Yale Lift-Tech SHAW-BOX Guide

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OPERATION, SERVICE & PARTS MANUAL
SERIES 700
SHASHA
SHASHA
SHAWW
WW
W-BO-BO
-BO-BO
-BOXX
XX
X®
WIRE ROPE ELECTRIC HOISTS
INCLUDING
WEIGHT WATCHER OVERLOAD CLUTCH MODELS
RATED LOADS THRU 25 TONS
Before installing hoist, fill in the
information below. Refer to the
Hoist and Motor data plates.
Model No. _______________
Serial No. _______________
Purchase Date ___________
Voltage _________________
Rated Load ______________
July, 2003 COPYRIGHT 2003,Yale!!
!!
!Lift-Tech, division of Columbus McKinnon Corporation Part No. 113533-60

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FOREWORD
This book contains important information to help you install,
operate, maintain and service your new SHAWBOX electric
hoist. We recommend that you study its contents thoroughly
before putting the hoist into use. Read ANSI B30.16 safety
code for hoists. Then, thru proper installation, application of
correct operating procedures, and by practicing the
recommended maintenance suggestions you can expect
maximum lifting service from the hoist.
It will likely be a long time before parts information found in
Section IX is needed; therefore, after the hoist is installed and
you have completely familiarized yourself with operation and
preventive maintenance procedures, we suggest that this book
be carefully filed for future reference.
When ordering replacement parts from this book, it will be
necessary that you include, with your order, the Hoist Serial
Number, Model Number and Catalog Number which is found
on the nameplate attached to motor end of hoist (Figure 4-1).
For your convenience, a space has been provided on the front
cover of this Manual for entering this information. We
recommend that you fill it out immediately so it is readily at
hand when needed.
Figure 1-1. Cutaway View of Standard Series “700” SHAW-BOX Electric Hoist
This cutaway view illustrates the high quality and precision construction of your new SHAW-BOX electric hoist. An examination of
its makeup will show it is designed and built to give you long service life with a minimum of attention. Notice that it has wide-faced
helical gearing made of heat-treated steel, ball bearings throughout, large diameter grooved rope drum and large lower block rope
sheave. In addition, this hoist offers unusually easy accessibility to all working parts. It is designed so that you needn’t take your
hoist down for servicing. A hinged side cover gives quick access to electrical components. Removable lightweight aluminum end
covers provide full access to brake mechanism, motor brake, load brake and gearing.

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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.
NOTICE: Information contained in this book is subject to change without notice.
INDEX
SECTION I GENERAL DESCRIPTION Page
Paragraph 1-1 General ................................................................................................................................................4
Paragraph 1-2 Basic Construction ..............................................................................................................................4
SECTION II INSTALLATION
Paragraph 2-1 General ................................................................................................................................................4
Paragraph 2-2 Suspending Hoist ................................................................................................................................4
Paragraph 2-3 Connecting Hoist to Electrical Service ...............................................................................................5
Paragraph 2-4 Pre-Operation Checks.........................................................................................................................5
SECTION III OPERATION
Paragraph 3-1 General ................................................................................................................................................7
Paragraph 3-2 Push Button Operation........................................................................................................................7
Paragraph 3-3 Overload Clutch Operation .................................................................................................................7
Paragraph 3-4 Operating Precautions ........................................................................................................................7
SECTION IV LUBRICATION
Paragraph 4-1 General ................................................................................................................................................8
Paragraph 4-2 Change Gearcase Oil..........................................................................................................................8
Paragraph 4-3 Lubricate Hoist Cable..........................................................................................................................8
Paragraph 4-4 Lubricate Upper Sheave & Lower Block Assembly............................................................................8
Paragraph 4-5 Limit Stop Lever Lubrication ...............................................................................................................8
Paragraph 4-6 Lubricate Limit Switch .........................................................................................................................8
SECTION V INSPECTION AND PREVENTATIVE MAINTENANCE
Paragraph 5-1 General ................................................................................................................................................9
Paragraph 5-2 Inspect Lower Block ..........................................................................................................................10
Paragraph 5-3 Inspect Upper Block and Hoist Suspension .....................................................................................10
Paragraph 5-4 Inspect Electrical Controls ................................................................................................................12
Paragraph 5-5 Inspect Motor Brake and Actuating Mechanism...............................................................................12
Paragraph 5-6 Inspect Mechanical Load Brake and Gearing ..................................................................................12
Paragraph 5-7 Inspect Rope Drum and Shaft ..........................................................................................................14
Paragraph 5-8 Rope Inspection, Replacement & Maintenance...............................................................................14
Paragraph 5-9 Rope Reeving....................................................................................................................................15
Paragraph 5-10 Testing Hoist ....................................................................................................................................20
SECTION VI TROUBLESHOOTING CHART ................................................................................................................20
SECTION VII ADJUSTMENTS
Paragraph 7-1 Mechanical Load Brake.....................................................................................................................22
Paragraph 7-2 Motor Brake Adjustment....................................................................................................................22
Paragraph 7-3 Block Operated Limit Switch .............................................................................................................22
Paragraph 7-4 Geared Rotary Limit Switch Adjustment ..........................................................................................23
Paragraph 7-5 Overload Clutch Adjustment and Testing .........................................................................................23
Paragraph 7-6 Shortening of Push Button Cable .....................................................................................................25
SECTION VIII WIRING DIAGRAMS..............................................................................................................................25
SECTION IX PARTS LIST
Paragraph 9-1 General ..............................................................................................................................................25
Paragraph 9-2 List of Parts Illustrations....................................................................................................................25
FOREWORD (Continued)
The contents of this manual are of necessity, general in nature
and may cover features not incorporated on your hoist; or, you
may have ordered features not covered by this manual.
Therefore, the user must exercise care in applying instructions
given in this manual. If specific information not in this manual
is required, contact the factory at Muskegon, Michigan 49443.
THE INFORMATION CONTAINED IN THIS MANUAL IS FOR
INFORMATIONAL PURPOSES ONLY AND LIFTTECH
INTERNATIONAL DOES NOT WARRANT OR OTHERWISE
GUARANTEE (IMPLIEDLY OR EXPRESSLY) ANYTHING
OTHER THAN THE COMPONENTS THAT LIFT-TECH
MANUFACTURES AND ASSUMES NO LEGAL
RESPONSIBILITY (INCLUDING, BUT NOT LIMITED TO
CONSEQUENTIAL DAMAGES) FOR INFORMATION
CONTAINED IN THIS MANUAL.

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SECTION I - GENERAL DESCRIPTION
1-1. GENERAL. SHAW-BOX Series “700” electric hoists are
wire rope and drum type hoists which are manufactured in two
basic models: A standard model, available in four conventional
suspensions (Lug Mounted, Push Trolley, Hand Geared Trolley
and Motor Driven Trolley); and, a low headroom model with
three special low-headroom design trolley suspensions (Push,
Hand Geared and Motor Driven types). The standard model
hoist comes in eleven load sizes, ranging from 2 thru 20 tons,
with various lifts and lifting speeds, while the low headroom
model comes in 7 load sizes, from 2 thru 10 tons, and various
lifts and lifting speeds. Both of the basic models are available
with single or two-speed lifting control. Deck mounted and base
mounted hoists are also available as modifications of the basic
hoist models. Deck mounted hoists are available thru 20 ton
rated load.
NOTICE
SHAW-BOX hoists thru 15 tons are available with an
optional built-in mechanical overload clutch. Hoists having
this device are identified with words “WEIGHT
WATCHER” on the hoist.
The “WEIGHT WATCHER” overload limiting device permits
operation of your hoist within its rated load and helps prevent
lifting of excessive loads which could cause permanent
deformation of a properly maintained hoist or trolley.
1-2. BASIC CONSTRUCTION. Series “700” standard model
and low headroom model electric hoists are of the same basic
construction, differing primarily in the suspension method and
rope reeving.They consist of a rugged steel frame which houses
a lifting drum and serves as the suspension for carrying the
entire hoist load. A mounting lug, for attaching the hoist trolley
or mounting to an overhead suspension (standard model), is
located on the top of the frame. An aluminum alloy gearcase,
attached to one end of the hoist frame, houses a two-reduction
gear train and a mechanical load brake. A gearcase cover and
a brake cover, both of aluminum alloy, mounted on the end of
the gearcase, houses an automatic motor brake. An electric
driving motor is mounted at the other end of the hoist frame.
Electrical system components, located in a compartment at
the front of the hoist frame, control operation and rotating
direction of driving motor. Hoisting cable and an enclosed lower
block assembly is used for lifting loads. An upper limit stop is
used to limit the travel of the lower block in the raising direction
to protect hoist from damage. A push button control station for
operating the hoist is suspended on a wire strain cable attached
to hoist frame at the motor end of the hoist.
SECTION II - INSTALLATION
2-1. GENERAL. SHAW-BOX Series 700" electric hoists are
lubricated and tested before being shipped from the factory. To
place hoist in service, attach a suitable suspension (Paragraph
2-2), connect to electrical service (Paragraph 2-3) and perform
pre-operation tests and checks (Paragraph 2-4).
Before attempting installation of hoist or trolley, the
main power switch must be locked in the open position
(off).
WARNING
Design and installation of hoist support shall be
performed only by qualified persons.
WARNING
2-2. SUSPENDING HOIST. Hoist may be suspended in a fixed
location servicing only the area directly below the hoist (Lug
Mounted). Hoist may be attached to a moveable trolley or
trolleys which in turn may be mounted on an I-beam attached
to a building or crane, servicing a large area (Trolley Mounted).
a.Lug Mounted hoists attach to adequate supports welded
or bolted to a building or other structure. The supporting
structure must have sufficient strength with appropriate
safety factor, to support the weight of the hoist and rated
load as well as other loads to which the supporting
structure may be subjected.
Steel angles or plates used to suspend hoist should be
spaced as close to the hoist suspension lug as possible.
Mounting bolts or threaded studs, attaching hoist to
mounting structure, shall have a diameter not less than
recommended by manufacturer and material equivalent
to ASTM A 325. Make certain that mounting bolts or
studs are long enough so that the threads do not engage
the mounting support and that mounting bolts or studs
are secured with nuts and lockwashers, selflocking nuts
or cross bolting, if unthreaded.
b.Trolley Mounted hoists are attached to moveable trolleys.
If hoist is mounted on an existing trolley, a qualified person
shall determine that the trolley and its supporting structure
are adequate to support the rated load and weight of the
hoist. Hoist/trolley units may be shipped from the factory
with trolley packaged separately. If the trolley can be
installed directly over the end of the supporting beam,
assemble trolley to hoist. Be certain that the spacing
between wheel flanges, after assembly, is 1/4" greater
than exact width of beam flange. (See Figure 2-1 below
and instruction sheet furnished with trolley.) Using proper
equipment, carefully lift trolley and hoist and install on
end of beam.
For trolleys which are to be mounted along the span of a
beam not having open ends, measure exact width of
beam flange and assemble trolley to hoist so that spacing
between wheel flanges is 1/4" (see Figure 2-1) greater
than beam width (3/8" if beam has curves). This is
accomplished by rearranging the spacer washers on the
bolts connecting trolley side plates to hoist mounting lug.
If trolley is shipped separate from hoist, see instruction
sheets furnished with trolley for orientation and installation.

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Be certain that electrical power supply is OFF and
locked in the open position before attempting any
electrical connections to the hoist. This equipment
must be effectively grounded according to the National
Electric Code, or other applicable codes. If the
grounding method used is through the trolley wheels,
then each section of track must be grounded by 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.
WARNING
Mounting of the hoist/trolley unit on the monorail
and final pre-operation inspection shall be performed
only by qualified persons properly supervised.
WARNING
Recheck spacer washers to make certain that the number
of washers between the side plate and hoist suspension
lug are equal, and also the number on the outside of
each side plate are equal. The suspension stud nuts
should only be snugged up on the lockwashers until a
load has been applied on the hook. A partial load
(approx. 25 percent rated hoist capacity) placed on the
hook will properly seat hoist in the trolley. Tighten
suspension stud nuts only after hoist has been properly
seated in the trolley.
CAUTION
When proper spacing has been determined, loosen mounting
nuts (Item 1, Figure 2-1) to allow trolley wheels to spread far
enough to pass over edges of beam flange. (Some installations
may require complete removal of one trolley side plate.) Using
adequate equipment carefully lift the hoist and trolley so the
wheel treads will rest on the lower beam flange. Replace side
plate and washers if removed for installation. Replace
suspension stud nuts.
Figure 2-1. Sectional View of Trolley showing
proper wheel and washer spacing
2-3. CONNECTING HOIST TO ELECTRICAL SERVICE.
Electrical service to the hoist may be power cable or a guarded
system having sliding shoe or wheel type collectors.
a.Follow national, state and local electrical codes when
providing electrical service to the hoist.
Power supply to the hoist and/or trolley must be the
same voltage, frequency and phase that is specified on
the hoist and trolley nameplates. Single speed hoists
are reconnectable for use on either 460 V. or 230 V.
Check terminal board connections on dual voltage hoists
with wiring diagram to make certain that the motor,
transformer and brake leads are located on proper
terminals.
CAUTION
b.Make electrical connections using the appropriate wiring
diagrams furnished with the hoist. All electrical
connections, including connections to collectors or power
cord shall be made only by qualified journeyman
electricians.
c.When trolley is shipped separate from hoists, see special
instructions furnished with trolley for orientation and
installation.
d.For deck mounted three speed hoists, secondary resistors
are furnished. These are to be mounted by the customer
to suit his requirements. Since resistors generate heat,
they are to be located outside of the control panel
enclosure in a well ventilated area that will allow the heat
to readily dissipate.They must be guarded from accidental
contact by personnel (perforated metal covers are often
used). Provision must be made to prevent molten metal
from falling on personnel (drip trays may be provided).
Failure to properly mount resistors may be hazardous
to personnel and equipment.
WARNING
2-4. PRE-OPERATION CHECKS.
a.Check Oil Level. (Figure 4-1) The gearcase has been filled
with oil to proper level and grease points for upper and
lower sheaves (when so equipped) have been lubricated
at the factory. However, this should be rechecked before
operating hoist.
12207A

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Check oil level by removing plug locate on side of the
gearcase adjacent to the embossed words “OIL LEVEL".
When properly filled, oil should be level with bottom of
tapped hole. Fill to this level with oil as specified in
Paragraph 4-2.d. Grease fittings in sheave pin ends
should show evidence of grease.
b. Check Push Button Operation and Phasing:
To properly check the phase of the hoist, follow steps below:
(1) With “POWER OFF” operate all the push buttons and
determine that they do not bind or stick in any position.
(2) Temporarily connect hoist to power source.
(3) Operate “UP” button briefly to determine direction of
hook travel.
(4) If hook raises, phase is correct. Turn power off and
make temporary connections permanent.
(5) If hook lowers, hoist is “Reverse Phased.” TURN
POWER OFF and correct by interchanging any two
leads at power source connection. Do not change
internal wiring of hoist.
c.Check Limit Switch Operation.
(1) A block operated upper limit stop (Figure 2-2) is
furnished as standard equipment on most Series “700”
electric hoists (some long lift and all deck mounted
hoists have geared type limit switches as standard).
This limit stop is factory set to stop lower block at
safest high position, guarding against overtravel and
possible damage to hoist.No adjustment can be made.
However, the hoist should be tested by jogging lower
block against limit weight (Figure 2-2) to be sure the
limit switch is functioning properly. When lower block
lifts limit weight, hoist will automatically stop. If lower
block coasts through the stop limit switch when lifting
at maximum height, in most SHAW-BOX hoists a
reversing switch will automatically close and reverse
direction of motion to lowering.
Figure 2-2. Schematic Diagrams of
Upper Limit Stop Arrangement
On three phase hoists it is possible to have “Reverse
Phasing” causing the lower block to lower when the
“Up” button is depressed.When this condition exists
the automatic limit stop switch is inoperative and
hoist operation will be dangerous.
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.
WARNING
Some hoists are shipped with the electrical controls
loose (disconnected) and will not have the upper
and lower limit switches connected. DO NOT
OPERATE HOIST UNTIL LIMIT SWITCHES ARE
PROPERLY CONNECTED AND ADJUSTED. Failure to
do so may allow hoist to be operated beyond proper
travel limits which can cause load to drop, resulting
in damage to equipment or injury.
WARNING
NOTICE
Under normal operating conditions stop hoist travel
before engaging limit switches. Limit switches are safety
devices and should not be used as normal operating
control.
(2) A geared rotary type upper and lower limit switch is
provided optionally when both upper and lower limit
stops are required (Figure 7-1). This switch is
adjustable and although roughly preset by the factory,
it should be adjusted at time of installation to the
desired high and low limits of lower block travel. Refer
to SECTION VII, Paragraph 7-4.
d.Check Lower Block and Hoisting Cable. Depress “DOWN”
push button and run lower block to its lowest position. No
less than two wraps shall remain on the drum with the
loaded hook in its lowest position, unless hoist is equipped
with a lower limit switch in which case no less than one
wrap shall remain on the drum. Also check to see that
lower block and rope does not twist excessively. If it does
twist, to the extent that two ropes rub against each other,
disengage rope from the frame anchor and twist rope
four or five turns in a direction opposite to that which the

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block turns. Reconnect rope to 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 repeat process until twisting is corrected.
e.Lubricate hoisting Cable. For longer cable life, it is
recommended that the cable be lubricated at time of
installation by applying a heavy coating grease as outlined
in SECTION IV, Paragraph 4-3.
SECTION III - OPERATION
3-1. GENERAL. Operation of Series “700” SHAW-BOX electric
hoists is controlled by a convenient pendant push button station.
With it, the hoist can be controlled to give fast lifting and
lowering; or controlled to lift or lower load in small increments,
providing accurate spotting. The push button station has a
built-in interlock to prevent depressing opposing buttons
simultaneously.
When first using hoist, break in by operating under lighter
loads to full travel before applying maximum load.
3-2. PUSH BUTTON OPERATION.
a Depress push button marked “UP” to raise load.
b.Depress push button marked “DOWN” to lower load.
c.Jogging the push buttons will give “hairline” load
movement. The quickness of the depressing motion will
determine the amount of movement. Excessive use of
this “Jogging” feature will cause premature burning of
contact tips and motor overheating.
d.On two-speed hoists, partial depression of button operates
hoist at slow speed; depressing button completely
operates hoist at fast speed.
3-3. OVERLOAD CLUTCH OPERATION (optional). The
overload clutch is factory preset and tested so that the hoist
will lift its full rated load but will refuse to lift overloads which
could cause deformation or weakening of your hoist. If the load
to be lifted exceeds the clutch setting, the hoist motor will
continue to run when the “UP” button is depressed and rotate
the load brake gear without lifting the load. Whenever this
slipping occurs, immediately release the “UP” push button to
prevent overheating of the clutch friction surfaces and the hoist
motor.
3-4. OPERATING PRECAUTIONS
Always know load to be lifted. Lift-Tech does not
recommend lifting loads greater than the rated load
of your hoist.
WARNING
Equipment covered herein is not designed or suitable
as a power source for lifting or lowering persons.
WARNING
Safe operation of an overhead hoist is the operator’s
responsibility. Listed below are some basic rules that can make
an operator aware of dangerous practices to avoid and
precautions to take for his own safety and the safety of others.
Observance of these rules in addition to frequent examinations
and periodic inspection of the equipment may save injury to
personnel and damage to equipment.
a. DO read ANSI B30.16 Safety Standard for Overhead
Hoists and the Operation, Service and Parts Manual.
b. DO be familiar with hoist operating controls
procedures and warnings.
c. DO make sure hook travel is in the same direction as
shown on controls.
d. DO make sure hoist limit switches function properly.
e. DO maintain firm footing when operating hoist.
f. DO make sure that load slings or other approved
single attachments are properly sized and seated in
the hook saddle.
g. DO make sure that the hook latch is closed and not
supporting any part of the load.
h. DO make sure that load is free to move and will clear
all obstructions.
i. DO take up slack carefully, check load balance, lift a
few inches and check load holding action before
continuing.
j. DO avoid swinging of load or load hook.
k. DO make sure that all persons stay clear of the
suspended load.
l. DO warn personnel of an approaching load.
m. DO protect wire rope from weld splatter or other
damaging contaminants.
n. DO promptly report any malfunction, unusual
performance, or damage of the hoist.
o. DO inspect hoist regularly, replace damaged or worn
parts, and keep appropriate records of maintenance.
p. DO use the hoist manufacturer’s recommended parts
when repairing a hoist.
q. DO use hook latches.
r. DO apply lubricant to the wire rope as recommended.
s. DO NOT lift more than rated load.
t. DO NOT use the hoist load limiting device to measure
the load.
u. DO NOT use damaged hoist or hoist that is not
working correctly
v. DO NOT use the hoist with twisted, kinked, damaged
or worn wire rope.
w. DO NOT lift a load unless wire rope is properly seated
in its groove(s).
x. DO NOT use load rope as a sling or wrap rope around
the load.
y. DO NOT lift a load if any binding prevents equal
loading on all supporting ropes.
z. DO NOT apply the load to the tip of the hook.
aa. DO NOT operate unless load is centered under hoist.
ab. DO NOT allow your attention to be diverted from
operating the hoist.
ac. DO NOT operate the hoist beyond limits of load rope
travel.
ad. DO NOT use limit switches as routine operating stops
unless recommended. They are emergency devices
only.
ae. DO NOT use hoist to lift, support or transport people.

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af. DO NOT lift loads over people.
ag. DO NOT leave a suspended load unattended unless
specific precautions have been taken.
ah. DO NOT allow sharp contact between two hoists or
between hoist and obstructions.
ai. DO NOT allow the rope or hook to be used as a ground
for welding.
aj. DO NOT allow the rope or hook to be touched by a
live welding electrode.
ak. DO NOT remove or obscure the warnings on the hoist.
al. DO NOT adjust or repair a hoist unless qualified to
perform hoist maintenance.
am. DO NOT attempt to lengthen the load rope or repair
damaged load rope.
an. Personnel not physically fit or properly qualified, shall
not operate hoist.
ao. Do not operate hoists unless hook moves in the same
direction as indicated on the push button. If opposite
direction occurs, see preoperation checks, Paragraph
2-4.b.
ap. Do not operate hoist unless limit switch is operating
properly.
aq. Center hoist over load before operating. Avoid side
pulls and swinging of load or load hook when
travelling hoist.
Figure 4-1. View of Hoist Showing Location of
Name Plates and Oil Plugs
Do not operate the hoist with the hoisting rope out
of the drum grooves. Such operation may result in
the rope breaking and dropping the load which can
cause damage to equipment and injury to operator
or other personnel. Hoist rope will remain in the drum
grooves during proper operation under normal
operating conditions, however, slack or kinked rope,
excessive side pulls, swinging or jerking of load, or
similar abuse, may cause the rope to leave the
grooves.
WARNING
ar. Observe recommended inspection and maintenance
procedures.
as. Use common sense and best judgement whenever
operating a hoist.
SECTION IV - LUBRICATION
4-1. GENERAL. The lubrication services outlined in Paragraphs
4-2 thru 4-6 should be performed at regular intervals to maintain
top hoist performance and insure long life. Intervals of at least
six (6) months, coinciding with spring and fall seasons, are
recommended. The reason for this is that, on hoists installed
out-of-doors and in unheated areas, a “cold test” oil is required
in cold (below freezing) climates making seasonal changes
necessary.
4-2. CHANGE GEARCASE OIL. (Figure 4-1)
a. Remove oil drain plug from bottom of gearcase and drain
out oil.
b. Flush out hoisting using kerosene. Reinstall drain plug.
c. Remove oil level plug from front of gearcase cover.
11058LB
d. Refill thru filler hole to proper level (bottom of oil level
plug hole) using Automatic Transmission Fluid DEXRON
III Type, suitable for all temperature ranges. The amount
of oil required depends upon overall size of gearcase;
two sizes are used for Series “700” hoists. To determine
size and amount of oil to add, measure width of hoist at
gearcase cover. If the width is 24-3/4 inches, add 6 quarts
of oil; and if 34-1/4 inches, add 18 quarts.
4-3. LUBRICATE HOISTING CABLE. Hoists are shipped from
the factory without an exterior coating of grease on hoisting
cable. It is recommended, where conditions permit, that the
cable be thoroughly coated at installation and kept well
lubricated with LUBRIPLATE Chain and Cable Fluid or equal.
4-4. LUBRICATE UPPER SHEAVE AND LOWER BLOCK
ASSEMBLY
a. Some hoists are equipped with roller-type upper and lower
sheave bearings and have grease fittings located in ends
of sheave pins. If hoist is so equipped, apply (*) NLGI No.
2 grease, such as Shell Oil Company’s Alvania No. 2 or
equivalent, for operating temperatures from +50°F to
+125°F For colder temperatures, (-20°F to +50°F) use
NLGI No. 1 such as Shell Oil Company’s Alvania No. 1 or
its equivalent. Hoists not equipped with grease fittings in
sheave pins have shielded ball bearings with lubricant
sealed in and do not require additional lubrication.
b. On Low Headroom Models, apply a few drops of S.A.E.
No. 50 oil to thrust bearings at trolley brackets.
(*)National Lubricating Grease Institute.
4-5. LIMIT STOP LEVER LUBRICATION. Some hoists are
equipped with a bar operated limit switch. Apply a few drops of
S.A.E. No. 50 oil to pivot points of limit rod.
4-6. LUBRICATE LIMIT SWITCH. Provide a light film of NLGI
No. 2 grease on bevel gear of limit switch.

Page 9
SECTION V - INSPECTION AND PREVENTIVE
MAINTENANCE
5-1. GENERAL. All SHAW-BOX, Series “700,” hoists are
inspected and tested at the factory. Regular in service inspection
and preventive maintenance programs not only help reduce
overall maintenance costs but may also prevent service
shutdowns by forewarning of problems that could cause these
shutdowns. Regular inspections, periodic minor adjustments,
regular cleaning and lubrication and replacement of worn parts
can help preserve good performance and operation of your
hoist.
Many factors influence the inspection and preventive
maintenance program required for your hoist. Frequency and
severity of service and material handled, local environmental
conditions and various applicable codes are some of the factors
that the user must consider to adjust inspection and
maintenance program outlined in this section to meet his
specific conditions.
The inspection and maintenance services outlined in this
section are considered minimum. Recommended in the
schedule are minimum inspection and maintenance intervals
based on average daily use in a normal environment. Average
daily use is based on 1000 operational hours per year maximum
and intermittent operation of the hoist eight hours per day, five
days per week with a maximum 40 percent “on” time and the
average loading not exceeding 65 percent of rated load.
Environmental conditions in which the hoist operates are also
important considerations for the user when adjusting hoist
inspection and maintenance programs to local conditions.
Frequency of inspection and maintenance must be increased
if hoist is subjected to severe atmospheric environmental
conditions, such as corrosive vapors, extreme heat or cold,
cement or dust and other airborne contaminants. The user
should carefully consider all environmental conditions and adjust
frequency and degree of maintenance for his local conditions.
Consult Lift-Tech Field Service Department for advice for
unusual environmental conditions.
Various codes also regulate inspection and maintenance
programs. Attention must be given to applicable federal
standards, OSHA regulations, national standards, state and
local codes which may include mandatory rules relating to
hoist inspection and maintenance. The user should become
familiar with all applicable codes for his area and be guided
accordingly.
Listed on the Recommended Inspection and Maintenance
Schedule are inspection frequencies and requirements. Perform
these inspections regularly as scheduled and additional
inspections as may be required for activity, service and
environment of your hoist. The hoist operator must be
responsible for determining the operating conditions and severity
of service.
Inspection Schedule and Maintenance Report Form.
Shown on page 11 of this manual is a recommended Inspection
Schedule and Maintenance Report form which lists various
components of the hoist. The form also includes trolley
components, runway components, and miscellaneous items.
This form is suggested as a guide for written inspection reports.
Inspections are recommended each month and should be
performed thoroughly enough to inform the hoist user of
deficiencies for any item listed. This form does not supersede
the Inspection and Maintenance Schedule listed below but may
be used to record scheduled inspection and maintenance
services required.
The user should revise the inspection interval, add additional
units or provide a similar form to suit particular conditions
which may exist.However, written, dated and signed inspection
reports should be maintained particularly on critical items, such
as hoist hooks, hoisting ropes, sheaves, drums and brakes.
Periodic review of old inspection reports can point out service
life of hoist components, forecasting need for adjustment, repair
or replacement of these components.
As a matter of expedience, appointed maintenance personnel
inspecting hoist can also take care of minor adjustments, repairs
and cleaning, where required. Note column on Inspection
Schedule and Maintenance Report form headed Corrective
Action and Notes. When corrective action is made during
inspection, note condition of part or unit as inspected in
appropriate Condition column with a check mark ("). Note
“during inspection” corrective action taken and date in space
provided. In this manner, items requiring further attention will
be checked (") without showing corrective action. This will
advise the designated person responsible for hoist operation
and safety, who reviews the reports, that deficiencies exist.
The designated person will check all deficiencies as listed and
reexamine or otherwise determine whether they constitute a
safety hazard.
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.
WARNING
Do not operate a hoist having unusual vibrations,
sounds or with anything wrong or apparently wrong.
Danger may be present that the hoist operator cannot
see. Determine and correct cause of unusual
conditions and make certain hoist can be operated
safely.
WARNING
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.

Page 10
5-2. INSPECT LOWER BLOCK.
a. Check lubrication of all parts. Also lubricate the shank of
the hook which passes through the crosshead. If thrust
bearing is removed, apply NLGI No. 2 grease.
b. Check each sheave to insure rope groove is smooth and
free from burrs, or other surface defects.
c. Check each sheave for freedom of rotation, replace
bearings if defective.
d. Make certain that dowel pin holding the hook nut to the
hook, is securely in position.
e. If hook is equipped with a safety latch or rotational lock,
check to determine that they are in good operating
condition.
f. Check throat opening of hook. (Refer to Figure 5-1.) It is
recommended that upon receipt of the hoist, a
measurement be made and recorded of the hook throat
opening. OSHA regulations require that the hook be
replaced if the throat opening exceeds 15 percent of the
original opening, or if the hook is twisted more than 10
degrees from the unbent plane. A gage block, properly
identified to the hoist, similar to the one shown in Figure
5-1 is suggested to be made for each hook for use in
these measurements.
g. Hooks showing signs of cracks must be replaced. Hooks
should be inspected at least once per year using dye
penetrants, magnetic particle or other suitable crack
detecting methods.
h. Check wear of the hook, especially at the saddle and
replace if badly worn.
5-3. INSPECT UPPER BLOCK AND HOIST SUSPENSION.
a. Check upper block sheaves (when hoist is so equipped)
for wear, damage and freedom of rotation.
If sheaves do not rotate freely, disassemble block and inspect
bearings. Replace worn or damaged bearings, washers, pins
or sheaves.
b. Make certain that all sheaves, bearings and hanger pins
are free of foreign material and properly lubricated.
Bearings without grease fittings are lubricated for the life
of the bearing and require no further lubrication. After
inspection lubricate all upper block lubrication fittings.
c. Make certain that rope guide is not bent, loose or
otherwise distorted; guide must have close clearance to
sheave flange to keep rope in sheave grooves.
d. Check hoist suspension bolts on lug suspended hoists;
make certain that bolts are secure, properly tightened
and free from damage.
e. Check hoist suspension bolts on trolley mounted hoists.
Make certain that bolts are secure, properly tightened
and free from damage. On low headroom hoists, and
other two trolley hoists, suspension bolts to both trolleys
must be inspected.
Do not operate hoists having worn or damaged
suspension bolts.
WARNING
Figure 5-1. Method of measuring hook throat opening
12172
RECOMMENDED INSPECTION AND MAINTENANCE SCHEDULE
TIME INTERVAL INSPECTION OR MAINTENANCE
Daily or start * Check operation of all functional mechanisms including limit switch operation, brakes and control. Check hoist cable
of each shift for kinks, abrasions, corrosion or broken wires or evidence of improper spooling on drum. Inspect hooks, upper and
(visual) lower blocks, and all load bearing components for damage.
1 Month * HOIST CABLE - Inspect and lubricate per Paragraph 5-8.
1-3 Months * ELECTRICAL CONTROLS - Inspect per Paragraph 5-4. Check hoist gearcase oil level - add oil as required per
Paragraph 4-2.d.
6 Months * LOWER BLOCK - Inspect per Paragraph 5-2.
UPPER BLOCK - Inspect per Paragraph 5-3.
Annually * Motor brake and actuating mechanisms. Inspect and adjust per Paragraph 5-5. Inspect hooks with crack detecting
procedures per Paragraph 5-2. Drain and refill hoist gearcase per Paragraph 4-2.
6 Months or * Inspect electrical controls per Paragraph 5-4. Change hoist gearcase oil - Fill with oil per Paragraph 4-2.d. Lubricate
500-750 hours hoist cable per Paragraph 4-3. Lubricate upper and lower hook block per Paragraph 4-4. Lubricate limit stop lever
“on” time per Paragraph 4-5. If a screw type limit switch is furnished, add a light film of NLGI No. 2 grease to bevel gear.
5 Years elapsed * Complete inspection, disassembly, and maintenance required. It is recommended that your SHAW-BOX Repair
time or 5000 Station be contacted for this service.
hours “on” time

Page 11
INSPECTION SCHEDULE AND MAINTENANCE REPORT
HOIST SERIAL NO. (MFGRS) _______________________ CUSTOMER CRANE IDENTITY NO._______________________
RATED LOAD _________________ LOCATION IN PLANT __________________________________
TYPE ________________________ THIS INSPECTION IS MONTHLY #ANNUAL #
VOLTAGE _____________________ SEMI-ANNUAL #
INSPECTED BY: ________________ DATE _____________
*
Recom- CONDITION
COMPONENT, UNIT OR PART mended (Check column best indicating condition when CORRECTIVE ACTION
and location Inspection part or unit is inspected. Use note column to NOTES
Interval the right if condition is not listed below.)
COMPONENT,
UNIT OR
PART
(Indicate corrective action taken during inspection and note date. For
corrective action to be done after inspection, a designated person must
determine that the existing deficiency does not constitute a safety hazard
before allowing unit to operate. When corrective action is completed,
describe and note date in this column.)
Typical Inspection Schedule and Maintenance Report form.
User must adjust inspection interval and components to suit his individual conditions and usage. 12375B
Monthly
Good
HOIST LOCATION
*See text for DAILY & WEEKLY REQUIREMENTS. SIGNED & DATED REPORT REQUIRED – OSHA.
INSPECTION INTERVAL. XMAGNETIC PARTICLE OR EQUIVALENT EXAMINATION REQUIRED.
TROLLEYRUNWAYS RESISTORS
MISC.
DATE
Motor
Motor Brake
Mechanical Load Brake
Overload Clutch
Couplings
Gears, Shafts & Bearings
Upper Block
Lower Block
Hook & Throat Opening XRecord Hook Throat Opening
Hoist Rope
Rope Drum
Guards
Limit Switch
Pushbutton
Wiring
Motor
Brake (when so equipped)
Couplings
Gears, Shafts & Bearings
Frame
Wheels
Bumpers
Guards
Conductors
Collectors
Hoist
Trolley
Monorail Joints
Monorail
Main Conductors
Main Collectors
General Condition
Load Attachment Chains
Rope Slings & Connections
Change Gearcase Lub.
Grounding Faults
CONTROL
STATION OR
PUSH BUTTON
Annual
Semi-Annual
Adjustment
Required
Repair Required
(Loose Parts or
Wires)
Replacement
Required
(Worn or Damaged)
Lubrication
Required
(Low Oil or Grease,
Rust or Corrosion)
Cleaning or
Painting Required

Page 12
5-4. INSPECT ELECTRICAL CONTROLS. Arrangement of
electrical control equipment varies with the type of control,
physical space and the optional control features ordered with
the hoist.
Note the location in the electrical compartment of the control
circuit fuse, transformer, limit stop switches and the hoist
contactors. Trolley contactors and optional hoist and trolley
fuses may also be located in this compartment on certain
models. (Note: The rope anchor on single reeved hoists is
accessible from this compartment.)
Hoist and trolley fuses and trolley contactors may be located in
electrical compartment located on trolley on certain models.
Use wiring diagram furnished with hoist to determine electrical
components on your hoist; then determine component location
and identity on your hoist.
Be certain that main power switch is locked in open
position before opening hinged access cover on side
of hoist.
WARNING
Check to be certain main power switch is locked in
open position before removing brake cover.
WARNING
a. Open hinged access cover at side of hoist and inspect
wiring and terminals. Terminals should be securely
crimped to wires and insulation sound. Terminal screws
should be tight.
b. Check condition of contactor assembly, transformer, and
upper limit switches.
5-5. INSPECT MOTOR BRAKE AND ACTUATING
MECHANISM.
a. Remove one hex button head cap screw from brake cover
and lift brake cover away from gearcase cover.
b. Unplug electrical leads and loosen set screw in gearcase
cover (Ref. No.1 in Figure 9-6).Turn actuating mechanism
counterclockwise, by hand or with a plumber’s strap
wrench, and remove from gearcase cover.
c. Check to see that brake plunger moves freely. Inspect for
evidence of overheating or other damage.
d. Replace all worn or damaged parts. Operating spring on
actuating mechanism is color coded for brake torque;
when replacing spring use spring having same color code.
When replacing body assembly, also replace brake
operating spring.
e. Reassemble brake and cover only if further disassembly
to check friction surfaces and hub spline is not required
at this time. Refer to “MOTOR BRAKE ADJUSTMENT’
paragraph 7-2 for adjusting instructions. For further
disassembly proceed to step “f.”
f. To check motor brake friction surfaces (Figure 5-3), drain
oil from gearcase. Disconnect solenoid coil leads. Remove
hex head cap screws securing gearcase cover to
gearcase. Remove gearcase cover and attached motor
brake actuating mechanism from gearcase.
g. Remove retaining rings from the brake pilot studs and lift
off the compression plate. Lift off washer and lining
assemblies, release springs, and motor brake plates. (Note
for reassembly, that two of the washer and lining
assemblies have friction surfaces on one side only and
must be replaced at each end. Three washer and lining
assemblies, with friction surfaces on both sides and
release springs are replaced between the motor brake
plates; see Figure 5-3). Check motor brake plates for
warping, scoring or other signs of deterioration. Also check
spline fit of motor brake plates to the brake hub for
gouging, mushrooming of the plates or other signs of
distress or wear. Replace plates if these conditions are
found. Brake plates which are replaced because of spline
wear should also receive a replacement brake hub. Check
condition of friction material on the washer and lining
assemblies, and replace assemblies if required. Reinstall
brake plates, release springs, and friction washers in
sequence as shown in Figure 5-3 and replace retaining
rings. On the Size 3 hoist it is possible to get the lining
assemblies misoriented. When installed properly the
friction linings will be on a horizontal line (not vertical).
Clean and flush gearcase and replace gearcase cover
using a new gasket. Refill with new lubricant.
5-6. INSPECT MECHANICAL LOAD BRAKE AND GEARING.
Check to be certain main power switch is locked in
open position before removing brake cover.
WARNING
Figure 5-3. Motor Brake Friction Plates
11988
a. To inspect hoist, drain oil from gearcase, remove motor
brake actuating mechanism per Paragraphs 5-5.a and 5-
5.b, remove hex head cap screws from gearcase cover,
and remove gearcase cover.

Page 13
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.
WARNING
The complete mechanical load brake assembly is
heavy (approx. 150 lbs.). Provide adequate means to
support weight of assembly before removal from
gearcase, especially if brake assembly is removed
with hoist suspended.
WARNING
b. Remove compression plate, washer and lining assemblies,
springs and brake plates as described in Paragraph 5-
5.g. Remove hex nuts and hex head bolts holding
gearcase spider and remove spider. Inspect gearing for
tooth wear or damage, (see Figure 5-4). If replacement
parts are indicated, disassemble load brake and gearing
as follows:
(1) Pull out motor pinion shaft from gearcase, (see Figure
5-4).
(2) The complete load brake assembly can now be pulled
out from the gearcase or removed part by part.
Figure 5-4. View of Gearing - Spider Removed
10028
c. To disassemble and inspect mechanical load brake without
overload clutch, either in or removed from hoist, proceed
as follows:
(1) Remove the two (three on larger models) selflocking
screws from each of two retaining plates and remove
plates from groove on splines of brake shaft (Figure
5-5).
(2) Pull off brake helix (Ref. No. 12, Figure 9-4).
(3) Pull off brake gear (Ref. No. 11, Figure 9-4).
Note: It may be necessary to apply some force to
end of shaft when removing brake gear.
(4) Remove (1) friction washer, roller and ratchet
assembly, and another friction washer. The roller and
ratchet assembly should not be disassembled;
replacement, if required, as an assembly is
recommended.
(5) Remove brake shaft and flange assembly.
(6) Check condition of all parts for evidence of wear or
damage. Replace worn or damaged parts.
(7) Reinstall in reverse procedure from disassembly
making certain helix is seated and that retaining plates
are properly seated in groove on shaft spline (Figure
5-5).
d.To disassemble and inspect mechanical load brake with
overload clutch, either in or removed from hoist, proceed
as follows:
(1) Remove the two (three on larger models) selflocking
screws from each of two retaining plates and remove
plates from groove on splines of brake shaft (Figure
5-5).
(2) Pull off brake helix. Surface of brake helix may be
below brake adjusting collar (Ref. No. 24, Figure 9-4).
With some pressure on end of brake shaft, pull brake
gear toward end of shaft about one inch. Then return
gear to original position to expose outside of helix.
Grasp outside of brake helix and slide off from splined
shaft.
(3) Do not remove the overload clutch adjusting screws
unless clutch requires service. See Paragraph 5-6.e
below. Remove clutch and brake gear as one unit by
pulling off from brake shaft while exerting some
pressure on end of brake shaft.
(4) Remove (1) friction washer, roller and ratchet
assembly, then the other friction washer. The roller
and ratchet assembly should not be disassembled;
replacement, if required, as an assembly is
recommended.
(5) Remove brake shaft and flange assembly.
(6) Check condition of all parts for wear or damage.
Replace worn or damaged parts.
(7) Reinstall in reverse procedure from disassembly
making certain helix is seated and that retaining plates
are properly seated in groove on shaft spline (Figure
5-5).
e.Disassembly of overload clutch. It is recommended that
disassembly, inspection, and reassembly of the overload
clutch be performed by a factory approved SHAW-BOX
Repair Station. Fine adjustments can be made with clutch
installed. (See OVERLOAD CLUTCH ADJUSTMENT,
Paragraph 7-5.)

Page 14
Figure 5-5. Installing Retainer Plates on Load Brake Shaft
10024
Figure 5-6. All Gearing Removed except Drum Gear
10026
f. To remove drum gear, remove spirolox retaining ring from
end of drum shaft and pull drum gear from splined shaft
(Figure 5-6). This should be done after complete load
brake shaft assembly has been removed.
g. Replace motor pinion shaft.
h. Reinstall spider and motor brake plates on gearcase.Make
certain motor pinion shaft bearing on a size 2 hoist and
load brake shaft bearing (Figure 5-7) are installed with
the external retainer firmly seated against the inside (hoist
side) of the spider and retainer side of bearing toward
hoist. On a size 3 hoist the motor pinion shaft bearing is
caged to the spider.
j. Replace gearcase gasket and cover and refill gearcase
to bottom of oil level plug.
k. Reconnect motor brake leads.
Figure 5-7. Installing Load Brake Shaft Ball Bearing in
Gearcase Spider (Size 2 Hoist Shown)
11990
I. Before replacing brake cover, fine adjustment can be made
to overload clutch if your hoist is so equipped. See
OVERLOAD CLUTCH ADJUSTMENT - Paragraph 7-5. If
clutch adjustment is not required replace brake cover.
5-7. INSPECT ROPE DRUM AND SHAFT.
a. To remove rope drum, remove hoisting cable, gearcase
cover, and remove load brake and gearing as outlined in
Paragraph 5-6.
b. Remove hinged side cover, hinge plate and cover bridge
from hoist frame.
c. Take out four bolts holding gearcase to frame and remove
gearcase. Drum and shaft will remain in frame.
d. Remove four bolts holding drum shaft bearing retainer to
inside of gearcase and pull ball bearing and oil seal from
bore in gearcase.
e. Pull drum and shaft from frame.
f. Check parts for wear and damage. Replace drum or shaft
if there are any signs of cracks or other damage. Replace
oil seal if the sealing edge appears worn or cracked.
g. Reinstall parts following a procedure in reverse of
disassembly. Refill gearcase to proper level with correct
grade of oil. (See SECTION IV - LUBRICATION.)
5-8. ROPE INSPECTION, MAINTENANCE AND
REPLACEMENT.
Wire rope improperly handled or abused can create a
SAFETY HAZARD. Read and comply with Inspection,
maintenance and replacement information given
herein.
WARNING

Page 15
a.Inspection. Wire rope on your hoist is` one of the most
important components requiring frequent inspection and
maintenance. All wire ropes will eventually deteriorate to
a point where they are not safe and will require
replacement. Wire rope should be thoroughly inspected
at regular monthly intervals by an authorized person and
a determination made when further use of the rope would
constitute a safety hazard. Each inspection should include
a written, dated and signed report of rope condition.
Reports should be filed and reviewed each month and
any rope deterioration carefully noted. Inspections
revealing but not limited to the following conditions, should
cause inspector to question remaining strength of rope
and consider replacement:
(1) Twelve randomly distributed broken wires in one rope
lay or four broken wires in one strand.
(2) Wear of one-third of the original diameter of outside
individual wires.
(3) Kinking, crushing or birdcaging.
(4) Heat damage from any cause.
(5) Reductions from nominal diameter of more than
(a) 1/64" for 3/16", 1/4", and 5/16" diameter rope.
(b) 1/32" for 3/8" and 7/16" diameter rope.
(c) 3/64" for 9/16" diameter rope.
(6) Rope corrosion, internal or external.
(7) Effects from improper lubrication.
(8) Rope idle for month or more due to shutdown.
Special attention should be exercised when inspecting
rope normally hidden during inspecting procedures.
b. Maintenance. Keep rope well lubricated to help reduce
internal friction and prevent corrosion. Lubricant, as
described in Paragraph 4-3, should be applied as a part
of the regular maintenance program. Special attention is
required to lubricate sections of rope over equalizing
sheaves and other hidden areas.
Avoid dragging ropes in dirt or around sharp objects which
will scrape, nick, crush or induce sharp bends in the
rope.
c.Replacement. When recommended by an authorized
inspector, the rope should be replaced.Replacement rope
assemblies are shipped from the factory carefully coiled
to prevent damage by kinking. Care must be taken to
avoid twisting or kinking when uncoiling and handling
during reeving.
Before replacing rope, check condition of grooves in
sheaves and drums to determine if they are excessively
worn.
Use only factory approved rope with swagged wire
rope sockets.
WARNING
Before removing the old rope, refer to reeving diagrams, Figure
5-8. Face the rope drum on your hoist from the side which the
rope comes off drum.To assist with rereeving your hoist, select
the reeving diagram for your hoist. Note the description (such
as 3 part double reeved, Figure 5-8, $) and refer to paragraph
below with the same description which describes rereeving
procedure.
b.Removing old rope - for all reevings.
(1) Lower the bottom block to a scaffold located 6 to 7
feet below hoist to relieve tension on wire rope.
(Bottom block may be lowered to floor if desired;
however, to handle less weight and for ease of
rereeving adequate scaffold below the hoist is
recommended.)
(2) Remove bottom block sheave guard.
(3) Remove key plates from both sides of sheave pin
and slide sheave pin from bottom block.
(4) Lift out sheaves from the top of the bottom block and
remove wire rope.
(5) Remove key plates or snap rings from upper block
sheave(s) and slide out upper block sheave pins,
releasing upper block sheaves. Remove wire rope
from sheaves.
(6) Make certain all personnel are clear of hoist and
operate hoist “DOWN” to completely unwind all wire
rope from drum. Stop hoist so drum anchor slot(s) is
accessible. Remove live rope end socket(s) from drum.
(7) TURN OFF POWER TO HOIST.
(8) Open electrical compartment cover on single reeved
hoists to remove dead end socket.
Remove cotter pin from socket, slide rope toward socket
until rope end fitting clears socket. Lift out rope and end
fitting through groove provided. Remove old rope. Close
electrical compartment cover.
c.Installing new rope.
It is imperative that rope reel or coil rotate as rope
unwinds. If coil or reel does not rotate the wire will be
twisted as it is uncoiled and kinking will result. A kinked
rope may be damaged and unsafe for maximum service.
CAUTION
When first using hoist after rope replacement, break in rope by
operating under lighter loads to full travel before applying
maximum load.
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.
WARNING
5-9. ROPE REEVING.
a.General. Before unreeling rope from a coil or reel be sure
floor is clean. Dirt picked up by the rope can cause
excessive wear and abrasion. Uncoil the rope by rolling
the coil or reel along the floor; or, place reel on stand
with shaft thru center of reel so rope can be pulled straight
out with reel rotating.

Page 16
SINGLE REEVED HOISTS
Stretch new cable on floor in one continuous length. Make
certain there is no twist in rope.
(1) Place one end of rope in rope drum anchor slot. Be
sure end fitting is properly seated.
(2) With all personnel clear of hoist - TURN ON POWER.
(3) Operate hoist “UP,” guiding new rope into drum
grooves with gloved hand, until the following lengths
remain unwound:
(a) 2 part single reeved - about 14'-0"
(b) 4 part single reeved - about 28'-0"
(c) 6 part single reeved - about 42'-0"
(d) 8 part single reeved - about 56'-0".
(4) Proceed with reeving as described in appropriate
paragraph below and the reeving diagram for your
hoist.
DOUBLE REEVED HOISTS
Stretch new cable on floor in one continuous length. Make
certain there are no twists in rope.
(1) Pull far end of rope toward end of rope nearest hoist,
until both ends are even and a loop is formed. Place
fittings on both ends of rope in anchor slots on rope
drum. Be sure end fittings are properly seated.
(2) With all personnel clear of hoist - TURN ON POWER.
(3) Operate hoist “UP,” guiding rope into grooves at both
ends of drum, until the distance from the drum to the
loop is:
(a) 2 part double reeved - about 14'-0"
(b) 3 part double reeved - about 21'-0"
(c) 4 part double reeved - about 28'-0"
(d) 5 part double reeved - about 35'-0"
(e) 6 part double reeved - about 42'-0".
(4) Proceed with reeving as described in appropriate
paragraph below and the reeving diagram for your
hoist.
d.Reeving - 2 part single.
See Figure 5-8, %for diagram.
See Figure 9-14 for bottom block parts with 3/8" or 7/16"
rope.
See Figure 9-15 for bottom block parts with 9/16" rope.
With new rope installed on drum as described in
Paragraph 5-9.c, single reeved above, proceed with
rereeving following steps below:
(1) Thread the remaining cable end through limit switch
weight, then pass it over partial sheave, inside hoist,
and insert in anchor fitting at hoist frame. Be certain
power is off before opening electrical compartment
cover for access to anchor fitting. Properly seat rope
end fitting in socket and replace cotter pin in end of
socket.
(2) Grasp loop, formed after installing end anchor, and
place bottom block sheave in loop. Lower sheave into
bottom block and insert sheave pin.Replace key plates
and bolts holding sheave pin in place.
(3) Replace sheave guard. Make certain rope is not
twisted. Should the two parts of rope tend to wind
around each other, remove cable from anchor slot
and untwist cable. Reattach the cable anchor.
(4) Lubricate cable per Paragraph 4-3.
e. Reeving - 4 part single.
See Figure 5-8, &for diagram.
See Figure 9-14 for bottom block parts with 1/4", 5/16",
3/8", 7/16" rope.
See Figure 9-15 for bottom block parts with 9/16" rope.
With new cable installed on drum as described in
Paragraph 5-9.c, single reeved above, proceed with
rereeving following steps below:
(1) Grasp the cable near the middle (about 14'-0") of the
unwound end and form a loop. Place upper sheave in
this loop. Slide upper sheave with cable into sheave
pocket.
(2) Insert sheave pin into sheave. Replace key plates
and bolts to hold sheave pin in place.
(3) Thread rope end socket through limit switch weight;
then, pass it over partial sheave, inside hoist, and
insert in anchor fitting at hoist frame.Be certain power
is off before opening electrical compartment cover for
access to anchor fitting. With end fitting properly
seated in anchor, replace cotter pin in end of socket.
Two loops have now been formed for bottom block
sheaves.
(4) Place one sheave in each loop. Install one sheave
with cable in bottom block; partially insert sheave pin
to hold sheave in place. Note: Some blocks have
spacer washers between sheaves. Be certain to install
spacer washers between sheaves, when shown on
parts illustration. Install second sheave with cable into
bottom block. Slide sheave pin through sheave.
Replace key plates and bolts securing sheave pin.
(5) Replace sheave guard.
(6) Lubricate cable per Paragraph 4-3.

Page 17
Figure 5-8. Reeving Diagrams
2 PART SINGLE @
2 PART DOUBLE
BALANCED REEVING
Gl
3 PART DOUBLE ®
5 PART DOUBLE
4 PART SINGLE CD
3 PART DOUBLE
BALANCED REEVING ®
4 PART DOUBLE (])
6 PART DOUBLE
6 PART SINGLE 0
4 PART DOUBLE
BALANCED REEVING
~
8 PART SINGLE ®

Page 18
f. Reeving - 6 part single.
See Figure 5-8, 'for diagram.
See Figure 9-15 for bottom block parts - 9/16" rope.
See Figure 9-19 for bottom block parts - 3/8" rope.
With new cable installed on drum as described in
Paragraph 5-9.c, single reeved above, proceed with
rereeving following steps below:
(1) Grasp cable at a point one-third (approx. 14’0") the
distance hanging below the rope drum and form a
loop. Place one upper sheave in this loop. Slide upper
sheave with ca ble into sheave pocket; partially insert
sheave pin to hold sheave in place.
(2) Repeat (1) above and install second upper sheave
with rope. Insert sheave pin and install key plates and
bolts to secure sheave pin.
(3) Thread rope end socket through limit switch weight;
then, pass it over partial sheave, inside hoist, and
insert in anchor fitting at hoist frame. Be certain power
is off before opening electrical compartment cover for
access to anchor fitting. With end fitting properly
seated in anchor, replace cotter pin in end of socket.
Three loops have now been formed for bottom block
sheaves.
(4) Place sheave in each loop. Install one sheave with
cable in bottom block; partially insert sheave pin to
hold sheave in place. Note: Be certain to install spacer
washers between sheaves, when shown on parts
illustration.
(5) Repeat step 4 for remaining bottom block sheaves.
Install sheave pin through sheaves. Replace key plates
and bolts securing sheave pin.
(6) Replace sheave guard.
(7) Lubricate cable per Paragraph 4-3.
g.Reeving - 2 part double.
See Figure 5-8, (for diagram.
See Figure 9-16 for block parts.
With new rope installed on drum as described in Paragraph
5-9.c, double reeved above, proceed with rereeving
following steps below:
(1) Form loops in the two ropes coming from rope drum.
Place these loops into bottom block pockets and slide
pipe or rod through sheave pin holes. Note position of
ropes passing limit stop bar.
(2) Partially insert upper block sheave pin in opening and
install one spacer washer. Raise remaining rope up to
hoist, form a loop and place upper sheave in this loop.
(3) Place sheave with rope into upper sheave pocket and
slide pin partially thru sheave. Install remaining washer
and push pin thru side plates. Install snap ring on
each end of pin to secure pin in place.
(4) Insert lower sheave pin into bottom block removing
pipe as sheave pin is inserted. Be certain washers are
replaced as shown on parts illustration. With sheave
pin installed, replace key plates and bolts to secure
sheave pin.
(5) Replace sheave guard.
(6) Lubricate rope per Paragraph 4-3.
h. Reevinq - 3 part double.
See Figure 5-8, $for diagram.
See Figure 9-17, for block parts.
With new rope installed on rope drum as described in
Paragraph 5-9.c, double reeved above, proceed with
rereeving following steps below:
(1) Form loops in the two ropes coming from rope drum.
Place these loops into bottom block pockets and slide
pipe or rod through sheave pin holes. Note position
of ropes passing limit stop bar.
(2) Grasp remaining rope at midpoint loop and raise two
rope parts up to the hoist. Carefully form two upper
sheave loops and insert into upper sheave pockets.
Slide pipe or rod through sheave pin holes to hold
the two ropes.
(3) Pull remaining rope down to the lower block equalizer
sheave. Place equalizer sheave in loop and sheave
with rope in sheave pocket. Insert sheave pin thru
one washer, the sheave and the other washer.
(4) Push sheave pin thru side plates and install snap
ring on each end of pin to secure pin.
(5) Insert lower sheave pin into bottom block thru washers
and sheaves as shown on parts illustration, removing
pipe as sheave pin is inserted.
(6) Install key plates and bolts to secure pin.
(7) Repeat steps 5 & 6 for upper block sheaves.
(8) Replace sheave guard.
(9) Lubricate rope per Paragraph 4-3.
j. Reevinq - 4 part double.
See Figure 5-8, )for diagram.
See Figure 9-18, for block parts.
With new rope installed on rope drum as described in
Paragraph 5-9.c, double reeved above, proceed with
rereeving following steps below:
(1) Form loop in each rope coming from rope drum. Place
these loops into outside sheave pockets in bottom
block. Note position of ropes passing limit stop bar.
Slide pipe or rod thru sheave pin holes to hold the
two ropes.
(2) Grasp remaining rope at midpoint loop and raise loop
with two ropes up to the hoist. Carefully form two
upper sheave loops and insert sheaves with rope
into upper sheave pockets. Slide pipe thru upper
sheave pin holes to hold the two ropes.
(3) Pull loop and two ropes down to the bottom block.
Pass ropes across bottom block between ropes placed
there in step 1. Note position of ropes passing limit
stop bar.
(4) Carefully remove pipe while holding first two ropes in
bottom block and insert ropes in step 3 into outside
block pockets between existing ropes.

Page 19
(5) Pull remaining rope up to upper equalizer sheave.
Partially insert sheave pin thru yoke side plate and
one washer. Place sheave in rope loop and insert
sheave with rope into sheave pocket. Slide pin thru
sheave and remaining washer into opposite side plate.
Secure pin by installing snap ring on each side of
pin.
(6) Insert upper block sheave pin thru side plate and one
washer. Place upper block sheaves in rope loop and
insert into sheave pocket removing pipe or rod as pin
is inserted. Make certain to install one washer on
each side of upper sheaves.
(7) Install key plates and bolts to secure pin.
(8) Partially insert lower block sheave pin into block side
plate opening and thru one washer removing pipe as
pin is inserted. Place outside sheave into rope loop
and insert sheave with rope into sheave pocket. Slide
pin into sheave. Repeat this procedure installing
sheaves and washers in both outside pockets of
bottom block. Center pocket of bottom block is not
used for sheaves.
(9) Replace key plates and bolts to secure sheave pin.
(10) Lubricate rope per Paragraph 4-3.
k. Reeving - 3 part double.
See Figure 5-8, *for diagram.
See Figure 9-15, for block parts.
With new rope installed on rope drum as described in
Paragraph 5-9.c, double reeved above, proceed with
rereeving following steps below:
(1) Form loops in the two ropes coming from rope drums.
Place these loops into bottom block pockets and slide
pipe or rod through sheave pin holes.
(2) Grasp remaining rope at midpoint loop and raise loop
and two ropes up to the hoist. Carefully form two
upper sheave loops and insert into upper sheave
pockets. Slide pipe or rod through sheave pin holes
to hold the two ropes.
(3) Pull the remaining rope down to the lower block. Insert
loop in between the two ropes already in lower block
by partially removing pipe while holding original ropes
in place. Note: This last loop must be rotated 90° as
it is placed between existing ropes into lower block;
refer to reeving diagram.
(4) Complete installation following steps 4 thru 9 in
Paragraph 5-9.h.
I. Reeving - 4 part double.
See Figure 5-8, +for diagram.
See Figure 9-15, for block parts.
With new rope installed on rope drum as described in
Paragraph 5-9.c, double reeved above, proceed with
rereeving following steps below:
(1) Form loop in each rope coming from rope drum. Place
these loops in sheave pockets in bottom block. Slide
pipe or rod thru sheave pin holes to hold the two
ropes.
(2) Grasp remaining rope at midpoint loop and raise loop
with two ropes up to the hoist. Carefully form two
upper sheave loops and insert into upper sheave
pockets.Slide pipe or rod thru upper sheave pin holes
to hold the two ropes.
(3) Pull loop and two ropes down to the bottom block.
Pass ropes across bottom block between ropes placed
there in step 1.
(4) Carefully remove pipe while holding first two ropes in
bottom block and insert second pair (step 3) of ropes
in bottom block between existing ropes.
(5) Pull remaining rope up to upper equalizer sheave
(center sheave). Remove pipe while holding first two
ropes in place far enough to insert last loop. Note:
This last loop must be rotated 90° as it is placed
between existing ropes into upper block. Refer to
reeving diagram.
(6) Complete installation following steps 6 thru 10 in
Paragraph 5-9.j.
m.Reeving - 8 part single.
See Figure 5-8, ,for diagram.
See Figure 9-21, for block parts.
With new rope installed on drum as described in
Paragraph 5-9.c, single reeved above, proceed with
rereeving following steps below:
(1) Grasp cable at a point one-fourth (approx. 14'-0") the
distance hanging below the rope drum and form a
loop. Place one upper sheave in this loop. Slide upper
sheave with cable into sheave pocket; partially insert
sheave pin to hold sheave in place.
(2) Repeat (1) above and install second upper sheave
with rope.
(3) Repeat (1) above and install third upper sheave with
rope. Insert sheave pin and install key plates and
bolts to secure sheave pin.
(4) Thread rope end socket through limit switch weight;
then, pass it over partial sheave, inside hoist, and
insert in anchor fitting at hoist frame. Be certain power
is off before opening electrical compartment cover for
access to anchor fitting. With end fitting properly
seated in anchor, replace cotter pin in end of socket.
Four loops have now been formed for bottom block
sheaves.
(5) Place sheave in each loop. Install one sheave with
cable in bottom block; partially insert sheave pin to
hold sheave in place. Note: Be certain to install spacer
washers between sheaves, when shown on parts
illustration.

Page 20
SECTION Vl - TROUBLE SHOOTING
Trouble Probable Cause Possible Remedy
(6) Repeat step 5 for remaining bottom block sheaves.
Install sheave pin through sheaves. Replace key plates
and bolts securing sheave pin.
(7) Replace sheave guard.
(8) Lubricate cable per Paragraph 4-3.
n. Reeving - 5 part double.
See Figure 5-8, -for diagram.
See Figure 9-20a, for block parts.
Reeve similar to Paragraph 5-9.1.
o. Reeving - 6 part double.
See Figure 5-8, .for diagram.
See Figure 9-22, for block parts.
Reeve similar to Paragraph 5-9.1.
p. Checking for and removal of rope twisting,
Although rereeving of hoist may have been done carefully,
sometimes after new rope has been installed twisting
may occur.With new rope installed, the hoist block should
be raised and lowered several times with gradually
increasing loads through full lift. If the block still rotates
excessively at no load, the rope may have twists which
should be removed.
(1) To remove rope twist in single reeved hoists.
(a) Observe direction block tends to rotate.
(b) Lower the block to a low position and turn off
power.
(c) Rotate rope near the anchor end several turns in
a direction tending to correct block rotation. This
rotates rope end fitting in the anchor.
(d) Turn on power; raise and lower the block several
times to feed the correcting twist in the rope
through the reeving.
(e) If block still tends to twist repeat the above
procedure until block rotation is corrected.
(2) To remove rope twist in double reeved hoists.
(a) Observe direction block tends to rotate.
6-1. Hoist Will Not Operate. a. No power to hoist. a. Check switches, circuit breakers or fuses
and connections in power supply lines.
b. Wrong voltage or frequency b. Check current rating on motor data plate
against power supply.
c. Loose or broken wire c. Shut off power supply, open hinged cover
connections in hoist on hoist and check wiring connections. Also
electrical system. check connections in push button station
and limit switches.
(b) Lower the bottom block unspooling rope from rope
drum until only one quarter (1/4) turn remains to
rope end anchors in drum.
(c) Rotate rope near ends entering drum in a direction
tending to correct block rotation.This rotates rope
end fittings in the drum.
(d) Turn on power; raise and lower the block several
times to feed the correcting twist in the rope
through the reeving.
(e) If block still tends to twist repeat the above
procedure until block rotation is corrected.
5-10.TESTING HOIST.
a. General. Before placing hoist in service, hoist should be
tested to insure safe operation when hoist has been
disassembled and reassembled. To test, suspend hoist
from an overhead supporting member of sufficient strength
to support the weight of the hoist and the rated load.
Hoists having overload clutches require an overhead
supporting structure capable of supporting with
appropriate safety factor a load equal to 175 percent
rated load and the weight of the hoist - see OVERLOAD
CLUTCH ADJUSTMENT - Paragraph 7-5. Connect hoist
to power supply as shown on hoist nameplate and perform
the checks listed in b and c below:
b. Check hoist as outlined in PRE-OPERATION CHECKS,
SECTION II, Paragraph 2-4.
c. Check hoist with rated load.
(1) Attach rated load to lower hook
(2) Depress “UP” push button and raise load.When push
button is released, hoist should immediately stop and
hold load at that level.
(3) Depress “DOWN” push button, lower load a short
distance and release button. Hoist should stop
immediately and hold load at that level.
Note:
If load drifts downward slowly in step 2 or 3 above,
motor brake requires adjustment - see MOTOR BRAKE
ADJUSTMENT - SECTION VII - Paragraph 7-2.