Fmea E-109-2

Failure Modes and Effects Analysis
For
5 ton Acco Wright Series 32
Electric Wire Rope Hoist
E-109-2
PREPARED BY: Phillip Ezzell, Crane Safety Associates of America, Inc. 03/30/2010
________________________________________________ __
A.V. HANAGUD, DEPUTY RECERT MANAGER Date
Crane Safety Associates of America, Inc.
FAILURE MODES
E FEeT ANALYSIS
ACCO WRIGHT Product Series 32 Wire Rope Electric Hoist
BY: PHILLIP EZZELL
March 30th, 2010
FAILURE MODES EFFECT ANALYSIS
Table of Contents
INTRODUCCfION .......................................................................................................................... 5
SINGLE POINT FAILURE POINTS ............................................................................................. 6
MAIN COMPONENT: HOIST DRUM (FIGURE 4) ..................................................................... 6
MAIN COMPONENT: GEAR BOX & MECHANICAL LOAD BRAKE (FIGURE 5) ..................... 6
MAIN COMPONENT: HOOK BLOCK (FIGURE 5) .................................................................... 6
MAIN COMPONENT: WIRE ROPE (FIGURE 6) ....................................................................... 7
MAIN COMPONENT: TROLLY WHEELS & MOUNTING STUDS (FIGURE 12 & 13) .............. 7
MAIN HOIST ASSEMBLy ........................................................................................................... 8
HOIST MOTOR ........................................................................................................................... 8
HOIST MOTOR ~ FIGURE 1 ...................................................................................................... 9
HOIST DRUM ............................................................................................................................ 10
HOIST DRUM ~ FIGURE 2 ....................................................................................................... 11
MOTOR HOIST BRAKE ............................................................................................................ 12
MOTOR HOIST BRAKE ~ FIGURE 3 ....................................................................................... 13
GEAR CASE AND MECHANICAL LOAD BRAKE ..................................................................... 14
GEAR CASE ~ FIGURE 4 .......................................................................................................... 15
GEAR CASE PARTS LIST ~ FIGURE 4A .................................................................................. 15
HOOK BLOCK ........................................................................................................................... 17
BEARINGS, SPACERS AND SHEAVES ..................................................................................... 17
AXLE - THROUGH SHAFT ........................................................................................................ 18
HEX NUT ................................................................................................................................... 18
HOOK ........................................................................................................................................ 18
HOOK COMPONENTS ~ FIGURE 5 ......................................................................................... 19
WIRE ROPE .............................................................................................................................. 20
WIRE ROPE INSPECTION ....................................................................................................... 20
WIRE ROPE ~ FIGURE 6 ......................................................................................................... 21
HOIST LIMIT SWITCHES ......................................................................................................... 32
HOIST LIMIT SWITCHES ~ FIGURE 7 .................................................................................... 33
HOIST LIMIT SWITCHES ~ FIGURE 8 .................................................................................... 34
FESTOON AND PENDENT CONTROL STATIONS .................................................................. 35
PENDENT CONTROL BOX ~ FIGURE 9 .................................................................................. 36
TROLLEY ASSEMBLY .............................................................................................................. 37
TROLLEY MOTOR .................................................................................................................... 37
TROLLEY MOTOR BRAKE ....................................................................................................... 37
TROLLEY MOTOR BRAKE ASSEMBLY ~ FIGURE 10 ............................................................ 38
TROLLEY GEAR BOX ............................................................................................................... 39
TROLLY GEAR BOX ~ FIGURE 11 .......................................................................................... 39
TROLLEY DRIVE WHEELS ...................................................................................................... 40
TROLLEY DRIVE WHEELS ~ FIGURE 12 ............................................................................... 41
LOAD BAR ASSEMBLY - FIGURE 13 ..................................................................................... 42
HOIST SPECIFICATIONS ~ FIGURE 14 .................................................................................. 43
P age 3
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INTRODUCTION
This analysis is based on drawings, blue prints, and parts and operations manuals. The hoist has
been separated into two major components, the hoist and the trolley mechanizes. Much of the
component descriptions will be reference to drawings or other illustrations. This manufacturer
utilizes one common manual for several hoists models. Some illustrations may not be exact;
however component function and location will be the same .
This analysis is based on subject equipment being properly assembled, tested and in the correct
configuration as prescribed by the manufacturer.
P age 5
SINGLE POINT FAILURE POINTS
MAIN COMPONENT: HOIST DRUM (FIGURE 4)
1. Part Name and Drawing: Wire rope attachment hardware and drum
2. Parts Function: A spooling surface to take up and play out wire rope during hoisting.
3. Failure Mode and Cause: Failure or loosening of the hardware used to secure the rope to
the drum and failure of the drum due to damage or extreme wear.
4. Failure Effect on the System: Complete loss of service and possible load damage
5. Effect on Job or Personnel: May cause work stoppage and lor possible injury or death
MAIN COMPONENT: GEAR BOX & MECHANICAL LOAD BRAKE (FIGURE 5)
1. Part name and Drawing: Drum pinion shaft item 18, change gear item 40, drum shaft 12,
and drum gear item 13 and key items 37 and 38.
2. Parts Function: Connects the gear train from the mechanical load brake to the hoist drum.
3. Failure Mode and Cause: Failure of above items will cause the hoist drum to free wheel
with loss of load.
4. Failure Etfect on System: Complete loss of service
5. Effect on Job or Personnel: May cause work stoppage and lor injury or death
MAIN COMPONENT: HOOK BLOCK (FIGURE 5)
1. Part Name and Drawing: sheaves, bearings, axle, hex nut, and hooks
2. Part Function: Provides a means to attach a load to the hoist and increases the number of
wire rope reeving to increase hoisting strength and efficiency.
3. Failure Mode and Cause: Failure of above items will cause the wire rope to fail or
become unattached.
4. Failure Effect on System: Complete loss of service
5. Effect on Job or Personnel: Work stoppage and possible injury or death
P age 6
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MAIN COMPONENT: WIRE ROPE (FIGURE 6)
1. Part Name and Drawing: Wire rope Figure 6
2. Part function: Provides the means and support for hoisting the load.
3. Failure Mode and Cause: Wire rope failure occurs due to damage to individual wires,
strands, and cores. Sudden rope failure will occur with significant overload, and damage
to certain components mentioned above .
4. Failure Effect on System: Complete loss of service
5. Effect on Job or personnel: Work stoppage and possible injury or death
MAIN COMPONENT: TROLLY WHEELS & MOUNTING STUDS (FIGURE 12 & 13)
1. Part Name and Drawing: Trolley wheels and mounting Studs Figure 12 and 13
2. Part Function: Connects trolley to and provides vertical support and vertical movement
of the hoist.
3. Mode Failure and Cause: Load failure will occur if the trolley wheel space adjustments
are incorrect. Adjusting space washers can be effected by damage to the trolley rail, or
trolley wheel bearings .
4. Failure Effect on System: Loss of service
5. Effect onjob and Personnel: Work stoppage and or possible injury or death .
P:1 g c 7
MAIN HOIST ASSEMBLY
The function of the main hoist system is to raise and lower a load. Basically the system is a hoist
drum driven by an electric motor through a gear case. A drum, usually grooved is used to take
up and payout the wire rope used to raise and lower the load. This hoist has an electric motor
brake to stop and hold the load. Located in the gear case is a mechanical load brake which
provides lowering control and serves as a safety brake. The gear box has reduction gears t o ~
provide the necessary operational requirements of the hoist.
These components will be shown with a complete description of their function
HOIST MOTOR
This unit utilizes a 460 volt, two speeds, 1800 RPM, 5 horsepower motor which drives an
attached gear box as described in figure 1 to raise and lower loads.
The hoist is not subject to a single point failure. Should the hoist motor fail the motor brake
backed up by the mechanical load brake will prevent loss of load.
To insure proper operation an inspection by the operator should be conducted prior to the lift.
P age 8
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HOIST MOTOR - FIGURE 1
PARTS LIST ::-.PRODUCT __________ .. ____________ .
HOIST MOTOR - PARAt..I..,EL. MOUNTED HOIST
HOIST "'0""01; PA.RTS.
IfEIA'NC,
-------+---+---'

fa) 'nclud..e ",,1ft ha:.t n.aOf. AI!su ""-tiil..ut" ImJlvh,j"".II!(,
[b) stBrdard hol9C! m.olW by part ,"umbar aco::m::fin.g lc rn:;>tor as f.;:.!lows:
lI!ItJ'rr-at <i!OI!I
1la777.()2
6S777.fX3 575
limo
184TC
-- 31'1
511-2/:3
I __ , __ ,. __
Far C!Ihe' s;>ectfiEld BP<><:i'al ,.,0"""", '"l .. r ,., addlll(lfInl /nlormat.on """""'" I>""pfad ..... Iin manua ..
P age 9
HOIST DRUM
The hoist drum is parallel to the monorail and double grooved allowing the wire rope to be taken
up in order to raise the load. The drum is mounted to the frame unit as seen in figure 2.
The hoist drum if properly classified has a relatively long life and is rarely subject to failure.
However failure of the drum could occur due to extreme wear. A worn or damaged drum could
lead to wire rope failure and loss of load. Also, loss of load could occur with the failure of the
drum drive and ring gear or failure of the wire rope end attachment hardware at each end of the
drum.
The drum should be inspected by the operator, lift coordinator or other lift team member during
the pre lift meeting. The hoist should not be used unless a minimum of two wire rope wraps
remain on the drum while the hook block is in its lowest position. The drum should not be used
if the surface or the grooves are worn beyond 25% of the nominal diameter of the wire rope. The
inspector should look for signs of movement or wobble of the drum, oil leaks or other signs of
leaking seals. Leaking seals can contaminate the motor brake chamber and cause loss of motor
brake function.
End attachments should be checked for proper fit of lugs or tightness of bolts and clips
depending on attachment type.
P age 10
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HOIST DRUM - FIGURE 2
PARTS LIST - PRODUCT SERIES 32
2PD 5USf'!l.NSION PARTS
SUSPENSION - 2PO REEVING
PARALLEL MOUNTED HOIST
p
Il1011:: ('l) PAd fur !tam Wire FlDjJ6 Assan:bly. QIl; 'or stendanl non u5im 31a ::J!ll. 6.:37 XII" Wire
rooe. Fa 5ijJ1!1(;ia1 1J5InQ oihoI :;I:!(t 'JI' Wfret 'tlpe, refM 10 lta wire m:e part n:Jnt>er i:i5tiKl in additional
page!! indudedlf/ilh mill rr!llnuru; or co:rtad /!oIxD Chain & Utlng ?roc1lCl$ or the distributor Dj Iha hoist
(h} For C9C;(-fJlOl.ltrted. ?all No. 70'30.
(0; tJe.e of Swivel Trolllr\'!l fBQIH'el! dffenm! Merna Unit See pa.q8: 37
Page 11
MOTOR HOIST BRAKE
Description: This hoist is equipped with an electric disc motor hoist brake. The brake is spring
set and magnetically released. When power is applied a circuit closes and applies power to both
the motor figure 3 and the brake coil (item 10). The energized brake coil pulls ,armature
compression springs (item 8) releasing the brake. When power is disconnected or the control
button is released, the circuit to the motor and brake coil opens allowing the springs to set the
brake.
The hoist motor brake is not a single point failure item. Should the motor brake fail, the
mechanical load brake will prevent loss of load. Should an electrical failure occur the motor
brake will be applied. The crane operator, the lift coordinator, or other lift team member should
inspect for proper operation prior to the lift. The periodic inspection should include a visual
inspection for wear of 3\ 16 inch or more.
Page 12

4
4
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4
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MOTOR HOIST BRAKE -- FIGURE 3
HOlST MOTOR SR.A.KE ASSEMBLY
HOIST MOTOR aFlAKE PARTS
'"
H) 2 51462 51"lSa
'11 Arma1UI"Q 2 51441 51441.
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""i'-bi,..; a'i,r---;5;:1C:<af:=;-----t--:.;;,;'7
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1.l; Stud 3 6971SQ 69750
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W1II$h"" 1S.1o:ii
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Page 13
la) sta:ndar.:l GII'!;;;jllo'4'pl4ed and
speed hDt.sll:::i" ! e l;;r. fl.. lurq.Jt# Uf
r;.f3 with S I--tP- :"f'lO'Ii:ll"'::!l .al"td 33 lb.
11 Inrqut9 ;i-f.f'J iN'1h fi riP
motors.
lb) Numbers on nOilding of chart ill,.<1
Heist ." tI: 0" Sral". 1''''''''''111:>1 y
numbe<:r!lw
Ie} Thla !Jrake is 'lOC ",sad on hoiets In
HazardQus roeatians as
j::hnttm_ 1:>', the NIiIII011,,'

{d) Screw wfth se1t .. la::tlc.ng rT-tJ5i
::>0 utilized. SUOSll!UIEIS arEl no:

lej Sp<"ihl1S an oalor """' .... d. Spring
iP .... n...sa' for 1 a lb. ft. torq""" ;-l'J
C.lU' cole . Sp.-n-g (pA$C77. fo> 33 Ib
It. !O'-q"EI ",rak\); is cad-'1li""" =Ior.
(f) "'0' part numbers. ref.;s..- le, pagea !l
and 9_
with :>lo!sl motor. AI'S(J
a. ... aJlaI:lle In:li ...
PageS
GEAR CASE AND MECHANICAL LOAD BRAKE
Description: The function of the gear case is to transmit motor torque. As illustrated in figure 4,
the gear case consist of a number of different size pinions and gears, helical or spur, housed in a
gear case and meshed with each to provide a continuous transmission of power from the input
shaft to the output shaft. Gears are pressed and fitted onto a keyed shaft, and supported in the
gear case by antifriction bearings enclosed in a bearing capsule. Gear 13, gear pinion shaft 12,
and shaft key are single point failure points. Should anyone of these three items fail the load
would be lost. The gear itself has a very low probability of failure, the most likely of the three
unlikely will be the key and or the pinion shaft key way. Some hoists are equipped with
double key ways and keys to provide extra security.
The function of the mechanical load brake is to hold the load after hoisting, and to control the
speed of the load when lowering. The mechanical load brake consist of a threaded shaft (item
28) and a fixed flange, a motor gear (item 30) with a threaded bore, a ratchet (item 27) with
friction linings riveted to each side, and a spring controlled pawl (item 33) mounted in the gear
case. During the raising cycle the motor gear is driven clockwise causing the motor gear to
compress the ratchet between itself and the fixed flange. The spring controlled pawls are thrown
away from the bracket, therefore no braking action occurs. Gears, keys, and pinions associated
with the portion of the gear box are not single point failure locations. Failure of any would
activate the motor brake.
During the lowering cycle the motor gear is driven counterclockwise attempting to release the
ratchet simultaneously, the load on the hook drives the fixed flange counterclockwise, attempting
to close the brake. The pawl engages the ratchet and forces the ratchet to slip between the motor
gear and flange, thereby creating braking torque.
The mechanical load brake is not a single point failure risk. It is always backed up by the
magnetic motor brake. Should the mechanical brake fail the operator could stop the hoisting
function allowing the motor brake to stop and hold the load.
It is recommended that the mechanical load brake be inspected during the hoist periodic
inspection. Prior to the lift the operator should check for proper operation by insuring that there
is no chattering of the brake, the gear case oil is clean and at the proper level.
P age 14
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GEAR CASE"", FIGURE 4
HOIST GEAR HOUSING ASSEMBLY
~ P age 15
GEAR CASE PARTS LIST,." FIGURE 4A
P age 16
PARTS LIST - PRODUCT SERIES 32
HOIST GEAR HOUSING ASSEMBLY
HOIST GEAR HOUSING PARTS
DESCRIPTION
Housing Co .....
3J11-16 " 1-114
4 PA13B0 0., Lavel Plug
5 PA7ga Pipe PlUg
S .... 69713 Gasket
7 69709 Output Spid ....
8 69710 Input Spid ....
9 (aJ Gear Housing
10 .. PA1390 OB Seal
11 PA1369 Bearing
12 69733 0nIm Shaft
13
NOTE:
(a) Gear Housing part numbers:
Parallel Mounted Holst----- 69112
Cross Mounted Holst 70777
(b) Motor Plnton Shaft part numbers:
?arallal Mounted Hoist 69734
Cross Mounled Holst 70778
1
4
iE
DESCRIPTION
Oil Seal
23 PA2389 Bearing
24 I !b) Motor Pinion shaft
25 I PA13B7 6earing
""
Pawl Spring
27 54982
28 55054 Brake Shaft Unit
29 PA6569 NaedIe Bearing, Outer
30 PA6568 Needle Bearing, Inner
31 54979 6ral<e G_
32 54984 ClIeck Slsws
33 40493 Pawl
34 69745 Pawl Pin
3B PA4053 Retaining Ring
36 PA6294 Key
37 PA13!11 Key
38 PA73!I:! Kay
39 PA7381 Vent Plug
40 [el Change GeM
41 tel Change Pinion
OTYI
ASSY
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
,
,
1
reI Gearing varill$ wi!h the speed of the holst. Three gear sets are available. each idenlifilld by Gear Housing Assembly
No. 69750 wI1h clash number suffix (-011hru -03 for parallel mounted hoist and '1 Ihru 13 for cross mounted
hois1). SSIecl proper dash number by counting and comparing number of teeth In gear and pinion.
The parts of tills assembly which atlecl the speed oi the holst are Items 40 ancl 41.
jGEAR HOUSING ASSEMBL
69750-01 I 69750-02 69750-03 PARALLEL MOUNTED HOIST I
69750-11 I 69750-12 69750-13 CROSS MOUNTED HOIST
I
UFTlNG SPEED 15 FPM I 22 FPM 30 FPM
ITEM NO, I DESCRIPTION PART NO.
I PART NO. PARTNQ,
40 I Gear 69737 (lJ3 teeth) 169736 (76 teeth 69739 (69 teeth)
41 I Pinion 69742 (29 teeth) 169741 (36 tooth 69740 (43 teeth)
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HOOK BLOCK
Hook blocks are used to increase hoisting efficiency on crane and hoisting systems by means of
increasing the number of running wire ropes through encased sheaves. Attached to the
encasement is a single barb hook. The hook provides a means to attach loads usually using
suspension gear such as slings .
This hoist comes with a variety of reeving options that can be used based on the weight of the
loads to be hoisted and the hoisting speeds desired. The description given for this analysis and
inspection will apply to the PD2 option .
The hook block is a 2PD reeve which stands for two parts double or a total of 4 parts wire rope
supporting the load. The wire rope passes through the two block sheaves from opposite sides of
the hoist drum after passing through the equalizer sheave figure 2. Rope is attached to the drum
with pressed lugs or bolted clips. The equalizer sheave and pins are single point failure points.
The lift coordinator or other lift team member should inspect for worn sheave surfaces, defective
bearings and missing pins.
BEARINGS, SPACERS AND SHEAVES
Hoist Block Sheaves figure 5, operate within the block, and with the assistance of spacers' (item
8). Spacers separate steel sheaves in order to provide a necessary even and balanced load. The
hook block is supported by wire rope secured on both ends of the hoist drum and balanced by the
middle of the wire rope system threaded or reeved through the steel equalizing sheave figure 2.
Bearings, (item 3) allow sheaves to rotate with a minimum of friction, lateral movement, or
wobble. Defective sheaves, bearings, and spacers may cause the sheaves to freeze or wear in the
sheave grooves may cause eventual failure of the wire with loss of load.
A visual inspection should be conducted by the crane operator, lift coordinator, or other lift team
members during the pre-lift meeting on the job site .
The inspection shall consist of insuring that all sheaves are operating properly and no damage or
excessive wear is present. Sheaves shall support the wire rope from 135 to 150 degrees of the
wire rope circumference. Sheave grooves shall be smooth and not worn, flanges shall not be
broken and sheave guards shall be in place and undamaged. The equalizer sheave shall be
inspected for wear and for wire rope fatigue in the bend.
Page 17
AXLE-THROUGH SHAFT
Hook block sheaves, figure 5, (item 3) are held in place by a shaft (item 6) which passes through
the sheaves and attaches to the inner plates or frame (item 5) of the block housing. If the axel
shaft breaks the sheaves and the wire rope may fail or detach causing loss of load.
The hook block should be inspected by the crane operator or mechanic in the absence of a recent
NDT report or certification. The inspection by the crane operator, the coordinator, or other lift
team members should be for visual signs of excessive sheave wobble or binding.
HEX NUT
The hex or shank nut figure 5 (item 11) holds the hook in the block assembly. Should the hex
nut completely fail, the hook would separate from the hook block, resulting in loss of load.
A visual inspection of the hex nut shall be performed by the crane operator, lift coordinator, or
other team member during the pre-lift meeting at the job site. Inspection should insure there are
no distortions or cracks on the nut, and the nut has proper tightness. There should be no signs of
thrush washer wear which would be indicated by a loose or wobbly hook or a frozen hook.
HOOK
The hook is the load bearing point of the hook block, figure 5 (item 1). Structural failure of the
hook will result in loss of load.
The hook should undergo a visual inspection during the pre-lift meeting by the crane operator,
lift coordinator or other members on the lift team. The inspection can be performed on site and
does not require disassembly.
The hook inspection should consist of looking for hairline cracks, spreading of the hook by more
than 15% of the original throat opening, loss of 10% or more of the original hook material,
twisting, and evidence of heat damage such as welding. An annual NDT certification of the
hook, nut is recommended and should be presented to the lift co-coordinator.
P age 18
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HOOK COMPONENTS,.., FIGURE 5
- PRODUCT S.=E=RI=ES=---=.:32=--__

t- '._
LOAD BLOCK 2PO REEVING
3/8 r ROPE DIAMETER
LDEd Block A:;sltIntry ooee+a1 511:1d1 SfJlill\, !.JlICt, l'yPif "yfy .. JI, ....
LDEd ElloDl: alllillrd 9Nlvei Ls:ch Type r-olamide
Le<:.d Block eafiQ.403 Brol'lZll Spri!lg LsJc.h Type hook, PolyamJd9 Sbss'IE
LC>l!d 8IIX:K Asseomby 1l!l54.M. SpOrn; lll!d1
Lo:.d monk A.ssOOlb v BlllIlll'd StIlI'ai lx.cll TI'P8 Hook, 5neaWj
LDild Block S9$4-()6 erorlZll Spri'l!i I..alch Type Hook, Stsal
LOAD f3l.0CK PARTS
IlLL A'lO I.'.TCH EflO'lZE SfI'llfIG lJITCH
TYPS: RJD:( lYPE c,::o.
'40TES:
'aJ Sprin. !..alch Htr:lf,s il!e baifYJ philSC<i Cti!)1 10 .. ne11 st>/ie El:lring L;;id; Hooks haye
a hole II. lip of :he hook hole allaws tna adOOCfl of a 10 :ltwllflt 1M I<it::l! OjJet1Ifg. Cottar
p.n i, flI)t SlJpplletllly ,1I,:;co. Ne'/( ;t}ie hooks are Inlilfcha,,?-.abfe w;!1! old imaJc;, but "OW "'')lilt j ,llive
1tll:1rer cross soctiell. L:ilches are between the !WO 1QOiI:S. Il:; :;000 iI:i :;\(h;k 01
is jefliSl90. c:>mm! wii no long'" be L1tcMS lor ,:urrent ;lyle \.m <;:rr;1i-<t,A
'11100 urdllirQ, Idem:;fy wIletnar or net heok hes a r<lie the lro anti 5!lled llitrl (\UlMar.;
accordingiy fr.JIT' the above ;:nm. '
P age 19
52f.ilj;j' 010
2 tOnlrec . ;;900;;; om
S lUf!!iI: 695/13'roa
5 tonm; , ea6!13
WIRE ROPE
The load line on this hoist is a 3\8 6x37 RRL IWRC XIPS designed specifically to be used as
running wire rope. This means the rope is designed to travel through and around s h e a v ~ s located
within the hook block and the equalizer sheave attached to the hoist frame. The term 6x37
means the rope construction consist of 6 strands of 37 small wires.
The wire rope is designed to perform to the necessary bending, wear, and fatigue factors
common in hoisting operations. It is made up of three main components; wires, strands, and a
core rope usually an independent wire rope core or center. In order to meet U.S. standards the
ropes must only be loaded to a fraction of the breaking strength or ultimate strength. Six and
eight strand ropes used for overhead hoist shall work with a factor of safety of no less than 5: 1 or
20% of breaking strength.
WIRE ROPE INSPECTION
Inspection and maintenance of wire rope is an ongoing process.
The load cable (wire rope) is constantly monitored for signs of fatigue, wear, broken wires,
valley wire breaks, flat spots, kinks, broken strands, and bird caging.
The inspection minimum standard for wear is based on the diameter of the rope. A 3/8 inch wire
rope shall be removed from service when it has lost 1132 of its diameter. It shall also be removed
when it has loss 113 of the diameter of the outside strand wires.
Six and eight strand ropes shall be removed when twelve randomly broken wires are present in
one rope lay or four broken wires in one strand in a rope lay. A rope lay is the distance it takes
for one rope strand to travel 360 degrees around the rope. See wire rope figure 6.
Failure of the load cable will result in loss ofload.
Wire rope shall be inspection by the operator, lift coordinator, or designated lift team member
during the pre-lift meeting.
P age 20
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WIRE ROPE", FIGURE 6
WIRE ROPE INSPECTION GUIDELINES
When in use, all. WIfe ropes
degrade and lose strength,
regardless of the application.
Not conducting proper wire
rope inspections can lead to
dangerous and costly situations.
Properly performed inspections are,
therefore, an essential part of the safe
and efficient use of every wire rope.
This is precisely why industry safety standards developed and
published by the Occupational Safety and Health Admlnlstration
(OSHA), American National Standards Institute (ANSI), American
Society of Mechanical Engineers (ASME) and various other
industry and governmental organizations require frequent, periodic
inspections witb pennanent records. The rope user is responsible
for using the proper standard for inspection.
The following information will be a useful aid in planning and
making an inspection program for any wire rope installation
or usage.
HOW TO INSPECT
An inspection program is an integral part of every wire rope
application and requires a specific schedule, trained and qUalified
inspectors. the criteria applicable to tbe usage, and permanent
records.
TIlere are also tools and technlques the inspector must have in
order to evaluate a rope's condition, and the knowledge to
determine if a rope can continue to perfonu tbe work required of
the installation.
A basic anderstanding of how wire ropes and wire rope slings
are designed and manufactured. and how they operate. is also use-
ful. The inspector must be able to recognize specific evidence of
damage and degradation in them .
REQUIREMENTS FOR INSPECTION
Inspection requires certain tools, sucb as a micrometer. calipers,
steel tape measure, groove gauges and fonus for recording data.
The specific criteria published in industry standards and
governmental regulations are also necessary .
The inspector must also have access to the entire rope length and
ability to see the rope's condition close-up .
Specific aspect, of wire rope illspection are discussed on the
following pages including diameter, broken wires, internal rope
inspection, etc.
ACCESS FOR INSPECTION
There are two types of inspections. and access requirements are
different for each. Daily. work shift, or frequent inspections may
not require examining the entire length of a rope. These inspections
are visual observations and are concerned with discovering gross
damage and potential problems, Periodic inspections, where
permanent records are annually mandated by OSHA. ASME and
other regulatory agencies, require more stringent attention to
specific details through the entire length of the rope including
diameter, lay measurement, broken wire counts, evidence of rope
core failure. abuse and wear.
o 20CB The Wire Rope Techincal Beard a-mail: [email protected] Printed in USA 10M
P age 21
P age 22
breaking in period. That is the to be recorded as the initial diameter.
The actual rope diameter must be measured. This is defmed as the diameter of the
circumscribing circle. (i.e., its largest cross sectional dimension) To insure accuracy
this measurement should be made with a wire rope caliper using the correct method
(B) shown on the facing page. Special techniques and equipment mrtstbe employed
for measuring ropes with an odd number of outer strands. (e.g., circumferential
tapes, calipers with plates - see illustration on facing page).
Wear occurring at the crowns of outer wires is normal. Many standards state
a rope must be removed from service when its actual diameter is reduced to
95% of the nominal diameter. The accompanying photos show examples of
heavy nOlmal wear on both regular and lang lay wire ropes.
Regular Lay Lang Lay
This picture simulates 6 x 25 fw construction wire ropes with surface wear (only) of 113 the
outer wire diameter.
Plastic enhanced ropes (impregnated or filled) require careful measurements.
It is essential to measure the metal, not plastic on the exterior of the rope.
Exterior measurement cannot be used to determine diameter reductions of the
wire rope in plastic coated (jacketed) ropes.
Rope core deterioration usually results in a reduction of the rope's diameter,
making careful measurement important. Becanse the core provides less than
10% of the rope's strength (on standard six or eight strand IWRC ropes), that
loss of strength may not be the primary concern. Deterioration of the core leads
to increased stress and broken wires in the outer strands of the rope. These bro-
ken wires are usually valley breaks which can be more difficult to detect.
BROKEN WIRES
Broken wires are another primary indicator of rope degradation and remaining
useful life. The accompanying table shows allowable wire breaks in typical
installations. These broken wire removal criteria apply to wire rope operating on
steel sheaves and drums. The user shall contact the sheave, drum, or equipment
manufacturer or a qualified person for broken wire removal criteria for wire
ropes operating on sheaves and drums made of material other than steel. If no
other information is available, the standard broken wire removal criteria should
be used. However, since the use of plastic sheaves may canse internal wire
breakage, the inspector must pay particular attention to evidence of valley
breaks or breaks against the core and corrosion in the rope Valleys.
3
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WHEN TO REPLACE WiRE ROPE BASED ON NUMBER OF BROKEN WIRES*
Running Ropes
I No. Broken Wires No. Broken Wires In No. Broken Wires
I in Standard Ropes Rotation Resistant Ropes , ,
---- - -
In all strands In one In one At End
Standard Name in one strand in Rope Lay COlmectiuns
Rope Lay one
I
Rope Lay
ASMElB30.2 Overhead & 12** 4 -- --
I
--
Gantry CnUles
I
AS lVlElB30A Portal, Tower 6** 3 4 in all strands in one --
I
& Pillar Cranes rope lay or 2 in one
strand in one rope lay
; ASMf<JB30.5 Crawler, 6** 3 2 in 6 rope diameters Of 3 2
. Locomotive 4 in 30 rope diameters
I
I & Truck Cranes
I
I
ASMElB30.6 I Denicks 6** 3 -- 3 2
AS l\IlElB 30.7 Base Mounted 6** 3 -- 3 2
Drum Hoists
I
ASMPJB30.8 Fioating Cranes 6** 3 -- 3 2
& Derricks
;
I
AS1v1ElB30.l61 Overhead Hoists 12**
I
4 2 in 6 rope dianleters or -- --
I i
4 in 30 rope diameters
ANSUAlO.4 Personnel Hoists 6"* 3 -- 2** 2
j, For ropt operating on steel sheaves and dmrns. Contact the sheave, drum. equipmer.l or a qualified person for removal criteria for
wire ropes on sheoves and drum mode of material oUler than steel.
f'J:Also remove for valley break (at strand-to-stmnd contact point) or one protruding or looped wire broken at strand-toHcore contact point.
Wire breaks gener-
ally arc seen in two
locations on a
rope; at the crowns
of outer strands
and in the valley,;
betweeu outer
strands.
4
P:-1; c 23
Crown Win: Break> Valley Wire Breaks
;
i
Wire Breaks at End Termination
P age 24
Crown wire breaks usually are due to nonnal wear and typically have square
ends. Valley breaks may indicate an abnormal condition, such as loss of core sup-
port, small sheave grooves or deterioration from unusually heavy rope loading.
When a wire has broken from excessive loading or a tensile overload, the ends of
the wire will be pulled or necked down in diameter on each side of lhe break, in
contrast to the typical square ends of crown wire breaks. In nonnal serviCe, the wire
breaks will exhibit characteristics of both axial loading and fatigue.
A wire broken under a tensile load that exceeds its strength is recognized by the "cup and cone"
confignmtion at the fracture point (a). Tbe necking down of the wire at this point shows that failure
occurred while the wire retained its ductility. Sbeructensile fracture (b), usually exhibiting an angular
flat plane failure surface, occurs in wire subjected to a combination of transverse and arialload .
Fatigue breaks are usually characterized by squared-off end. perpeadicuJar to the wire either straight
across or Z-shaped (c&d).
TYPES OF WIRE BREAKS
As a wire rope moves over sheaves and drums, each strand and eaeh wire in
every strand moves and adjusts. Bending the rope or observing it moving slowly
over a sheave can help the inspector find broken wires.
Once wire breaks appear. their numbers will increase if the rope continues
in service.
Valley and strand-to-core contact point breaks are difficult to detect in a rope
and must be taken vcry seriously. These types of wire breaks are indicative of
conditions that result in internal degradation occurring at a faster rate than exter-
nal degradation.
Wire breaks at rope tenninations are also indicators of rope degradation. A single
broken wire at a termination is usually reason to question continued use of a rope;
more than one break is usually-sufficient reason to remove the rope from service.
Flexing a rope can often expose broken wires hidden
in valleys between strands.
5
6
P age 25
HOW TO COUNT BROKEN WIRES
Criteria for wire breaks, provided in Table on page 4 have been published by
OSHA, ASME and other industry and governmental organizations for specific
applications. The criteria applied must be appropriate for the application and
wire rope being inspected. I
Allowable broken wires are stated either in relation to the rope's lay or i:nulti-
pIes of rope diameter. Rope lay is one of the characteristics of wire rope that
needs to be understood by a qualified inspector. Many industry standards and
government regulations base the broken wire removal criteria oU: the number of
wire breaks in a specified length or distance called a rope lay. Each wire rope
has its own particular lay length. Just as the initial rope diameter was not deter-
mined until the rope had been installed, loaded and, ideally, broken in, the same
practice should be followed with regard to the initial rope lay. The initial rope lay
measurement should be recorded along with the initial rope diameter measurement.
To measure one rope lay, mark a spot on one strand, then with a finger, trace
that strand along one complete wrap around the rope, then make another mark
on the same strand T h i ~ distance beween the marks is one rope lay.
It is possible to measure rope lay by placing a sheet of paper on the rope and
stroking the paper with the side of a pencil. The image can be used to measure
the rope's lay length. Count the number of outer strands in the rope, mark a
starting point on one strand impression; count the same number of impressions
as the number of outer strands; and make another mark. The lay length is the
distance between the marks made on the image.
By maintaining records of lay measurements at all inspections, a comparison can
be made to detect changes in lay length that provides evidence of degradation. Any
significant change in the rope's lay length between subseqnent inspections is usually
an indication that degradation has occured and a more careful inspection is warrant-
ed. To utilize this inspection and evaluation technique, the lay measurement compar-
isons must be made of impressions or measurements of the same section of rope on
subsc4uent inspections.
Imprint showing one rope lay.
P age 26
SPECIALTY ROPES
Round strand wire rope designs that have been in use for more than a
century have been replaced in numerous applications by several enhanced
rope constructions. These include compacted ropes, compacted strand
ropes, plastic filled ropes, plastic coated ropes, rotation resistant ropes,
shaped-strand ropes, and coreless ropes. .
The same inspection techniques apply to all ropes. The diameter, broken
wires per specified interval, and change of lay length are important.
Specialty ropes can pose challenges in determining operating limits and the
necessity to remove from service. The rope manufacturer should be contact-
ed for any specific instructions or recommendations.
PLASTIC ENHANCED ROPES
Wire breaks can occur in all plastic enhanced ropes, however in the case
where the plastic inhibits visual inspection, normal broken wire criteria can-
not always be applied. In plastic coated wire ropes diameter reduction can be
a better indicator of rope degradation than visible broken wires. Removal cri-
teria for these ropes are normally provided by the equipment manufacturer.
In plastic filled ropes and plastic coated IWRC ropes, normal inspection
techniques will detect broken wires, but they may be more difficult to tind.
Since the p l a ~ t i c covering the crown wires of plastic filled ropes is relative-
ly thin and wears away quickly, finding crown wire breaks is similar to
standard ropes. Valley breaks are more difficult to detect. If a valley wire
break is detected, it is prudent to increase the frequency of inspections and
to be conservative in assessing continued use of the rope.
Plastic Coated
Wire Rope
Plastic Filled
Wire Rope
Plastic Processed Wire Rope Cmss Sections.
Plastic Coated IWRC
WrreRope
Corrosion can occur in plastic enhanced ropes, and have the same effect as
in standard ropes. Core condition and damage can be detected by diameter
reduction and lengthening of lay.
Separation of plastic coating is not necessarily an indicator of rope deteri-
oration, however, it indicates a potential problem, and warrants close
observation.
7
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6x26
Warrington Seale
Compacted Strand
IWRC
8 x 19 Seale
IWRC
P age 27
8 x 26
Warrington Seale
Compacted Strand
IWRC
8 x 25 Filler WIre
IWRC
COMPACTED ROPE AND COMPACTED STRAND ROPES
During manufacture, these specialty ropes are drawn through dies and/or
swaged to compact the metal content of the rope. Strands may be compacted
before the rope is closed, or the entire rope compacted.
When inspecting these ropes, follow basic guidelines. Diameter anillay meas-
urement procedures are no different than with standard ropes. It is essential to
record a new rope's actual diameter and lay length immediately after installation
to establish the base line for comparison at future inspections.
Wire breaks can be more difficult to detect than in standard ropes, because the
ends of the break do not always displace or separate. Any suspected wire break
should be viewed with a magnifying glass to determine if it is a break. Bending
the rope or observing it moving slowly over a sheave helps the inspector detect
broken wires.
Due to compaction, the spaces between wires and s t r a n d ~ inside a rope are
minimized, and lubrication is critical so that sliding and adjusting of wires and
strands is not restricted. The inspector should be observant to the lack of or need
for lubricant.

19x 19
Seale
COmpllCted Strand
3 x 19
Seale
Compacted (Swaged)
ROTATION RESISTANT ROPES
6x 26
Warrington Sea/e
COmpIlCted (Swaged)
IWRC
6dl
Warrington Seale
Compacted (Swaged)
IWRC
These wire ropes are designed so that the inner strands are laid counter to the
outer strands. Under eertain operating conditions, this design can resu!t in accel-
erated internal wear. Careful initial measurements of diameter and lay are essen-
tia! for comparisons in future inspections.
Inspection procedures are generally {be same as other ropes; however, the bro-
ken wire removal criterion is more restrictive .
18x 7
PC

19x7 19 x 19 Seale 35 x7 35 x 19 Seale
P age 28
RESUI,TS OF ABUSE
Abuse from handling and poor operating conditions may cause damage and
can result in reduced service life of the wire rope. It is important to recognize
the effects of these abuses to properly assess rope serviceability.
Kinks (see Figure a&b left) are tightened loops with distor-
tion that result from improper handling when a rope is being installed or while
in service. A kink happens when a loop is permitted to form and then is pulled
down tight, causing permanent distortion of the strands. The damage is irrepara-
ble and the kink must be cut out or the entire rope taken ouf of service.
Doglegs (see Figure c) are permanent bends caused by improper use or han-
dling. If the dogleg is severe, the rope should be removed from service. If the
dogleg is minor, (exhibiting no strand distortion) and cannot be observed when
the rope is under tension, the area of the minor dogleg should be marked for
observation and the rope can remain in service.
Wavy rope occurs when one or more strands are misaligned with the rope
body. This results from a variety of causes, including failure to properly seize
the end of a rope prior to wedge socket installation; tight sheave grooves; or per-
mitting torque or twist to develop during installation or operation. While not
necessarily resulting in loss of strength, this condition may accelerate rope dete-
rioration and requires increased frequency of inspections. Ropes must be
removed from service when the height of the wave (d
l
) measures more than
33% of the nominal rope diameter above the nominal rope diameter in sections
not bending around a sheave or drum or more than 10% of the nominal rope
diameter above the nominal rope diameter in sections bending around a sheave
or drum.
IVV'RC or strand core protrusion between outer strands, commonly called bird
caging or popped core, usually results from shock loading during operation, but
can also be caused by improper handling. The damage is irreparable and the
affected area must be cut out or the entire rope taken out of service.
Crushing or flattening of the strands or rope is caused by various factors,
including poor spooling on a drum, heavy loading and even poor installation
procedures. This can result in broken wires or the accelerated deterioration of
the rope.
Abrasion (metal loss) and peening (metal deformation) occur when the rope
contacts another metallic or abrasive surface, or from passing over the drum or
sheaves. These result in the reduction of diameter and broken wires.
Corrosion is most often the result of a lack of lubrication. It may result in pre-
mature fatigue failure of individual wires. It is especially important to inspect
ropes at end terminations.
Heat damage comes from any heat source such as welding, fire, power line
smkes, or lightning. The damage is irreparable and the affected area must be cut
out or the entire rope raken out of service.
Protruding broken wire is a condition where one outer wire is broken at the
point of contact with the core of the rope and has worked its way out of the rope
structure and protrudes or loops out from the rope structure.
9

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P age 29
abrasion
The damage is irreparable and the affected area must be cut out or the entire
rope taken out of service. There are occasions when a valley break (at strand to
strand contact point) will protrude or raise above the surface of the TOpe. This
also is a condition of serious concern and somewhat difficult to differentiate
from a wire break at the strand to core contact point. When there are'two or
more valley breaks in a rope lay the affected area must be cut out or the fope
taken out of service.
INSPECTION RECORDS
Periodic inspections require a permanent record of each rope on the equip-
ment. The sample form included in this brochure may be copied and completed
by the inspector for the permanent record. This form is designed to provide a
road map for recording pertinent data as an inspection proceeds.
Any wire rope manufacturer that is a member of the Wire Rope Technical
Board can provide inspection criteria, including recommendations and require-
ments of OSHA, ASME, ANSI, and other industry and governmental regulations.
Permanent records of inspections are required by OSHA and other govern-
mental regulations, and will be used for reference at the next inspection. These
can be kept with the operator and maintenance manuals for the application, or in
permanent office tiles.
These plan views and cross sections
show the effects of abrasion and
peening on wire rope. Note that
a crack has fonned as a result of
heavy peening.
peening
DIAGNOSTIC GUIDE TO COMMON WIRE ROPE DEGRADATION
Mode
Fatigue
Tension
Abrasion
Abrasion
plus Fatigue
Abrasion
plus Tension
Cut or Gouged
or Rough Wire
Torsion or
Twisting
Mashing
P age 30
Symptoms
Wire break is transverse--either straight
across or Z shape. Broken ends will
appear grainy.
Wire break reveals a mixture of cup and
cone fracture and shear breaks.
Wire break mainly displays outer wires
worn smooth to knife edge thinness. Wrre
broken by abrasion in combination with
another factor will show a combination
break.
Possible Causes
Check for rope bent around too small a raaius;
vibration or whipping; wobbly sheaves; rollers'too
,mall; reverse bends; bent shafts; tight grooves;
corrosion; small drums & sheaves; incorrect rope
constraction; improper installation; poor end term-
inations. (In the absence of other modes of degrada-
tion, all rope will eventually fail in fatigue.)
Check for overloads; sticky, grabby clutches; jerky
conditions; loose bearing on drum; fast starts, fast
stops, broken sheave flange; wrong rope size &
grade; poor end tenninations. Check for too great a
strain on rope after factors of degradation have
weakened it
Check for change in rope or sheave size; change in
load; overburden change; frozen or stuck sheaves;
soft rollers, sheaves or drums; excessive fleet angle;
misalignment of sheaves; kinks; improperly
attached fittings; grit & sand; objects imbedded in
rope; improper grooving.
Reduced cross section is broken off A long term condition normal to the operating
square thereby producing a chisel shape. process.
Reduced cross section is necked down A long term condition normal to the operating
as in a cup and cone configuration. process.
Tensile break produces a chisel shape.
Wrre ends are pinched down, mashed Check on all above conditions for mechanical
andlor cut in a rough diagonal shear-like abuse, or either abnormal or accidental forces
manner. during installation.
Wrre ends show evidence of twist andlor Check on all the above conditions for mechanical
cork-screw effect.
Wires are flattened and spread at
broken e n d ~ .
abuse, or either abnormal or accidental forces
during iustallation.
Check on all the above conditions for mechanical
abuse, or either abnormal or accidental forces
during installation. (This is a common occurrence
on the drum.)
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Wire Rope Inspection Form
Date ____ Inspector's Name ____________ ,lnspector's Signature ___________ _
Descrrption of this installation/usage ______________________________ _
Rope Desoription ________________ ,Date Installed _______________ _
Manufaoturer's Identification! Reel No _____________________________ _
End Attachment No.1: Condition and Comment ___________________________ _
End Attachment No.2: Condttlon and Comment ________________ -,-__ ~ - - - - - - - -
Drum Condition and Comment ______________________ - - . . : . ~ ~ _______ _
Sheaves Condition and Commen! ________________________________ _
Wire Rope Technical Board
P age 31
HOIST LIMIT SWITCHES
The hoist limit switch is a safety device to prevent the bottom block from being over hoisted and
contacting the equalizer sheave and possibly the upper hoist frame or trolley. Limit switches are
designed to open electrical circuits and stop the motion of the hoist.
This hoist has two types of limit switch. The primary switch will be the geared switch, which
count the revolutions of the drum in order to open a circuit when the hook block reaches a
predetermined height or lowered to a predetermined level from the floor figure 8. The secondary
limit switch will be weight operated. A circuit switch is held open by a suspended weight.
When the hook block is raised to come into contact with the weight and relieves the tension
holding the switch closed the circuit opens and the upward motion stops figure 7.
Limit switches are single point failure risk if only one of the above switches is present. Should
the single limit switch fail the hoist will come into contact with equalizer sheave and would
cause the wire rope to part with loss of load.
Limit switch shall receive an operational check to insure they are both operational.
P age 32
HOIST LIMIT SWITCHES..., FIGURE 7
PARTS LIST - PRODUCT SERIES
Gravity Umit Switch Assembly
Gravity Umif Switch Assembly 7026HJ2
GRAVITY LIMIT SWITCH PARTS
GRAVITY LIMIT SWITCH
Usad on Sen!i!$ 32 and Senes 33 2PS.
and 4PD hoists.
Used on Series 33 4PS. Series 34, and
Saries 35 heists.
OTY. OTY.
I
ITEM NO.
I
PART ),/0. DESCRIPTION 70265-01 70265-0;>
1 70262 EnclnstJl'D
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1
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P.A.:l598 Bushin!'!
.-
en) 2
I :3 69193 Ann
!
1
4 3-06-130 Screw 1 1
!l .702:54 Cam 1 1
e 3-08-140 Screw 2 2
1 r-PA1400 Spring 1
,
8 3-OS2C Screw 3 3
9 3-010-6C SCf'OW 1 1
10 61111 Switah Unit 1 1
11
-702S3----
Shaft
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12 64104 In",,'utor 1
,
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PA3810 Spring Pin 1 1 13
1----- ..
PAS15S Salf-tapping S<;",.., 2 2 14
15 69804 eov .... 1 1
11'1 69_ G ..... k<!rt 1 1
17 PA2242 Oval Oable Sleeye
-r--:2- '---2---
16 PA3113 Wlt1!JRope A.R. A.A.
19 59627 Weight Half 2
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20 :35-4-160 Bolt
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22 17-40 lcckwWlhcr 2 2
23 Hl-oac lcckwasi ... ;;Trit. Tooth 1 1
24 3-010-6<:: Scnow 0 1 ASSEMBL Y-01
25 30-,l1C Hex Nut 0' t
26 I
35-4:241: Balt 0 2
27 i A2007L1 Weipht Hail. LIOn 0
,
2S
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Weight Half, Rlght 0
,
No Recommended Spare Parts
ASSEMBLY-02
NOTIES:
(a) Included wtth 110m
(b) GraYity limit switch attached to holst frame with 'iYJO (2) Round Head Screws. Part No. 3-010-16C. and two (2) locknuts,
Part No. PA2423.
P age 33
HOIST LIMIT SWITCHES", FIGURE 8
PARiS LIST - PRODUCT SEFIIES 32
GEARED LIMIT SWr-CH PAATll
No FEoommerdod BP10IS Parts
NOTE;
GEARED LIMIT SWITCH
(:11 Far G6etid Lirrf! eebd en fl'IJiX Mum l1ulTO .. r at Ir::llL stat 7Lfns l1u5t 1)2
t:;tn1 flumt':Jf )f
Witt ,;apdlUll gt'::aJIf'g.
f.mes car; Ill!
llltai nlirr;baf oi;ou..ea per W!."kiffa3'15J
,ll!;: t1fJ d?t ..iffl$ onwh,,;;", :hc !WI!!!h
4<):" Flalill CCitl ex' U5."d J): 1O 2PS Drum ,umber ;2 of;<PD ::Xum 'fumbar 5,
60:" =i:.ha cal: ca USiO J;; 70 2PS O'lm: XUlllbttt 4 :;)r <'''0 J:'Uff, 'hlmb,,' 1
nS:1iO c.1f1 t' jp 2PS DtulU !\I...IIlL1:1! e WI 2FC ::hUf.J lI.
P age 34
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FESTOON AND PENDENT CONTROL STATIONS
Power is supply to this crane by a suspended insulated power cord attached to the hoist. The
cable designed to follow the crane as it moves along the monorail by means of hangers that slide
or roll on a single support cable .
The hoist and trolley function are controlled by a sealed push button control box. The control
box will have a power on or start button, emergency stop button, hoist button, hoist down button,
and two buttons for trolling back and forth, figure 9 .
The festoon and control system is not a single point failure risk .
Hoist Trolley Assembly
The function of the hoist trolley drive is to propel the hoist along the monorail. This trolley
system consist of a mounting frame with two hoist connecting studs, a drive motor, a right angle
gear box, motor brake, and trolley wheels.
This trolley is parallel mounted, four wheels one of which drive the trolley. The trolley motor is
equipped with an electric motor brake and utilizes a worm drive gear box which serves a braking
function.
Each trolley component will be examined in detail.
P age 35
PENDENT CONTROL BOX - FIGURE 9
PSHtlANT CONTROl.. STA nON
P age 36
WAIiHIIG ..MIl.
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TROLLEY ASSEMBLY
TROLLEY MOTOR
The trolley motor is rated at 50 ft. per minute and functions the same as the hoist motor. The
trolley motor is not a single point failure risk. Should the motor fail, loss of load would not
occur.
The operator should insure proper operation prior to the lift.
TROLLEY MOTOR BRAKE
The trolley motor brake, figure 10 while simpler, functions the same as the hoist motor brake.
The trolley braking function is on a level plane is not as critical as the hoist brake. Should the
trolley motor fail the spring set brake will set and stop the travel motion of the hoist. Further
movement of the hoist will be stopped by the worm drive system which serves as a backup to the
trolley brake.
The trolley motor brake is not a single point risk. The operator should perform a function check
prior to the lift.
P age 37
TROLLEY MOTOR BRAKE ASSEMBLY - FIGURE 10
PARTS LIST - PROOUCT ______ _
TROLLEY MOTOR BRAKE ASSE.\9.. Y
P age 38
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TROLLEY GEAR BOX
The trolley drive or gear box is a right angle gear reducer figure. The gear box is not single point
failure risk. Any failure of the trolley drive gear box cannot result in loss ofload.
TROLLY GEAR BOX,." FIGURE 11
P age 39
PARTS UST - PRODUCT SERIES 32
MOTORIZEO TROli.EY
RfGHTAt4Gl! GEAR REDUCER
TROLLEY DRIVE WHEELS
This trolley has four 4 inch tapered trolley wheels one of which is a drive wheel. The wheels
have a nat track taper mounted on a six inch patented monorail beam. The wheels are secured to
the mount with washers and a hex nut and cotter key.
The trolley wheels are a single point failure risk. The wheels have an equal number of washers
on each wheel, figure 12 to insure proper alignment and to prevent the trolley from coming off
the monorail. The trolley wheel frame has two horizontal mounting studs which pass two
vertical mounting studs on the hoist mounting frame, figure 13. The mounting studs on the
trolley and the hoist frame are single point failure risk.
The trolley wheels and mounting studs shall be inspected during the pre-lift meeting by the
operator, lift coordinator, or other lift team member. Inspection shall include proper spacing of
the wheels. The wheels should not have more than 14 inch of clearance on each side. Check for
excessive surface wear or damage and insure all wheels move freely. The mounting studs shall
be inspected for any signs of distortion or bending, horizontal studs shall have all bolts, pins, and
keys in place.
P age 40
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2-WHeEl PLAIN TROllEY A ~ M S l Y
" IN. DtAMETER WHen. - NON-SWfVEUNG - TWO MOUHTfHG STUDS
P age 41
LOAD BAR ASSEMBLY..., FIGURE 13
P age 42
PARTS UST - PROOUCT SERtES 32

: ::>.JV SlU:lU W 1.2
HOIST SPECIFICATIONS - FIGURE 14
11-08-3201-20 SOLD TO:
E WILliAMSON & WILMER INC
)3ge 1 of 2
'/1412003
Date Shipped
SERIES 32 HOISTS - 2 to 5 TON - 2PD Processed By R DEHOFF I EMW
SERIAL NO.
53220-13411
Date 911
'roductlon Order ___ ...-:.:12::9;.::8.::.:85:.;1..:.;.1:....--__ _ Register No. ___ __ . Customer p.e. ___ 4..;;,26...;,.7
'obl Units Scheduled Completion __ 1..:.;0:.:,;:/231=2;.::00:.;9:....--_ Assy LfT 2 Wits,
'roduct No. ____ C_2_W_O_5_DO_2_0_-1_5-'M_2D_1 __ _ Mod 20 Capacity 5 Tons Reeved 2PO Lift
.lfting Speed 15 FPM Power Supply: Wiring Class __ .....;3:.:.,R:.-. 460 Volts 3 Ph 60 Hz
- -
:ontrol CIrcuit 115 VAC Brake Circuit 90 VDC Circuit Ampa<;ity 1.2 Amps
nounting: 0 Lug o Plain Trolley 0 Hand Geared Trolley o Motorized Trolley
'mlley Speed 50 FPM
8eam ______ ______ _
Flange Width 6-114" FL FlG 1/2" THICK
any items require special handling, mark SP in QTYIUNIT column. Us! specifications for these items on Modification Parts Us!, Form
;EAR HOUSING ASSEMSL Y Check one
I rt I
)< 69750-01XA Gear Housing Assembly 15 FPM
697S0-02X Gear Housing Assembly 22 FPM
1
Gear Housing Assembly 30 FPM_ 69750-03X
IOIS-r: MOTOR 3 PHASE, 60 HERTZ Check one. 30FPM 22FPM 15 FPM
)Q}
89777-01 200 V
6917702 2301460 V
3 HP -1800 RPM NlA 2 TON 2 3 TON
69177-03 575 V
Single Speed
69777-04 200 V
69777-05 230/460 V S HP -1800 RPM 2 TON 3 TON STaN
69177-06 S75V
69778-01 !200V
1 69778-02 230 V 3/1 HP
NlA 2TON 2-3TON
69778-03 460 V
1800/600 RPM
69778-04 S75V

6977S-05 200 V
69778-06 230 V 5/1.67HP
/'
(Iv
18001600 RPM
2 TON 3TON STON
6977S-07 460 V

69778-08 S75V
lOTOR SRAKE PARTS Check one
- 69757-01 3 HP Motors 18 FILb
1 6975702 5 HP Molors 33 FI-Lb
P age 43
FIGURE 14 - CONTINUED
Page 2 of 2
1f14103
FRAME & DRUM PARTS
X
6975605f1
1
69756-06
69756-01
.,
Check one.
20 FtUI! Drum No.4 69756-08 85 Ft Lift Dnlm No.8
36 Ft Uft Drum No.6 69756-11 26. Ft Lift Drum No.5 (Non-Standard Lift)
60 FI Lift Drum No.7
WIRE ROPE 3/8" PIA. XIP Check one.
><
69728-04 20 FtLlet Drum NO.4 69728-08 65 Ft Lift Drum No. a
1
6972806 36 A Lift Drum NO.6 6972805 26 Ft Lift Drum No.5 (Non-8tandard Lift)
6972807 60 A Lift Drum NO.7
LOAPBLOCK ASSEMBLY Check one. Steel Sheaves are Standard. Check N Ion only when speCmed on register:

Standard Hook Nylon Sheaves X 69554-04X Standard Hook Steel Sheaves
1

Bullard Hook Nylon Sheaves 6955405X BUllard Hook Steel Sheaves
Bronze Hook Nvlon Sheaves 69554-06X Bronze Hook Steel Sheaves
I
CAPACITY PLATES Check one.
i
.
British Ton
'.
Metric Ton
69683-020 2 Tan 69683-1020 2100ne
2 69663-030 3 Ton 69663-1030 3 tonne
;X 69683-050 5 Ton 69683-1050 5 tonne
OVERLOAD CUTOFF Check one.
39169-04 2 &. 3 Ton
Standard Overload
><
39170-04 STan
1 39169-05 2 &3 Ton
Overload when Warning Horn or light Is specified
39170-05 STan
eQUALlZlJIIG SHEAVE Check one. Steel Sheaves are Standard. Check Nvlon only when specified on register.
1
169746 I Nylon Sileave
I.?(IS9775 I Steel Sheave
MISCELLANEOUS ITEMS
1 IX 69643-01 Selial plate drive screws manual. plastic ba!l.
.50 Gal X 57901-01 Paint (Yellow)
GEARED LIMIT SWITCH Check one ony when specified on register.

1:1 Ratio 62.0 Max. Input Shaft Turns Use on Standard Drum Nos. 4. 5 &. 6
2 Circuit
1 :1 Ratio 63.3 IJiax. Input Shaft Turns Use on Standard Drum No. 7
Wright
7150103
2: 1 Rallo 124.0 Max. Input Shaft Turns Use on Standard Drum No. 8
1 6977912
40: 1 Rallo 38.0 Max. Input Shaft Turns Use on Standard Dnlm Nos. A&.5
4 Circuit
60: 1 Ratio 75.0 Max. Input Shaft Turns Usa on Standard Drum NO'5. 6 &. 7
69779-14
G.!:.
69779-02
111 : 1 Rano 104.0 Max. Input Shaft Turns Use on Standard Drum No.8
HM
riM
HM
HM
HM
HM
HM
HM
Note: Maximum No. of Input Shaft Turns must exceed Total No. of Grooves per Side of Drum.
COUNTERWEIGHT ASSEMBLY CheCK as required. Refer to Drawing D70098 for additional assemhfies. HM
X
710')Z..z.-zt1 Drum No.4 IZ+ LB.
70098-17 Drum No.5 110.1 LB.
1
70098-05 Drum NO.6 121.5 LB.
70098-07 I Drum No. 7 iS1.7LB.
70098-09 Dru,"'n No. 8 193.9 LB.
I
Note: 00 Not Check Counterweight Assembly for Lug Mounted Hoists Unless Specified on Register.
P a 0 e 44
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FIGURE 14 - CONTINUED
POWt:R

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P age 45

Fmea E-109-2

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Failure Modes and Effects Analysis

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