Tractel blocstop BSO 1020 User manual

BSO 1020 & BSO 1030
blocstop®
Service & Maintenance Manual
for Overspeed Brake
Date: 8/31/05
Version: 1

The Blocstop overspeed device is crucial and
MANDATORY for safe operation of the Tirak
machine. Therefore, an authorized repair station
must service it at least twice per year. The
following service recommendations may need to
be repeated more frequently depending on the
type of work environment.
2
WARNING
NEVER OPERATE THE TIRAK WITHOUT A
SECONDARY BRAKE!
THE BLOCSTOP SAVES LIVES!
Symbol Code Word Meaning Possible consequence
of non-compliance
WARNING IMMEDIATE or possible imminent
danger Fatal or serious injury!
CAUTION Possible danger situation Minor injuries to persons!
NOTE Possible danger situation Damage to equipment or
it's surroundings
N/A Instruction for documentation in
writing (i.e record keeping) N/A
Explanation of Symbols used in this manual
- Pin punch 5mm
- Allen key 5mm
- Flat screwdriver
- Vise
- 10mm Box wrench
- Special BSO tool (#20887)
- Measuring rod 9mm (#34415)
- or Measuring rod 10mm
- Hammer
- Caliper (micrometer)
- Needle nose pliers
- Needle nose Vise-grips
- 3 ft. 9mm test wire rope (1020)
- or 3 ft. 10mm test wire
rope (1030)
Tools Required for service and maintenance of Blocstop BSO 1020 & BSO 1030

1) SERVICE AND MAINTENANCE
1-1 Blocstop Removal
1-2 Clamping Jaw Test
1-3 Trigger Speed Check
1-4 Disassembly of the Control Compartment
1-5 Counterweight Adjustment & Repair
1-6 Disassembly & Service of the Jaw
Compartment
1-7 Jaw, Frame & Cam Removal
1-8 Roller Assembly Inspection
1-9 Counterweight Assembly Replacement
1-10 Reassembly of the Jaw Compartment
1-11 Installation of the Roller Assembly
1-12 Installation of the Pressure Spring
& Guide Tube
1-13 Casing Cover Installation
1-14 Preliminary Operational Test
1-15 Installation of the Counterweight Cover
1-16 Final Testing
2) EXPLODED VIEW AND PARTS LISTS
Parts Lists
Exploded View
3) TECHNICAL SHEETS
T-235, Checking and Maintenance
3
TABLE OF CONTENTS: Blocstop BSO 1030
Page
4
4
4
5
6
7
9
11
12
12
14
16
17
17
18
19
20
21
22
NOTE:
Any part #, position # (pos.) or page #'s
shown in "{ }" refer to the Parts List / Drawing
in the Spare Parts Lists included at the back
of this manual.

1) SERVICE AND MAINTENANCE
1-1 Blocstop Removal
Detach the Blocstop from the hoist by removing
the two cotter pins and mounting straps as shown
in Figure 101.
1-2 Clamping Jaw Test
1) Open the Blocstop and insert the measuring
rod (#34415) as shown in Figure 102.
2) Close the Blocstop by pressing the orange
emergency stop button which clamps the
jaws on the measuring rod.
3) Try to remove the measuring rod from the
Blocstop while the jaws are
engaged (Figure 103).
4) If you can pull the rod from the Blocstop
without twisting and turning, the jaws may
require replacement.
1-3 Trigger Speed Check
1) Open the Blocstop by pushing down on the
handle.
2) Insert the 9mm (1020) or 10mm (1030) test
wire rope through the entry bushing.
Continue until the rope exits the exit
bushing.
3) Hold the wire rope flush against the top of the
Blocstop entry bushing. Alternatively, you
can place a piece of tape around the wire
rope at its' entry to the Blocstop (Figure 104).
4) Release the Blocstop and allow it to free-fall.
Measure the distance between the entry
bushing and the tape or where your gloved
hand held the wire rope. The Blocstop jaws
should clamp on the wire rope with a travel
distance of 3-4 inches (See Figure 105).
5) If this distance is not 3-4 inches the triggering
speed must be adjusted as outlined in
Section 1-5.
4
Figure 103
Figure 101
Figure 102
Figure 104 Figure 105
CAUTION
Do not perform this test over your feet!

1-4 Disassembly of the Control Compartment
1) Before opening the Blocstop, the spring
tension must be reduced by pressing the
orange emergency stop button (Figure 106).
2) Inspect the handle {pos. 4, #41855} for
wear or damage. Ensure that there is no play
between the handle and the shaft {pos. 2,
#35147}. It must be tight without play. With
a 5mm pin punch, drive out the roll pin {pos.
74, #36786} as shown in Figure 107.
Replace any damaged parts.
3) Remove the (3) M6x60 casing screws
{pos. 75, #10166} and washers {pos. 79,
#36306} as shown in Figure 108.
4) Remove the casing cover {pos. 42, #18267}
to inspect the spring {pos. 72, #29446} and
cover for wear or damage. The spring should
be capable of compressing fully into the
brass cone without obstruction (Figure 109).
5) Inspect the centrifugal weights and the
release lever {pos. 3, #56235} for wear or
damage (Figure 110). Slight damage can be
filed, but you must inspect the air gap (0.4-
0.7mm) between the weights and release
lever upon completion (See Figure 111).
Replace any non-serviceable parts.
5
Figure 106
Figure 107
Figure 108
Figure 109
Figure 110
Figure 111

6) Inspect the handle release lever {pos. 1,
#39967} for wear, play or damage. Also
check the shaft of the jaw opening lever
{pos. 2, #35147} for bending or damage (See
Figure 112). Replace if necessary.
1-5 Counterweight Adjustment & Repair
1) If a slight adjustment (up to ¼") of triggering
speed is required, insert a screwdriver into
the white nylon eccentric screw {pos. 19,
#36475} on the counterweight system.
2) Carefully turn the eccentric screw to increase
or decrease the reaction time of the Blocstop.
A full revolution in either direction returns the
speed to its' initial setting.
If the correct setting cannot be obtained with the
eccentric screw, it may be necessary to replace
the pressure spring as follows:
1) Mark the nylon eccentric screw's {pos. 19,
#36475} orientation prior to removal to ease
adjustment after repair.
2) Begin by removing the white nylon eccentric
screw by pulling it vertically with pliers as
shown in Figure 113.
3) Remove the retaining clip {pos. 63, #33666}
as shown in Figure 114. Be careful not to
lose it.
4) Carefully disassemble the counterweight
spring assembly and replace the pressure
spring {pos. 62, #47615} (Figures 115 & 116).
6
NOTE:
If no service or repair is required, this section
should be omitted
NOTE:
4" IS THE IDEAL TRIPPING DISTANCE
(approx. 88 fpm).
Faster Tripping Speeds Require a Different
Tractel BSO Spring. Please Contact Tractel
for Further Information.
Figure 112
Figure 113
Figure 114
Figure 115
Figure 116

If the counterweights need replacement,
remove the two retaining clips {pos. 86,
#33656} and replace the left {pos. 20,
#38807} and right {pos. 25, #38817}
counterweights (Figure 117).
5) Reassemble in the reverse order being
certain all retaining clips are properly seated.
1-6 Disassembly and Service of the Jaw
Compartment
1) Install the Blocstop in the vise so the casing
is facing upward as shown. Remove the (2)
M6x50 casing screws {pos. 68, #12016} and
nyloc nuts {pos. 76, #7996} (Figure 118).
2) Carefully pry the casing cover open as
shown in Figure 119.
3) Remove the spring guide tube {pos. 53,
#36375} and pressure spring {pos. 80,
#29396} (Figure 120). Be careful not to lose
the washer {pos. 84, #7836} at the end of the
tube.
4) Remove the bearing {pos. 69, #10186}
and its' attached cover {pos. 31, #36525} as
shown in Figure 121 on the next page.
7
NOTE:
After completion of the service, the triggering
speed must be checked several times as
outlined in Sec. 6-1.4
CAUTION
Extreme caution must be used when opening
the cover as it contains springs under
tension. Most importantly, ensure nobody is
in the direction of the exit bushing.
Figure 117
Figure 118
Figure 119
Figure 120

5) Remove the (3) center bushings {pos.
55, #38565} and (2) distance bushings
{pos. 52, #36425} as shown in Figure 122.
6) There should be (1) washer (#9826, Pos.
11) on the top of each axle, for a total of 3
(Figure 125).
7) Remove the entry {pos. 12, #36415} and
exit {pos. 13, #33685} bushings and
inspect for wear Figure 126. Excessive wear
indicates incorrect rigging practices and
should be addressed with those persons
responsible.
8
NOTE:
The centering bushings have a long side
which serves as a guide for the casing cover
{pos. 42, #18267} (See Figure 123).
NOTE:
The adjusting washers are CRITICAL to the
proper operation of the Blocstop and must be
present!
NOTE:
Prior to the removal of the adjusting washers
{pos. 11, #9826}, verify that no washers
are stuck by grease to the casing cover as
shown in Figure 124.
Figure 121
Figure 122
Figure 123
Figure 124
Figure 125
Figure 126

1-7 Jaw, Frame and Cam Removal
1) Remove the top front {pos.8, #36235} and
rear {pos. 5, #825} cams paying attention
to their orientation (Figures 127 & 128).
Ensure that you remove both top adjusting
washers {pos. 11, #9826}. Clean and
replace if necessary.
2) Remove the spring guide bolt (Figure 133).
3) Disassemble the (2) anchor frames {pos. 28,
#36205} and (2) jaw frames {pos. 28,
#36205}. See Figure 134. The washers may
still be stuck to the frames after removal.
Clean and replace if necessary.
9
NOTE:
The cams are installed correctly if you can see
an “S” in them. See Figures 129-132
NOTE:
Occasionally the washers stick to the cams and
frames upon removal.
Figure 127 Figure 128
Figure 129
Figure 130
Figure 131
Figure 132
Figure 133
Figure 134

4) Remove the upper {pos. 6, #36245
(BSO 1020) or #45375 (BSO 1030)} and
lower {pos. 7, #36255 (BSO 1020) or #45385
(BSO1030)} jaws, paying attention to their
orientation (Figure 135). The dovetail
is on the entry side of the unit and help guide
the wire rope into the system correctly. Clean
the jaws thoroughly.
5) The jaws of the Blocstop are heat treated and
stamped with the correct wire rope
diameter. Ensure that the markings
correspond to the wire rope you are using
(Figure 136). If replacement jaws are being
installed, ensure they correspond as well. For
example, BSO10 indicates a special 10mm
dia.
6) Remove the (3) axles {pos. 09, #36365} and
(1) anchor axle {pos. 56, #36225}. See
Figure 137. Unlike the centering bushings {
pos. 55, #38565}, the axles can be installed
with either end facing down.
7) Remove the lower cams {pos.8, #36235} &
{pos. 5, #825} and adjusting washers
{pos. 11, #9826}. See Figure 138.
10
NOTE:
Replacement of the jaws can be accomplished
at this time if they failed the measurement test of
Sec. 6-1.3 due to wear.
Figure 135
Figure 136
Figure 137
Figure 138

1-8 Roller Assembly Inspection
1) The pressure roller {pos. 48, #18287}
usually dislodges when removing the top
casing cover. If necessary, use the Blocstop
tool {#20887} to remove it along with the
driving roller {pos. 50, #18237} (Figure 139).
2) Remove the (2) adjusting washers {pos. 11,
#9826} as shown in Figure 140.
3) Inspect both rollers for excessive wear or flat
spots (See Figure 141). Even if they show no
visible wear the inside of the groove must still
be measured with a caliper. The nominal
diameter is 27mm. If the diameter is less
than 25mm (1") the rollers must be replaced.
If one roller needs replacement, they both
must be replaced.
4) Inspect the pressure spring {pos. 58,
#37235}, spacer {pos. 70,
#38555} and guide tube {pos. 59, #36296} for
damage or wear (See Figures 142 & 143).
11
NOTE:
If the guide tube is worn and the end of it has
mushroomed, it must be replaced to prevent
interference with the roller.
Figure 139
Figure 140
Figure 143
Figure 142
Figure 141

1-9 Counterweight Assembly Replacement
If the bearing or counterweight assembly needs
replacement:
1) Remove the roll pin {pos. 77,
#29466} at the base of the centering axle
{pos. 46, #58015} (See Figure 144).
2) Carefully remove the complete assembly
from the middle casing cover.
3) Exchange the bearing {pos. 18, #36515} as
needed.
4) Reinstall the assembly and roll pin.
1-10 Reassembly of the Jaw Compartment
1) Clean all parts with mineral spirits.
2) Replace any defective parts.
3) Lightly grease the casing cover with wheel
bearing or white lithium grease (Figure 145).
4) Grease and install the lower cams. Ensure
the adjusting washers (Pos. 11, #9826) &
axles (Pos. 09, #36365) are in place (Figure
146).
5) Grease and install the jaws. Ensure that the
dovetail is towards the jaw opening lever as
shown in Figure 147.
6) Grease and install the spring axle on top of
the bottom actuating cam {pos. 10, #36395}
(Figure 148).
12
CAUTION
Never use a graphite or molybdenum
disulphide grease in the Blocstop or Tirak
Figure 144
Figure 145
Figure 146
Figure 147
Figure 148

7) Install the lower anchor frame
{pos. 28, #36205}. Place the remaining axle
{pos. 09, #36365} through the hole nearest
the rounded edge. Now install the anchor
axle {pos. 56, #36225} through the other
hole, and then through an adjusting washer
{pos. 11, #9826}. (Figure 149). Make sure
the anchor axle is properly seated in the BSO
casing.
8) Install the lower jaw frame
{pos. 57, #36215}. The frame must be
installed axactly as shown in Figure 147.
Make sure all axles slide through the
corresponding holes. Now place an adjusting
washer on top of the axles resting in the
jaw frame. See Figure 150.
9) Install the upper jaw frame
{pos. 57, #36215}. The frame must be
installed axactly as shown in Figure 151.
10) Install the upper anchor frame
{pos. 28, #36205}. The frame must be
installed axactly as shown in Figure 149.
13
Figure 149
Figure 150
Figure 151
Figure 152

11) Grease and install the upper cams. Ensure
that the letter "S" is present when looking at
the jaws (Figure 153).
12) Install the adjusting washers (Pos. 11,
#9826) on the axles (See Figure 154).
13) Install the (3) centering bushings and (2)
distance bushings (Figure 155). Ensure the
longer shoulders are pointed down (Figure
156).
1-11 Installation of the Roller Assembly
1) Install the (2) adjusting washers {pos. 11,
#9826} on the top and bottom of the pressing
roller {pos. 48, #18287} (See Figure 157).
14
Figure 153
Figure 154
Figure 155
Figure 158
Figure 157
Figure 156
NOTE:
After installation of the rollery assembly, the notch
should be away from the spring (on a BSO 500
for 9 mm (3/8”). See Figure 158.
NOTE:
To aid this procedure, please reference the
following technical sheet (T-235, Page 22).

3) Install the BSO tool pin into the hole of the
pressing roller and into the spring guide tube
{pos. 59, #36296} as shown in Figure 159.
4) Slide the spacer {pos. 70,#38555} then
spring {pos. 58,#37235} around the guide
tube (Figure 160).
5) Install the BSO tool as shown in Figure 161.
Apply pressure with your index finger and
thumb on the BSO tool.
7) Slowly and evenly, draw the tool and
pressure roller towards the spring (see
Figure 162). Keep the tool level. It will go
into the correct position without a struggle
after a little practice.
8) After the brass bushing of the pressure roller
is properly seated, turn the handle and hold.
9) Tilt the tool slightly down and remove the pin.
Remember to keep the BSO tool twisted
10) Install the driving roller, being sure it is
properly seated on the roll pin {pos. 77,
#29466}.
11) Gently release pressure on the BSO tool
until the rollers meet. Once all the pressure
is released the tool can be carefully removed.
Inspect the roller system assembly (Figure
163).
15
Figure 159
Figure 160
Figure 161
Figure 162
Figure 163
NOTE:
This procedure is much easier if the 2-piece
Blocstop tool (#20887) is used. This tool is
available from Tractel Inc.

1-12 Installation of the Pressure
Spring & Guide Tube
a) Install a casing screw {pos. 68, #12016}
through the distance tube {pos. 52, #36425}
as shown in Figure 164. Do not place a
washer between the screw head and
distance tube.
b) Place (2) washers {pos. 79, 36306} on the
underside of the casing.
c) Loosely install a nyloc nut {pos. 76, #7996}
on the underside.
1) Install the spring {pos. 80, #29396} on
the guide tube {pos.53, #36375}.
2) Wrap a rag around the spring and compress
by hand.
3) Carefully clamp the tube with a pair of needle
nose clamping pliers to hold the spring
compressed about 2-3" (Figure 165).
4) Install the spring washer {pos. 84, #7836}
on the end of the tube.
5) Install the complete assembly into the spring
bolt guide {pos. 10, #36395} (Figure 166).
6) Push back on the jaw assembly towards the
spring to limit the amount of spring travel
when released.
7) Apply pressure to the top cams to prevent
parts from jumping out of position and
release the Vise-Grips.
8) Install the bearing {pos. 69, #10186} and
bearing cover {pos. 31, #36525} as shown in
Figure 167.
16
CAUTION
Always wear proper eye protection!
NOTE:
The screw will be removed after the cover is
installed (see next Sec.) and replaced with the
proper washer configuration. This step helps
keep the distance tube from rolling and
accidentally release the spring assembly.
Figure 164
Figure 165
Figure 166
Figure 167
NOTE:
Use the following procedure to help keep the
pressure spring assembly in place during
reassembly:

1-13 Casing Cover Installation
1) Lightly grease the cover {pos. 47, #36685}
and install on the main body (Figure 168).
2) Use a punch or scribe to align the cover as
shown in Figure 169.
3) Install the (2) casing bolts {pos. 68, #12016}
with washers {pos. 79, 36306} and nyloc nuts
{pos. 76, #7996} as shown in Figure 171.
1-14 Preliminary Operational Test
1) Before installing the outer casing cover, open
the Blocstop jaws and insert the test rope to
test the unit's operation
2) Pull the wire rope quickly. The Blocstop
should activate and you should be unable to
pull the rope out.
3) Reset the Blocstop.
4) Check that the wire rope moves smoothly
through the Blocstop (Figure 173).
17
NOTE:
Do not over tighten the nuts. This may prevent
the Blocstop from operating correctly due to
compression of the internals components (Figure
172).
NOTE:
You may need to remove the screw installed
in step 1 of the previous section
Figure 168 Figure 172
Figure 170
Figure 171 Figure 173

1.15 Installation of the Counterweight Cover
1) Install the cover as shown. Ensure to align
the (3) bushings {pos. 55, #38565} and the
spring {pos. 72, #29446} (Figure 174).
2) After the cover is on and before the screws
are installed, open the Blocstop and push the
orange emergency stop button (Figure 175).
The Blocstop should trip. If not, remove the
cover and try installing it again. If this doesn't
work, the spring {pos. 72, #29446} may be
damaged.
3) Install the (3) casing screws {pos. 75,
#10166}. Do not over tighten.
4) Install the handle {pos. 4, #41855} and roll
pin {pos. 74, #36786} as shown in Figure
176).
18
WARNING
Damage may occur to the spring if the
cover is not installed evenly
Figure 176
Figure 174
Figure 175

1.16 Final Testing
1) Perform the Trigger Speed Testing
procedure outline in Section 1.4 (Figure 177).
The Blocstop must lock within 4" on the wire
rope. REPEAT THIS TEST AT LEAST 3
TIMES!
2) Install the Blocstop on the Tirak and perform
an operational check.
3) Load test the Blocstop by (Figure 178):
a) Placing the Tirak & Blocstop on the test
bench.
b) Lift 125% the rated capacity of the hoist a
couple of inches.
c) Press the emergency stop button on the
Blocstop.
d) Press the down button on the hoist until the
wire rope begins to accumulate between the
hoist and Blocstop.
e) Ensure the Blocstop holds the load securely
f) Press the up button on the hoist until the load
raises a couple of inches.
g) Reset the Blocstop.
h) Lower the load.
19
NOTE:
The following tests must be performed if any
inspection or repair is performed on the Blocstop.
Figure 179
Figure 177

Drawing No E-3058
Edition US-1
Date 1/05
Page 1 / 2
Position Part # Qty. Description Specifications List Price
-- 1Part#39967-BSO1020 (9mm) OR Part#23209-BSO1030 (10mm)
001 39967 1 RELEASE LEVER CPL.
002 35147 1 JAW OPENING LEVER CPL.
003 56345 1 Release lever BSO1020
004 41855 1 BSO HANDLE
005 825 2 Cam BSO1020
006 36245 1 Upper Jaw BSO1020 9mm OR Part#45375 for Upper Jaw BSO1030 10mm
007 36255 1 Lower Jaw BSO1020 9mm OR Part#45385 for Lower Jaw BSO1030 10mm
008 36235 2 CAM
009 36365 3 AXLE
010 36395 1 SPRING AXLE BSO
011 9826 10 Adjusting washer 17x24x1.5
012 36415 1 BUSHING BSO
013 33685 1 Wire rope guide bushing BSO
015 36605 1 Angle for BSO spring
016 22207 1 BSO1020 right cover complete with Pos. 15 and Pos. 59
018 36515 1 Inside bearing BSO
019 36475 1 Adjuster
020 38807 1 Centrifugal weight (left) BSO500
021 36335 1 MOVABLE STIRRUP
022 36345 1 FIXED STIRRUP
023 36355 1 STIRRUP PLATE
024 36585 1 BALANCING ROD
025 38817 1 Centrifugal weight (right) BSO500
026 36575 1 SPACER
028 36205 2 ANCHOR FRAME
031 36525 1 OUTSIDE BEARING
032 12605 1 SPRING
035 56245 1 Cam for release lever BSO500
036 36555 1 GUIDE AXLE
042 18267 1 COVER COMPLETE
046 58015 1 CENTERING AXLE
047 36685 1 COVER
048 18287 1 PRESSING ROLLER COMPLETE 25mm min. diameter
050 18237 1 DRIVING ROLLER 25mm min. diameter
052 36425 2 SPACER
053 36375 1 SPRING GUIDE TUBE
054 10555 1 SPRING STIRRUP
055 38565 3 Spacer
056 36225 1 ANCHOR AXLE
057 36215 2 JAW FRAME
058 37235 1 SPRING DIN 2076-C
059 36296 1 SPRING GUIDE TUBE DIA.6X1X60 6x1x60
060 9986 2 RIVET POP DIA.4,8X14,4 ALU 1.8x14.4
061 49636 1 CLAMPING SLEEVE 5X20 DIN 7344 5x20
062 47615 1 SPRING FOR BSO - For custom speed springs call Tractel
063 33666 2 RETAINING WASHER 5 DIN 6799 A5
065 9816 1 WASHER 13 X 19 X 1 DIN 988 13x19x1
068 12016 2 SOCKET HEAD CAP SCREW M 6X50 DIN 912 M6x50
069 10186 2 Ball bearing 6000-2RS1 10/26x8
070 38555 1 SPACER
071 37345 1 Fixed stirrup axle BSO
072 29446 1 SPRING 0,63X7,27X31
074 36786 1 ROLL PIN DIA.5X32 DIN 1481 5x30
075 10166 3 CAP SCREW M6X60 DIN 912-8.8 M6x60
076 7996 2 Nyloc nut M6
077 29466 2 ROLL PIN 4X16 DIN 7344 4x16
079 36306 7 WASHER A 6,5X14X1,6 DIN 6902 A6.5
080 29396 1 JAW SPRING 1,4X7,8X195
084 7836 1 WASHER A6
086 33656 3 RETAINING WASHER 6 DIN 6799 A6
087 33977 1 Plate for centrifugal weights
104 10376 1WASHER 13/19x0.5
(105)* 27105 1 SIGHT GLASS
Spare Parts BSO 1020 & 1030
Overspeed Safety Brake for 9 or 10mm Wire Rope