310
10119412
10119431
10378807
10235622
23384001
11781101
11802301
23382904
23382905
23382906
23391001
33292001
33292002
10791731
NO1951
10791731
NO1951
11802718
11803203
11803101
11802604
11803402
11802611
11802904
11803005
11680701
Wheel Axle
Plain Trolley Wheel
Geared Trolley Wheel
Ball Bearing
Internal Retaining Ring
External Retaining Ring
External Retaining Ring
Ball Bearing w/Retaining Ring
Flat Washer
Traverse Pinion
Key
Set Screw, M6
Traverse Cross Shaft
Cross Shaft, 6” Thru 8” Trolley Beam Flange Width
Cross Shaft, 8 1/8” Thru 14” Trolley Beam Flange Width
Cross Shaft, 14 1/8” Thru 20” Trolley Beam Flange Width
Torque Arm
Traverse Reducer
Traverse Reducer, 50 FPM
Traverse Reducer, 80 FPM
Hex Head Bolt, 3/8”-16
Lockwasher, 3/8”
Traverse Motor (Specify HP, Voltage, Frequency, No. of Speeds, Options)
Hex Head Bolt, 3/8”-16
Lockwasher, 3/8”
Socket Head Cap Screw, M10
Lockwasher, M10
Flat Washer, M10
Hex Head Bolt, M16
Lockwasher, M16
Hex Head Bolt, M10
Plain Hex Nut, M10
Locknut, M10
Bumper (Optional)
Qty.
Req’d
4
2
2
8
4
4
4
2
2
2
2
4
1
1
1
4
4
1
4
4
3
3
3
2
2
5
8
5
4
NOTES
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Figure 9-4. Lower Block Assembly.
“B” Frame: Lower Block Components for Figure 9-4.
Ref.
No.
Part
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
44931901
23383401
23380601
10380429
10171605
23383501
11801601
11800101
33290902
11803102
11802702
11803002
33290801
10377740
10008316
10119417
33290912
23382810
23382801
11802703
11803001
Description
Lower Block Assembly (Excludes Ref. Nos. 17 & 18)
Trunnion Crosshead
Hook & Nut Assembly
Thrust Bearing
Roll Pin
Sheave Pin
Spacer Tube
Lower Block Strap
Inner Sheave Cover
Flat Washer, M8
Socket Head Cap Screw, M8
Locknut, M8
Rope Sheave
Ball Bearing
Internal Retaining Ring
External Retaining Ring
Outer Sheave Cover
5t Capacity Label
SHAW-BOX Brand Label
Socket Head Cap Screw, M6
Locknut, M6
Qty.
Req’d
1
1
1
1
1
1
2
2
2
4
2
2
2
4
2
2
2
2
2
6
6
“C” Frame: Lower Block Components for Figure 9-4.
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Part
Number
44934901
44934901
23389301
23389201
10380430
10171691
23389401
11802201
11802101
33291802
11803103
11802710
11803003
33291501
10377703
10008303
10119421
33291812
23282812
23382811
23382801
11802709
11803002
Description
10t Lower Block Assembly (Excludes Ref. Nos. 17 & 18)
7.5t Lower Block Assembly (Excludes Ref. Nos. 17 & 18)
Trunnion Crosshead
Hook & Nut Assembly
Thrust Bearing
Roll Pin
Sheave Pin
Spacer Tube
Lower Block Strap
Inner Sheave Cover
Flat Washer, M12
Socket Head Cap Screw, M12
Locknut, M12
Rope Sheave
Ball Bearing
Internal Retaining Ring
External Retaining Ring
Outer Sheave Cover
Capacity Label
10t Capacity Plate
7.5t Capacity Plate
SHAW-BOX Brand Label
Socket Head Cap Screw, M8
Locknut, M8
Qty.
Req’d
1
1
1
1
1
1
1
2
2
2
4
2
2
2
4
2
2
2
2
2
6
6
NOTES
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Figure 9-5. Upper Block Assembly.
“B” Frame: Upper Block Components for Figure 9-5.
Ref.
No.
Part
Number
1
2
3
4
5
6
7
8
9
10
11
12
44932701
33291001
23384101
11801401
10119441
11803001
11802501
23381401
10119417
11800701
10008316
10377740
33290801
Ref.
No.
Part
Number
1
2
3
4
5
6
7
8
9
10
11
12
44934601
33291601
23387001
N/A
10119419
11803001
11802507
23386901
10119421
11802001
10008303
10377703
33291501
Description
“B” Frame Hoist Upper Block Assembly
Upper Block Yoke
Yoke Pin
Yoke Spacer (“B” Frame Only)
External Retaining Ring
Locknut, M6
Hex Head Bolt, M6
Sheave Pin
External Retaining Ring
Spacer Washer
Internal Retaining Ring
Sealed Ball Bearing
Rope Sheave
Qty.
Req’d
1
1
1
1
2
2
2
1
2
2
1
2
1
“C” Frame: Upper Block Components for Figure 9-5.
Description
“C” Frame Hoist Upper Block Assembly
Upper Block Yoke
Yoke Pin
Yoke Spacer (Not Required on “C” Frame)
External Retaining Ring
Locknut, M6
Hex Head Bolt, M6
Sheave Pin
External Retaining Ring
Spacer Washer
Internal Retaining Ring
Sealed Ball Bearing
Rope Sheave
Qty.
Req’d
1
1
1
0
2
2
2
1
2
2
1
2
1
Figure 9-6. Wire Rope Dead End Assembly with Limit Switch.
Ref.
No.
“B” Frame: Wire Rope and Dead End Assembly Components for Figure 9-6.
Part
Number
Description
Qty.
Req’d
“B” Frame Hoist Rope and Dead End Assembly (Excl. Ref. Nos. 11, 14 – 25)
Dead End Yoke
Yoke Pin
External Retaining Ring
Overload Beam
Dead End Pin
Spacer
External Retaining Ring
Overload Spring Base
Hex Head Bolt, M6
Locknut, M6
Wire Rope and Swaged End Assembly
Rope Assembly, 25’ Lift Model, 9mm
Rope Assembly, 40’ Lift Model, 9mm
Socket Head Shoulder Bolt, M8 Thread
Belleville Spring Washer
Hex Head Bolt, M5
Plain Hex Nut, M5
Limit Switch
Socket Head Cap Screw, M5
Hi-Collar Lockwasher
1
1
1
2
1
1
2
2
1
2
2
1
12
13
14
15
16
17
18
44932801
23385401
23385501
10119435
23385601
23385801
11800403
10119445
23385701
11802501
11803001
23383601
23383602
11802801
11781503
11802601
11802901
11801101
11802717
11803201
19
20
21
22
23
24
25
33290501
23391201
11697001
23336501
23391301
10062046
10404510
10264647
“B” Frame Block Operated Limit Switch – Optional Equipment
Limit Switch Bracket (Optional)
Limit Switch (Optional)
Limit Switch Hub (Optional)
Actuator Rod (Optional)
Pan Head Screw, #10 (Optional)
Lockwasher, #10 (Optional)
Socket Head Cap Screw, #10 (Optional)
1
1
1
1
1
2
2
2
1
2
3
4
5
6
7
8
9
10
11
1
4
1
1
1
2
2
Ref.
No.
“C” Frame: Wire Rope and Dead End Assembly Components for Figure 9-6.
Part
Number
Description
Qty.
Req’d
“C” Frame Hoist Rope and Dead End Assembly (Excl. Ref. Nos. 11, 14 – 25)
Dead End Yoke
Yoke Pin
External Retaining Ring
Overload Beam
Dead End Pin
Spacer
External Retaining Ring
Overload Spring Base
Hex Head Bolt, M10
Locknut, M10
Wire Rope and Swaged End Assembly
Rope Assembly, 25’ Lift Model, 12mm
Rope Assembly, 40’ Lift Model, 12mm
Socket Head Shoulder Bolt, M8 Thread
Belleville Spring Washer
Hex Head Bolt, M5
Plain Hex Nut, M5
Limit Switch
Socket Head Cap Screw, M5
Hi-Collar Lockwasher
1
1
1
2
1
1
2
2
1
2
2
1
12
13
14
15
16
17
18
44934701
23388901
23389001
10119436
23387901
23387801
11800404
10119409
23389101
11802508
11803005
23386501
23386502
11802802
11781503
11802601
11802901
11801101
11802717
11803201
19
20
21
22
23
24
25
33290501
23391201
11697001
23336501
23391301
10062046
10404510
10264647
“C” Frame Block Operated Limit Switch – Optional Equipment
Limit Switch Bracket (Optional)
Limit Switch (Optional)
Limit Switch Hub (Optional)
Actuator Rod (Optional)
Pan Head Screw, #10 (Optional)
Lockwasher, #10 (Optional)
Socket Head Cap Screw, #10 (Optional)
1
1
1
1
1
2
2
2
1
2
3
4
5
6
7
8
9
10
11
1
6
1
1
1
2
2
Figure 9-7. Rope Guide Assembly.
“B” Frame Rope Guide Components for Figure 9-7.
Ref.
No.
Part
Number
1
2
3
4
5
44931801
44931701
44930101
11802803
11783003
11800001
Ref.
No.
Part
Number
1
2
3
4
5
44933801
44933701
44930102
11802803
11783003
11800002
Description
“B” Frame Rope Guide Assembly
Rope Guide Body
Plastic Shroud
Socket Head Shoulder Bolt, M6 Thread
Compression Spring
Extension Spring
Qty.
Req’d
1
1
1
2
2
1
“C” Frame Rope Guide Components for Figure 9-7.
Description
“C” Frame Rope Guide Assembly
Rope Guide Body
Plastic Shroud
Socket Head Shoulder Bolt, M6 Thread
Compression Spring
Extension Spring
Qty.
Req’d.
1
1
1
2
2
1
Figure 9-8. Standard Hoist Motor Brake.
“B” Frame: Hoist Brake Components for Figure 9-8.
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Part
Number
33313849
33313850
33313851
BRAKE FAN
KIT
33313852
BRAKE HUB
KIT
33313853
HARDWARE
KIT
N/A
N/A
33313855
SHROUD KIT
Description
Complete Brake Assembly (Includes Ref. Nos. 1,11,16,17 & P/N 33313853)
Brake Friction Disc
Fan
External Retaining Rings (Fan Hub)
External Retaining Ring (Fan)
Fan Hub
Key (Fan Hub)
Key (Fan)
External Retaining Ring (Brake Hub)
Spacer (Brake Hub)
Key (Brake Hub)
Brake Hub
Hollow Core Bolts
O-Ring
Bolts (Brake Mounting)
Compression Springs
Magnet Body – Order Complete Brake
Armature Plate – Order Complete Brake
Fan Shroud
Bolts (Fan Shroud)
Qty.
Req’d.
1
1
1
2
1
1
1
1
1
1
1
1
3
1
3
7
1
1
1
4
Figure 9-8. Standard Hoist Motor Brake.
“C” Frame: Hoist Brake Components for Figure 9-8.
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Part
Number
33263249
33263250
33263251
BRAKE FAN
KIT
33263252
BRAKE HUB
KIT
33263253
HARDWARE
KIT
N/A
N/A
33263255
SHROUD KIT
Description
Complete Brake Assembly (Includes Ref. Nos. 1,11,16,17 & P/N 33263253)
Brake Friction Disc
Fan
External Retaining Rings (Fan Hub)
External Retaining Ring (Fan)
Fan Hub
Key (Fan Hub)
Key (Fan)
External Retaining Ring (Brake Hub)
Spacer (Brake Hub)
Key (Brake Hub)
Brake Hub
Hollow Core Bolts
O-Ring
Bolts (Brake Mounting)
Compression Springs
Magnet Body – Order Complete Brake
Armature Plate – Order Complete Brake
Fan Shroud
Bolts (Fan Shroud)
Qty.
Req’d.
1
1
1
2
1
1
1
1
1
1
1
1
3
1
3
7
1
1
1
4
Figure 9-9. Outdoor Service Hoist Motor Brake.
“B” Frame: Hoist Brake Components for Figure 9-9.
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Part
Number
33294049
33313850
33313851
BRAKE FAN
KIT
33294052
BRAKE HUB
KIT
33294053
HARDWARE
KIT
N/A
N/A
N/A
11803105
33313855
SHROUD KIT
Description
Qty.
Req’d
Complete Brake Assembly (Includes Ref. Nos. 1,11,16,17, 18 & P/N 33294053)
Brake Friction Disc
Fan
External Retaining Rings (Fan Hub)
External Retaining Ring (Fan)
Fan Hub
Key (Fan Hub)
Key (Fan)
External Retaining Ring (Brake Hub)
Spacer (Brake Hub)
Key (Brake Hub)
Stainless Steel Brake Hub
Hollow Core Bolts
O-Ring
Bolts (Brake Mounting)
Compression Springs
Magnet Body – Order Complete Brake
Stainless Steel Armature Plate – Order Complete Brake
Stainless Steel Friction Disc – Order Complete Brake
Spacer Washers
Fan Shroud
Bolts (Fan Shroud)
1
1
1
2
1
1
1
1
1
1
1
1
3
1
3
7
1
1
1
4
1
4
Figure 9-9. Outdoor Service Hoist Motor Brake.
“C” Frame: Hoist Brake Components for Figure 9-9.
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Part
Number
33294149
33263250
33263251
BRAKE FAN
KIT
33294152
BRAKE HUB
KIT
33294153
HARDWARE
KIT
N/A
N/A
N/A
11803106
33263255
SHROUD KIT
Description
Qty.
Req’d.
Complete Brake Assembly (Includes Ref. Nos. 1,11,16,17, 18 & P/N 33294153)
Brake Friction Disc
Fan
External Retaining Rings (Fan Hub)
External Retaining Ring (Fan)
Fan Hub
Key (Fan Hub)
Key (Fan)
External Retaining Ring (Brake Hub)
Spacer (Brake Hub)
Key (Brake Hub)
Stainless Steel Brake Hub
Hollow Core Bolts
O-Ring
Bolts (Brake Mounting)
Compression Springs
Magnet Body – Order Complete Brake
Stainless Steel Armature Plate – Order Complete Brake
Stainless Steel Friction Disc – Order Complete Brake
Spacer Washers
Fan Shroud
Bolts (Fan Shroud)
1
1
1
2
1
1
1
1
1
1
1
1
3
1
3
7
1
1
1
4
1
4
NOTES
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
Recommended Spare Parts
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