Titan Supply Crane Catalogue by Teresa Brown

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ITAN IGGING RODUCTS

Crane Products CATALOGUE

YOUR SOURCE FOR CRANE ROPE & FITTINGS REQUIREMENTS

About Us Titan Supply is an authorized distributor for WireCo WorldGroup which is the parent company to Casar and Oliveira, brands know worldwide for their performance as the premium option for Crane Rope. These Brands combined with the WireCo Union Brands such as the Flex-X products means we can offer the broadest range of Wire Rope for all applications and environments. ®

Titan Supply has recently invested in a wire rope “Annealing Machine” so that the requirement of finishing the ends of the Wire Rope can be done in-house and provides for a much quicker turnaround time.

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ITAN IGGING RODUCTS

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ITAN IGGING ERVICES

Titan Supply is an Authorized Crosby dealer ensuring that we can provide the highest quality fittings and equipment for all your lifting applications.

As the authorized fabricator for Slingmax Rigging Solutions we fabricate in-house a wide selection of the industries premium high performance slings both in Synthetic and wire. We also have a wide selection of engineered softeners that will ensure a safe lift.

Gunnebo Johnson crane blocks are dominant in the North American lifting Industry. Gunnebo Johnson snatch blocks, specialty tackle and ForgeFab® sheaves are found wherever experienced people insist on the best and most reliable products in the toughest applications. Gunnebo Johnson products give you quality performance and value unmatched in the industry.

* U.S. Patent 7,000,905 and 7,293,763

Table of Contents Wire Rope Casar

Starlift Xtra ....................................................................................................................... 1 Eurolift .............................................................................................................................. 2 Paraplast .......................................................................................................................... 3 Turboplast ........................................................................................................................ 4 Stratoplast ........................................................................................................................ 5 Turbolift ............................................................................................................................ 6 Unilift ................................................................................................................................ 7 Oliveira Sa NR Maxipact .................................................................................................................... 8 HD 8 K PPI ...................................................................................................................... 9 Union XLT4 ................................................................................................................................ 10 Flex-X 19 ......................................................................................................................... 10 Flex-X 6 ........................................................................................................................... 10 In Stock Crane Rope Assemblies Starlift Plus ................................................................................................................................. 11 NR Maxipact .............................................................................................................................. 11 Spelter Buttons Resin Spelter Buttons for Terex Crane Hoist Ropes .................................................................. 12 Resin Spelter Buttons for Liebherr Crane Hoist Ropes .............................................................. 12 Button Socket ........................................................................................................................................ 13 Socket Terminators ............................................................................................................................... 14 Crosby Split-Nut Retention System ...................................................................................................... 15 Crane Balls & Swivels ........................................................................................................................... 16 Crane Blocks McKissick® 380 Series Easy Reeve .......................................................................................... 17 McKissick® 380 Series .............................................................................................................. 17 McKissick® 680 Series Construction Blocks ............................................................................. 18 Quick Reeve Mobile Crane Block .............................................................................................. 18 Fixed Bail Construction Marine Blocks ...................................................................................... 19 Shorty “J” Crane Blocks ............................................................................................................ 19 McKissick® Easy-Lift® Overhead Bridge Crane Block ............................................................. 20 Snatch Blocks Johnson Snatch Blocks ............................................................................................................ 21 McKissick® Snatch Blocks ....................................................................................................... 21 Master Link Hybrid .............................................................................................................................. 22 Sheaves Crane Sheaves ......................................................................................................................... 23 Wire Rope Sheaves .................................................................................................................. 24 Slings Wire Rope Slings ...................................................................................................................... 25 Tuff-Lift® Slings ........................................................................................................................ 26 Twin-Path® Slings .................................................................................................................... 27 Slingmax® ................................................................................................................................ 28 Outrigger Pads .................................................................................................................................... 29 Crane Users Guide ............................................................................................................................. 30

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

Starlift Xtra Features

• The new high performance rotation resistant hoist rope that provides the user unique characteristics. • Is the strongest of all ropes in the Casar high performance rotation-resistant product line. • The balanced design results in minimal torque under load, providing superior rotation resistance. Under a normal working load range it has virtually no tendency to rotate, making it ideal for both single-part and multi-part hoist systems and also for those involving long falls where rotation resistance is required. • The multi-strand design combined with compacted strands and lang lay construction helps to maximize resistance to wear by greatly increasing wire and strand surface areas that contact sheaves and drums. • The characteristics of Starlift Xtra enhance its performance in multiple-layer spooling as well. The design provides excellent resistance to both abrasion and scrubbing that occurs at kick over areas and crushing that occurs at the crossover points in multiple-layer drum spooling. • May be used with a swivel • Meets Category 1 requirements according to ASTM A1023 and the general guidance on the use of a swivel given in Annex A ISO 21669 • Main Applications: Main and Auxiliary Mobile Crane Hoist Rope, Tower Crane Hoist Rope. Piling Hoist Lines and some Overhead Cranes

CASAR Starlift Xtra Strength and Weights Chart (millimeters) Diameter (mm) 16 19 22 25.4 26 28 30 32

Weight (lb/ft) 0.85 1.22 1.65 2.19 2.30 2.67 3.08 3.50

Minimum Breaking Force (tons of 2000 lbs) 30.6 42.9 57.2 75.8 79.3 91.6 105 119

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

Eurolift ®

Features • Rotation resistant flexible hoist rope made out of compacted outer strands and a compacted steel core • Fully lubricated. • Extremely high breaking load and a very good resistance against drum crushing. • A core in special design, avoiding crossovers between the strands of the core and preventing internal rope destruction. • Especially suited for multilayer spooling. • Main Applications: Main and Auxiliary Mobile Crane Hoist Rope, Tower Crane Hoist Ropes, Piling Hoist Lines and some Overhead Cranes.

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Paraplast ®

Features

• 8-strand rope in parallel construction made out of compacted strands • Fully lubricated • Plastic layer between the steel core and the outer strands • Very high breaking load • Good abrasion resistance and is very resistant against shock loading

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

Features • • • • • •

8-strand rope made out of compacted outer strands Fully lubricated Has a plastic layer between the steel core and the outer strands, giving the rope a high structural stability, avoiding internal rope destruction and protecting the core against corrosive environments Has a very high breaking load and a good resistance against drum crushing CASAR TURBOPLAST may not be used with a swivel Main Applications: Overhead Crane, Container Crane, Tower Crane Trolley Ropes, Boom Hoist Rope, Lattice Boom Crane Ropes, Gantry Crane, Clam Shell Ropes and Saw Mill Carriage Ropes.

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Features

• 8-strand rope made out of conventional strands • Fully lubricated and • Plastic layer between the steel core and the outer strands Minimum break ing load

Calcula ted aggrega te break ing load

with tensile strengt h o f wire

Nominal diameter

Metallic area

We ight

mm 2

kg/%m

8 9 10

30,6 38,8 48,8

27,3 34,5 43,4

54,2 68,6 86,4

5,53 7,00 8,81

60,1 76,0 95,6

6,12 7,75 9,75

47,2 60,0 74,0

4,80 6,10 7,53

52,3 66,4 82,0

5,34 6,78 8,37

11 12 12,7

59,6 68,3 78,0

53,0 60,8 69,4

105,4 120,8 138,0

10,75 12,32 14,07

116,8 133,8 152,8

11,91 13,64 15,58

88,5 106,6 119,4

9,00 10,84 12,17

98,0 118,0 132,2

10,00 12,05 13,48

13 14 15

81,7 95,1 110,8

72,7 84,6 98,6

144,6 168,3 196,1

14,74 17,17 20,00

160,1 186,4 217,2

16,33 19,01 22,15

125,5 144,6 166,3

12,76 14,71 16,91

138,9 160,1 184,1

14,18 16,34 18,79

16 17 18

125,4 140,3 157,7

111 ,6 124,8 140,4

222,0 248,2 279,2

22,63 25,31 28,47

245,8 274,9 309,2

25,06 28,03 31,53

189,0 211,5 239,8

19,22 21,51 24,38

209,3 234,2 265,5

21,36 23,90 27,09

19 20 21

178,6 198,2 217,1

159,0 176,4 193, 2

316,1 350,7 384,3

32,23 35,77 39,18

350,0 388,4 425,5

35,70 39,61 43,39

264,5 295,3 324,2

26,90 30,03 32,97

292,9 327,0 359,0

29,89 33,36 36, 63

22 23 24

245,4 258,1 280,0

218,4 229,7 249,2

434,4 456,8 495,6

44,29 46,58 50,54

481,0 505,9 548,8

49,05 51,58 55,97

356,2 386,8 423,4

36,23 39,34 43,06

394,5 428,3 468,9

40,25 43,71 47,84

25 26 27

302,0 326,8 353,2

268,8 290,8 314,3

534,5 578,4 625,1

54,51 58,98 63,75

591,9 640,4 692,3

60,36 65,31 70,59

464,3 504,7 535,8

47,22 51,32 54,49

514,2 558,8 593,3

52,47 57,03 60,54

28 29 30

375,2 407,7 435,8

333,9 362,9 387,9

664,1 721,6 771,4

67,72 73,59 78,66

735,4 799,1 854,2

74,99 81,48 87,10

576,2 618,0 666,3

58,59 62,85 67,76

638,0 684,3 737,8

65,10 69,83 75,28

31 32 33

464,3 495,4 526,4

413,2 440,9 468,5

821,8 876,9 931,7

83,80 89,42 95,01

910,0 971,1 1031,7

92,79 99,02 105,2 1

708,3 756,7 809,6

72,03 76,95 82,33

784,3 837,9 896,5

80,03 85,50 91,48

34 36 38

556,8 626,5 705,1

495,6 557,6 627,5

985,6 1108,9 1248,0

100,50 113,08 127,26

1091,3 1227,9 1382,0

111 ,29 125,2 2 140,9 2

853,7 952,4 1071,1

86,82 96,86 108,92

945,3 1054,7 1186,0

96,46 107,62 121,02

40 42 44

770,1 859,3 942,5

685,3 764,8 838,8

1363,0 1521,0 1668,2

138,99 155,10 170,1 1

1509,3 1684,3 1847,3

153,9 1 171,7 5 188,3 7

1181,1 1308,5 1430,1

120,1 1 133,06 145,44

1307,9 1448,9 1583,7

133,46 147,85 161,60

46 48 50

1031,6 1123,1 1212,7

918,1 999,6 1079 ,3

1825,8 1987,9 2146,5

186,18 202,71 218,88

2021,8 2201,3 2376,9

206,1 7 224,4 7 242,3 8

1556,7 1692,8 1850,7

158, 31 172,15 188,21

1723,8 1874,5 2049,4

175,90 191,27 209,12

52 54 56

1309,7 1410,5 1508,1

1165,6 1255,4 1342,2

2318,2 2496,7 2669,3

236,39 254,59 272,19

2567,0 2764,7 2955,9

261,7 6 281,9 2 301,4 1

2013,7 2175,3 2344,8

204,78 221,22 238,45

2229,9 2408,8 2596,5

227,54 245,80 264,94

58 60 62

1627,5 1730,0 1847,2

1448,4 1539,7 1644,0

2880,6 3062,1 3269,6

293,74 312,24 333,41

3189,8 3390,8 3620,6

325,2 7 345,7 6 369,2 0

2508,9 2621,5 2815,8

255,14 266,59 286,35

2778,2 2902,9 3118,0

283,49 296,21 318,17

64 66 68

1968,3 2093,3 2222,1

1751,8 1863,0 1977,6

3484,0 3705,1 3933,1

355,27 377,82 401,06

3857,9 4102,8 4355,3

393,4 0 418,3 7 444,1 1

3000,1 3198,3 3357,6

305,10 325,25 341,45

3322,1 3541,6 3718,0

338,99 361,39 379,39

70 72

2354,7 2491,2

2095,7 2217,2

4167,8 4409,4

425,00 449,63

4615,2 4882,7

470,6 2 497,9 0

3552,7 3751,7

361,29 381,53

3934,1 4154,4

401,44 423,92

1770 N/mm 2 (180 kp/mm 2)

1960 N/mm 2 (200 kp/mm 2)

1770 N/mm 2 (180 kp/mm 2)

1960 N/mm 2 (200 kp/mm 2)

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

Turbolift Features

• 8-strand rope made out of conventional strands • Fully lubricated and • Plastic layer between the steel core and the outer strands

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Features

• 8-strand rope in parallel lay construction made out of conventional strands • Fully lubricated • Very flexible • High breaking load • Can not be used with a swivel.

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

NR Maxipact Features • Non rotating construction with fully compacted strands. • Lang lay flexible hoist rope • Can be used with a swivel and can be used with a single fall • Fully lubricated (internal and external) • Extremely high breaking strength. • Main Applications: Tower Cranes, Mobile Cranes and all applications where non rotational properties are required.

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HD 8 K PPI Features

• When rotation resistant ropes are NOT required (twin hoist systems with right and left ropes, small heights, …). • Regular or Lang lay • 8 Outer compacted strands • Flexible • Resistant against drum crushing. • Plastic protected impregnated core (PPI) increases the structural stability. • Main Applications: Hoists for steel mill cranes, container cranes and all type of overhead travelling cranes or electric hoists, boom hoist. Used on multireeving systems for short height.

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

Union XLT4 • • •

Low-torque; high strength Can be used with a swivel Can be used with a design factor as low as 3.5 to 1 XLT4 is a revolutionary crane wire rope that has extremely low torque and is named so because "4" is the minimum breaking force of a 6-strand XXXIP (4X) IWRC wire rope.

Rope Dia. (in.) 1/2 9/16 5/8 3/4 7/8 1 1-1/8

This specialized wire rope has a unique design that packs more high tensile steel wire into the rope's diameter, giving it one of the highest strength-to-diameter ratios ever achieved with a minimum breaking force 33% higher than standard 6-strand XIP ropes. In addition, its compact construction keeps more steel in contact with sheaves and drums for unmatched resistance to crushing and wear - for lower maintenance, less downtime, and longer service life.

Rope Dia. (in.) 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8

Flex- X 19 Minimum Breaking Force (TONS) 11.2 14.6 18.5 22.7 32.4 43.8 56.9 71.5

Flex-X 19 •

• •

Tightly compacted smooth design offers: o More crushing resistance than standard 19x7 rope. o Higher strength-to-diameter. o Resistance to bending fatigue. o Exceptional stability. o Reduced wear to sheaves and drums. o Improved handling, operating, and spooling characteristics. Greater fatigue resistance substantially reduces rope expense and extends service life. Ideal for multi-part hoist lines wherever you encounter spooling problems, drum crushing, block twisting. or have fast line speeds.

Flex-X 6 • • • •

Minimum Breaking Force (TONS) 17.7 22.3 27.4 39.2 53 68.9 86.7

Provides greater surface area and more steel per given diameter, increasing rope stability and strength (When compared to conventional 6 strand ropes). Results in longer service life and less sheave and drum wear. Drum scrubbing between the lead line and the previous wrap is reduced. The smooth contact creates less interference, less metal loss and wire deformation.

Rope Dia. (in.) 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2

Flex-X 6 Minimum Breaking Force (TONS) 8.8 11.9 15.3 19.3 22.7 32.4 43.8 56.9 71.5 87.9 106 125

Minimum breaking force and weights for Flex-X 6 and Flex-X 9

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In Stock Crane Rope Assemblies Starlift Plus

Features • Rotation resistant flexible hoist rope with compacted outer strands and a special designed core. • Fully lubricated • High breaking load • Has a core in a special design, avoiding crossovers between the strands of the core and reducing the danger of internal rope destruction • Known worldwide for its excellent service life • Especially suited for multi-layer spooling • Main Applications: Main and Auxiliary Mobile Crane Hoist Rope, Tower Crane Hoist Rope, Piling Hoist Lines and some Overhead Cranes

In Stock Assemblies using Starlift Plus from Casar 109421-13mm 109422-17mm 109423-17mm 109424-21mm

13mm x 493' Starlift Plus 2160 RRL C/W Liebherr Fitting, One End Only 17mm x 657' Starlift Plus 2160 RRL C/W Liebherr Fitting, One End Only 17mm x 853' Starlift Plus 2160 RRL C/W Liebherr Fitting, One End Only 21mm x 821' Starlift Plus 2160 RRL C/W Liebherr Fitting, One End Only

Instock Assemblies using Maxipact from Oliveira 109770-13mm 109771-15mm 109772-17mm 109773-17mm 109774-21mm

13mm x 493' Maxipact Bright 2160 RLL C/W Liebherr Fitting, One End Only 15mm x 656' Maxipact Bright 2160 RLL C/W Liebherr Fitting, One End Only 17mm x 656' Maxipact Bright 2160 RLL C/W Liebherr Fitting, One End Only 17mm x 853' Maxipact Bright 2160 RLL C/W Liebherr Fitting, One End Only 21mm x 820' Maxipact Bright 2160 RLL C/W Liebherr Fitting, One End Only

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

Spelter Buttons Resin Spelter Buttons are intended to be a replacement for Terex’s swaged buttons Type A used on hoist ropes and attached to the original socket. To choose the proper Resin Spelter Button for a Terex crane’s hoist, match the button Type, the rope diameter, the button diameter and the overall length dimension with the current button on the crane. These buttons are to Resin Spelter Button be attached only to Casar Description Eurolift, Casar Starlift Plus or RSBTX-26-52-209 Oliveira NR Maxipact ropes. Please read and understand the Warnings and Instructions RSBTX-28-56-201 for Resin Spelter Button Kit.

Resin Spelter Buttons for Terex Crane Hoist Ropes

Shown below are the Resin Spelter Buttons currently available for Terex cranes. For convenience, the size Wirelock® kit required for attaching each button is indicated.

Type B

Type C

Type A

Rope Diameter [mm] 26

Button Diameter [mm] 52

Button Length [mm] 209

Maximum Tensile Grade [N/mm²] 2160

Size Wirelock® Kit Required [cc] 250

Broom Length [mm] 94

201

2160

250

RSBTX-32-64.5-263

64.5

263

2160

250

133

RSBTX-40-80-371

371

2160

500

175

For Terex button dimensions not shown, please inquire. Do not substitute “nearly the same” buttons.

Resin Spelter Buttons for Liebherr Crane Hoist Ropes WireCo’s Resin Spelter Buttons are intended to be a replacement for Liebherr’s swaged buttons used on hoist ropes and attached to the original socket. To choose the proper Resin Spelter Button for a Liebherr crane’s hoist, match the rope diameter, the button diameter and the overall length dimension with the current button on the crane. These buttons are to be attached only to Casar Eurolift, Casar Starlift Plus or Oliveira NR Maxipact ropes by WireCo WorldGroup or their authorized distributors. Please read and understand the Warnings and Instructions for Resin Spelter Resin Spelter Button Button Kit.

Type B

Size

Type

Rope Diameter [mm]

Button Diameter [mm]

Button Length [mm]

Maximum Tensile Grade [N/mm2]

Wirelock ® Kit Required [cc]

Broom Length [mm]

RSBLEB -15 -30 -90

13/15

2160

100

RSBLEB -17 -36 -108

108

2160

100

RSBLEB -21 -44 -126

126

2160

100

RSBLEB -23 -52 -175

175

2160

250

RSBLEB -25 -52 -175

175

2160

250

RSBLEB -28 -58 -203

219

2160

250

125

Description

Shown below are the Resin Spelter Buttons currently available for Liebherr cranes. For convenience, the size Wirelock® kit required for attaching the button is indicated.

Type A

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Button Socket SB-427 Button Socket • Button Spelter terminations have a 100% efficiency rating, based on the strength of the wire rope. • Designed for use with mobile cranes. • Can be used to terminate high performance, rotation resistant ropes, and standard 6 strand ropes. • Easy to install assembly utilizes Crosby® WIRELOCK® socketing compound. • Sockets and buttons are re-usable. • Replacement buttons and sockets are available.

Easy “In-Field” installation, utilizing Crosby® WIRELOCK® socketing compound, can be performed by trained Crosby® distributors.

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

Socket Terminators Crosby® Wedge Sockets S-423T

S-421T

NEW • Sizes Available:: 5/8” to 1-1/4” 1/4” (14-32mm) 1/4” rope sizes. • The Crosby by S-423T 3T Super TERMINATOR™ is the first wedge socket ocket designed to take ock advantage off the performa f forma nce properties associated with high performa f forma nce, high strength, compacted strand, rotation resistant wire rope. • Innovative design will significantly increase the termination efficiency over existing wedge socket ock s available today. ocket ay ay. • Patent pending design eliminates the difficulty of installing high performa f forma nce, high strength, compacted strand, rotation resistant wire rope into a wedge socke ck t termination. cke • Proper application of the Super TERMINATOR™ eliminates the “first load” requirement of conventional wedge socket ck terminations. cket • Available as a complete assembly, embly or as embly, a wedge kit that can be retrofitted onto e existin g Crosby by S-421T TERMINATOR wedge socket ock s. ocket • Available with bolt, nut and cotter (S-423TB).

US-422T

• Sizes Available: 3/8” to 1-1/4” 1/4” (9-32mm) 1/4” rope sizes. • Wedge socket terminations have an efficiency rating of 80% based on the catalog strength of XXIP wire rope. • Basket is cast steel and individually magnetic particle inspected. • Secures the tail or “dead end”” of the wire rope to the wedge, thus eliminating loss or “punch out” of the wedge. • The TERMINATOR ™ wedge eliminates the potential breaking off ff of the tail due to o ffatigue. • Incorporates Crosby’s patented QUIC-CHECK ® “Go” and “No-Go” featur feature cast into the wedge. • The 3/8”” (9.5mm) through 1-1/8”” (28.7mm) standard S-421 Wedge Socket can be retrofitted with the new style TERMINATOR™ wedge. • Available with bolt, nut and cotter pin (S-421B).

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Crosby® Button Spelter Sockets

• Available in sizes from 1/2” to 1-1/2”” (13mm - 38mm). • Button Spelter terminations have a 100% efficiency rating, based on the catalog strength of wire rope. • Designed for use with mobile cranes. Can be used to terminate high perf performance, rotation-resistant ropes and standard 6-strand ropes. • Easy to install assembly utilizes Crosby® WIRELOCK ® socketing compound. • Sockets and buttons are re-usable. • Locking king ffeature available to prevent rotation of rope. • Button contains cap with eye that can be attached to, and used to pull rope during reeving process. 14

Split-Nut Retention System McKissick® Split-Nut Retention System ®

I n n o v a t i v e M c K i s s i c k S p l i t - N u t R e t e n t i o n S y s t e m M a k e s I n s p e c t i o n E a s i e r.

Crane Block Hook Inspection in 4 Easy Steps STEP 1

Remove protectiv e vinyl cover

STEP 2

Remove retaining ring

STEP 3

Slide keeper ring off split nuts

Shankk hooks on crane blocks must be inspected cted in cted accordance with applicable ASME B30, CSA Z150 Z150 and other crane standards tandards tanda . These standa standards mandate the crane hook to be inspected for surface indication on, sdamage and corrosion which could ons could compromise the integrity rity of the crane ane block. Because of the type of environment in which whic ich h these hooks are required to perform, rform, th rform, the e removal of corroded nuts from the thr threads eadss ead can become a problem during inspecti cti ctions . ons The innovative patented* Split-Nut t-N -Nut ut ® Retention System m ffeatured on McKissick crane blocks makes inspection easier. With 4 easy steps, the hookk can b be e disassembled, inspected and put back into service in a fraction of the time of a conv ional threaded nut. convent

The Split-Nut is availa av ble upon request for McK Easy Reeve® crane blocks up to 100 tons. - Allows for easy inspection as required by ASME B30, CSA Z150 and other crane standards - Eliminates conventional threaded nut and problems associated with the nut removal for inspection. - Allows repeated installation and removal without without risk sk of damage to hook/nut interface nterface nte . - Zinc plated finish for corrosion resistance stanc stance - Replacement hookk and trunnion assemblies mblies mblies available for selected McKissick® 380, or Easy Reeve® & 790 blocks with threaded hooks. The new patented* Split-Nut can be purchased in a vari variet etyy of of configurations that can be used to retrofi retrofit the foll follo owing wing wi ng McKissick ck® blocks in the field or in the shop. - Over 100 tons and larger crane blocks, upon request - Bridge crane blocks - 80 Series tubing blocks In addition, the Split-Nut can be used to replace exis e ting hooks on existing crane blocks currentlyy iin the field (most manufac nuf turers makes and models) nufac els els) and on special designed lifti ipment. ®

STEP 4

Easily remove split nut halves to inspect shank hook * U.S. Patent 7,000,905 and 7,293,763

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

Crane Balls & Swivels McKissick ® UB500 Overhaul Balls • UB500 Overhaul Balls are available in Top T Swivel and Non-Swivel configurations. • Available in capacities from 4 to 30 tons. • Design fac f tor of 4 to 1. • All McKissick ® Overhaul Balls are RFID equipped.

S1316A SHUR-LOC ® Eye Hook

All hooks used on UB500 Overhaul Balls (S320, S320N and S1316A) are forged from alloy steel. The 320 and 320N style hooks come complete with latches. Sizes 4 tons through10 tons available with Crosby’s 1316A “Positive Locking”” SHUR-LOC® hook which may be used ffor lifting f personnel. Meets OSHA Rule 1926.550(g).

Both styles available with optional McKissick Wedge Socket Assembly

Socket which can be easily adjusted to fit various sizes of wire rope by changing the wedge e. (Ensure that correct wedge is used ffor selected wire rope size.) Each ball can be equipped with a McKissick® US-422T Wedge

Crosby ® Swivels

T Swivel Top Design

Non-Swivel Design

Equipped with Tapered Roller Thrust Bearing • • • • • • •

Suitable ffor frequent rotation under load. All swivels individually proof tested with certification. All hooks furnished with latches assembled. All jaws complete with bolts, nuts and cotter pins. Pressure lube fitting provided. NOT TTO BE USED ON DEMOLITION (WRECKING) BALLS. Other types and capacities up to 600 tons, available to meet your requirements.

S1 Jaw & Hook

S2 Jaw & Jaw

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S3 Jaw & Eye

S4 Eye & Jaw

S5 Eye & Eye

S6 Eye & Hook

Crane Blocks McKissick ® 380 Series Easy Reeve Crane Blocks • Standard block configurations can be from a single sheave design to a five sheave design. • Available from 5 to 80 metric tons. • Larger models and configurations available upon request. • All McKissick ick® 380 Series Easy Reeve Crane Blocks have a design factor of 4 to 1, unless otherwise her herwise noted in the Crosby General Catalog. ® • All McKissick ick Crane Blocks ar are RFID equipped. Sheave Guards open to allow block reeving without removing the rope end fitting. Forged Crosby alloy steel hooks with patented QUIC-CHECK ® markings and heavy duty positive locking hook latch.

Center “Dead End” to promote better block travel under various reeving configurations.

Flat bottom side plate for self standing during reeving process.

McKissick ® 380 Series Crane Blocks • Standard block configurations can be from a single sheave design to an eight sheave design. • Available from 5 to 300 metric tons. • Larger models and configurations available upon request. • All McKissick® 380 Series Crane Blocks have a design factor of 4 to 1, unless otherwise noted in the Crosby General Catalog. • All McKissickk® Crane Blocks are RFID equipped. Copyright © 2011 The Crosby Group LLC All Rights Reserved

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Crane Blocks McKissick® 680 Series Construction Blocks • Standard Block configurations can be from a single sheave design to a four sheave design. • Available from 5 to 100 tons. • Larger models and configurations available upon request. • All McKissick ® 680 Series Construction Blocks have a design factor of 4 to 1. • All McKissick ® 680 Series Construction Blocks are RFID equipped.

680 Series Blocks are available with Bolt Only, Hanger Only, or Hanger with Shackle.

Quick Reeve- Mobile Crane Block STANDARD FEATURES • Quick release, zinc plated, rope retention pin meets OSHA requirements for rope retention. Cannot be completely removed from block to avoid pin loss. • Johnson J-Latch™ heavy duty, steel, lockable, spring loaded latch meets OSHA personnel lifting requirements. • The Johnson J-Latch™ provides a fast hook deformation inspection point. • Available tonnage capacities from 5-300 tons. Larger capacities available upon request. • Quick Reeve™ upright design rests on its own hook for a stable base while reeving. • No bulky, drop down, trap door to handle or damage. • Wire rope end fitting will pass through block without removal from wire rope.

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WARNING

NEVER EXCEED PUBLISHED WORKING LOAD LIMIT

Crane Blocks Fixed Bail Construction and Marine Rigging Blocks STANDARD FEATURES • 10 to 135 ton capacity • 4 to 1 design factor • 1 - 6 sheaves • Full coverage side plates and center plates • Top dead-end shackle • Tapered roller bearings • Oval pattern side plates

OPTIONAL FEATURES • Bronze bushings • Diamond pattern side plates • Fully galvanized for corrosion resistance • High capacity, custom engineered blocks available upon request

WARNING NEVER EXCEED PUBLISHED WORKING LOAD LIMIT

Johnson offers a host of advantages in this product line. Beginning with 100 standard models, you are assured of selections that fit your every need. The lowest weight to capacity ratios, the quickest rigging and the easiest maintenance are a few additional benefits that prove once again that Johnson Blocks are consistent in quality and value.

Shorty “J” Crane Blocks Shorty “J” represents the

broadest line of standard crane blocks in the industry. In all, this company manufactures more than 1500 standard models of crane blocks, not including options. To our customers this means a better chance we’ll have exactly what the end user requires.

Shorty “J” is one of today’s most popular crane blocks, and for a good reason. The J-Block can be used with all types of mobile cranes, truck cranes, overhead cranes, hydraulic and cable cranes. Johnson Quick Reeve crane blocks are also available.

STANDARD FEATURES

• 3 thru 350 ton capacities • 4 to 1 design factor • 1 through 8 sheaves • 10 through 30 inch sheave diameters • Reeving guides, all models • Bronze bushed and roller bearing sheaves • Direct-channel sheave bearing lubrication through center pin • Flame hardened grooves on sheave sizes 16 through 30 inch diameters. • Dual action (swing/swivel) roller thrust bearing hooks • Forged steel hooks - 3 through 30 tons • Total disassembly capability

OPTIONAL FEATURES • Forged steel hooks - 35 through 300 tons • Cast alloy steel duplex hooks with bar latch 25 through 1,750 tons • Cast alloy steel quad hooks • Forged steel duplex hooks • Anti-rotation locking devices, all models • Swivel safety anchor shackles, all models • Sheave shrouds, all models • Detachable cast iron and steel cheek weights, all models • Pull test and certification, radiograph, magnetic particle, and other non-destructive testing to specification designated by customer

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Easy-Lift® Crane Blocks McKissick® Overhead Bridge Crane Blocks SEE APPLICATION AND WARNING INFORMATION

McKissick Easy-Lift Overhead Bridge Crane Blocks ®

• Wide range of product available (see tables below). • Removable housing allows block to be reeved without complete disassembly. • Bearing life and Design Factors meet: • ASME HST-4, Class H • CMAA 70 Class D • FEM9.511 Class 2m • ISO 4301.1 Class M5 • Adjustable sheave spacing in 1/2” increments (1/4” on 6 1/2 size). • Sheave pitch diameter minimum of 16 times rope diameter on standard sizes. • All single point shank hooks are genuine Crosby ® , forged alloy steel, Quenched and Tempered, contain the patented QUIC-CHECK ® markings and come with a world class latch that integrates with hook tip. • U.S. Patent 7,255,330 • All sizes are RFID EQUIPPED.

BC-751-Single Sheave WLL (t) Sheave O.D. Pitch Diameter Wire Line* 1/4” 6.5mm 5/16” 8mm 3/8” 9 - 10mm 7/16” 11mm 1/2” 12 - 13mm 9/16” 14mm 5/8” 16mm 3/4” 19mm 7/8” 22mm 1” 25 - 26mm

Model 751 - Single Sheave 2 3 5 6.5” 165mm 8” 203mm 10” 254mm 5.69” 151mm 7.38” 187mm 9.25” 235mm

7.5 12” 305mm 11” 279mm

Para Español: www.thecrosbygroup.com

• • • •

Sheave bearings are maintenance free and sealed for life (10,000 hrs.). Ability to attach optional anti two-block device. Available with shackle as lower connection point. Ultimate load is 5 times the Working Load Limit. Key to McKissick ® Easy-Lift ® Overhead Bridge Crane Blocks Single and Double Sheave Blocks

McKissick® 750 Series Bridge Crane Blocks

Working Load Limit (t)

Number of Sheaves S=1 D=2

Sheave Diameter (in.)

Center Pin Designation

Sheave Spacing in 1/8” Increments

10 14” 356mm 12.5” 318mm

BC-752 - Double Sheave WLL (t) Sheave O.D. (mm) Sheave Spacing Centerline (mm) Pitch Diameter (mm)

Model 752 - Double Sheave 3 5 7.5 6.5” 165mm 8” 203mm 10” 254mm 3.25” - 5” 4.5” - 6.5” 5.25” - 7.75” 82.6 - 127mm 114 - 165mm 133 - 203mm 5.95” 7.38” 9.25” 150 - 152mm 183 - 191mm 228 - 236mm

Double Sheave Blocks Only

BC-751 10 12” 305mm 6.5” - 10” 165 - 254mm 11” 273 - 282mm

15 12” 305mm 7.5” - 11” 191 - 279mm 11” 273 - 282mm

Wire Line* 1/4” 6.5mm 5/16” 8mm 3/8” 9 - 10mm 7/16” 11mm 1/2” 12 - 13mm 9/16” 14mm 5/8” 16mm 3/4” 19mm

* Additional wireline sizes available. = Primary Wire Line Size

= Other Wire Line Sizes

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BC-752 20

Snatch Blocks Snatch Blocks Johnson produces a wide variety of multipurpose snatch blocks.

Over 235 standard models of single and double sheave snatch blocks are offered. Capacities range from 2 through 30 metric tons; sheave diameters from 3 through 24 inches. Only top grade materials are used for each component.

Johnson Snatch Blocks have the convenient side opening feature. This is true even of our heavy duty top dead-end models, and makes it easy to reeve the block without removing any fittings from the end of the wire rope. Other features include choice of swivel hook, shackle, eye fittings, or Tailboard Blocks (which have no fittings at all). STANDARD FEATURES

• Easy to open side plates • 4 to 1 design factor • Bronze bushings • 3 through 24 inches sheave O.D. • 2 - 30 metric tons

Top Dead End Snatch Block with Hook

Tail Board Block

Double Sheave Snatch Block

4 Ton Snatch Block with Hook

OPTIONAL FEATURES • Hook latches • Roller bearings • Galvanized • High capacity, custom engineered snatch blocks available upon request

2 Ton Snatch Block with Shackle

4 Ton Snatch Block with Shackle

McKissick ® Snatch Blocks

With Hook With Shackle

Tailboard

• A wide variety of McKissick ® snatch blocks are availab • Capacities from 2 to 30 metric ton • Sheave diameters from 3” to 24” (76mm - 610mm) • Wireline sizes from 5/16” to 1-1/4” (7.9mm - 31.7mm) • Painted finish • Snatch Blocks have a design factor of 4 to 1, and most styles are Fatigue Rated. • 3” to 10” blocks furnished with dual rated wireline sheaves. • Furnished with either bronze bushings or roller bearings. • Pressure lube fittings for easy maintenance. • 408 and 409 models feature two sheaves. • All McKissick® snatch blocks are RFID equipped. Model 408

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Master Link Hybrid Features Master Link Hybrid (MFH), is completely new and unique on the market, designed to fit perfectly on DIN 15401 crane hooks. The top part of the master link has an extended radius, allowing a perfect fit on the crane hook. This minimizes the wear and tear of both the master link and the crane hook, which otherwise can lead to corrosion and a shorter product life span. Unlike the pear-shaped master link, the MFH has parallel legs offering generous space to connect multiple legs which also makes the assembly easier for the user. The lower half of the master link is rounded and this allows the load to automatically center with every lift, increasing balance and a safer working situation. The risk of tilting is completely eliminated.

Perfect fit

Perfect balance

Generous space

The upper part of the master link has a larger radius, ensuring a perfect fit on the crane hook. This means less wear and tear, both on the crane hook and the master link.

The shape of the lower half of the master link will automatically centre the load, increasing the safety in every lift.

Parallel legs provide generous space for connecting multiple legs to the master link, making assembly easier.

For crane Weight kgs hooks

230

125

≤ 12

1.9

250

135

≤ 12

3.2

280

135

≤ 16

4.6

320

175

≤ 25

8.6

355

225

≤ 50

9.9

For chain size, mm WLL 1-leg 2-leg 3-4 leg tonnes

Part #

Master link

691764

MFH-1310-10

7.5

691765

MFH-1613-10

691766

MFH-2016-10

691767

MFH-2220-10

691768

MFHW-2220-10

Safety factor: 4:1

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Crane Sheaves McKissick® Roll-Forged™ Sheaves Stepped Hub Design Proves Better The McKissick ® hub is stepped to eliminate stress failure in the weld, common in traditional hub designs. The hub is pressed into place with complete metal-to-metal contact. This helps ensure an accurate alignment to the hub’s axis so there is no wobble or lopping of the rotating sheave. The precision aligned hub/ sheave wheel combination adds to th f and keeps the sheave fe vienbearing life vin on the job longer.

Full Range of Standard Sheave Sizes McKissick ® Roll-Forged™ sheaves are available in a full range of sizes from 12 inches to 78 inches, and bearing styles and prices that best fit your application.. Crosby also manufactures custom McKissick ® sheaves and can make k minor ke modifications to standard sheaves as needed ffor special applications.

Closed Die Upset and Roll Forged – Not Split

* U.S. Patent 7,000,905 and 7,293,763

Crosby’s hardening technique is a science. It provides a precise maximum hardness for wearresistance across the wire rope contact area. The McKissick ® sheave groove is flame hardened to a minimum 35 Rockwell C for a 140°, contact area with the wire rope (upon special request the McKissick ® sheave groove can be flame hardened to a minimum 50 rockwell C for f a 150° contact area with the wire rope). The solid steel plate provides the ideal surface for flame hardening and a closer tolerance fit to the wire rope to reduce fatigue and wear.

Bearing Selection to Match Your Job Requirement

Full penetration weld is standard on 40” and larger sheaves.

Upsetting and roll forging forms the groove and flange walls in multiple steps, eliminating the need to split and weaken the groove. This exclusive forging process adds extra strength to the critical groove section. You can count on a McKissick ® sheave to give maximum life performance, because it’s forged to distribute the wire rope forces evenly over an accurately formed load surface. Plus, uniformity of the roll forged groove adds longer wire rope life.

Flame Hardened Groove

Solid Steel – No Casting Every McKissick ® Roll-Forged™ sheave starts as a single piece of solid carbon steel plate It’s flame-cut from closely checked cked stock, so there’s ck no inherent web/rim flaw as you find in cast sheaves. There’s better bal ance and better distribution ion of forces with a McKissick ® Roll-Forged™ sheave too. Casting can result in groove wall variations – either too thick or too thin – causing uneven stresses and early arly ffailure.

The McKissick ® Roll-Forged™ sheave is available in the following configurations: • Plain bore • Bronze bushed • Roller bearing • Tapered roller bearing • Lubrication thru hub • Key ways Key • Set screws • Full Complement Bearing Sheaves are available to API 8A and 8C. Copyright © 2011 The Crosby Group LLC All Rights Reserved

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

Wire Rope Sheaves Sheaves STANDARD FEATURES • 3 through 108 inch sheave diameters • 1/ 4 through 3 inch wire rope sizes • 4 to 1 design factor • Cast iron, ductile iron, cast steel, ForgeFab steel types

OPTIONAL FEATURES (Price on Application) • Custom designs to customer shaft, bearing mounting, hub, sheave O.D. or wire rope size requirement • Electroplate inorganic zinc compound and other corrosion resistant coatings available • Hub-located grease fittings • Modifications as required to API and other applicable industry standards • Special shafts, furnished for any sheave listed • AISE No. 6 specifications • Cold weather properties

Available in sizes ranging from 3” to 108”, and over 250 standard models, Johnson

Wire Rope Sheaves

are industry proven with over 100,000 in use. Cost efficient custom designs are available with no upfront tooling or pattern charges and no premium for small order quantities. 16” to 108” O.D. sheaves have flame-hardened, precision grooves for slow, even wear and long rope life. (Less than 16” O.D. flame-hardened upon request.) The integrity of Johnson’s single disc forged steel construction provides a sheave with superior strength.

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Wire Rope Slings

Tuff-Lift Wire Rope Slings ®

All wire rope used meets API specifications Flemish splice high efficiency eyes XIP strength increases capacity Customized to specifications Manufactured in accordance with ASME B30.9 standards All Titan Supply slings are manufactured using Crosby sleeves

! WARNING See wire rope technical data page for inspection & removal criteria

TRI-FLEX ® WIRE ROPE SLING This is a three part wire rope sling developed to give the rigger the advantages of strength combined with greater flexibility. It was created to replace large diameter single part wire rope slings which proved awkward and stiff. These slings are made in matching lengths.

T& D ULTRA-FLEX WIRE ROPE SLING This wire rope sling is an extremely flexible product with great applications for general rigging purposes in the utility industry. It makes a fantastic choker sling especially when lifting poles. Development was through a committee composed of utility company workers and members of the SLINGMAX ® design team.

GATOR-MAX MAX® SLING

This is the strongest multi-part sling with great flexibility. It will develop its full strength on small pins. For heavy lifting work this is the most efficient wire rope sling that meets all of the standards.This sling was developed to meet conditions specified by the US Navy and the Wire Rope Technical Board Sling Manual.

GATOR-LAID® WIRE ROPE SLING This is identical to the Gator-Max ® sling with the parallel eyes except it has metal sleeves for the splice connection. This is the product when a big lift but shorter sling is required. The Gator-Flex ® and Gator-Laid ® products were developed in conjunction with the off-shore oil industry to provide the worlds best heavy lift wire rope slings.

GATOR-FLEX® NINE PART GROMMETS Ultra flexible slings for that short heavy lift connection. These slings can be made shorter than standard multi-part slings but maintain all of the advantages.

GATOR-FLEX® WIRE ROPE SLING This sling has a nine part body style but the eyes are crossed or interwoven so that no wrapping is necessary. The sling was developed in conjunction with riggers in the field that wished to create a sling for heavy lifts that could be visually inspected and have the highest flexibility possible in a multi-part wire rope sling.

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

Tuff-Lift

Round Slings

• Superior flexibility and a low stretch construction ensures load grip • Non-sparking feature allows for use in explosive atmospheres • Durable polyester double cover protects loads and improves inspectability • Exclusive vertical weight load tagging system removes guess work from sling applications • Strong, lightweight, and easy to handle • Wear point distribution extends sling life

Web Slings

• Lightweight, pliable, and easy to handle • Optional eye or endless configurations for various lifting equipment • Non-sparking feature allows for use in explo sive atmospheres • Reinforced eyes for added durability • Highly visible poly tag stands up to all working conditions

Diamond Edge

• Typically damage to a web sling starts along the edge and progresses across the webbing material • Specially coated threads are used on the edges of Diamond Edge Slings which can provide superior edge cut resistance, increasing sling life • Same features and benefits as standard web slings • Simply add a DE order code suffix to the Tuff-Lift® regular stock number to have your sling made with Polyester Diamond Edge webbing • Available in 1,2,3,4 and 6 inch widths

Chain Slings

• Superior durability, wear resistance, and strength, our G80 & G100 Alloy chain slings are ideally suited for steel handling and other high demand applications. • Chain slings are easily repaired and recertified, with a full line of quality matched components. • All Chain Slings come standard with RFID tags, ask for more details on Micro-Trac.

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Twin-Path® Twin-Path® Extra Sling with Covermax® and K-Spec® Core Yarn TPXC This is the world’s first truly ergonomic sling with Covermax® covers for superior abrasion resistance. These are made in sizes up to 600 tons vertical rated capacity. Larger capacity slings are available on special order. These slings have overload indicators, inner red cover, and are used worldwide in place of wire rope slings for heavy lifts. They are approximately 10% of the weight of a steel sling. These products are repairable. The Twin-Path® patented design provides the rigger with two connections between the hook and the load for redundant back-up protection. These slings have less than 1% stretch at rated capacity. If ergonomics, productivity and safety are important, then these slings are the only choice. This is the lightest and strongest sling on the market today with K-Spec® – the longest lasting load bearing core yarn, backed by independent testing.

* Dimensions can vary according to the hardware or bearing points the slings are used with. Minimum is “tapered” width; Maximum is the flat tubing width. METRIC SLINGS AVAILABLE.

Check-Fast® Inspection System

(also known as the √ Fast System)

The Check-Fast® System is designed to improve job-site safety. The √ Fast® Tag and External Warning Indicator (EWI) on a roundsling product provides for a pass/fail inspection of the internal load bearing core yarn. Damage to the core yarn from ultraviolet (UV) light degradation, fiber on fiber abrasion, fatigue, and severe overload can be detected. If the sling is mistakenly overloaded beyond rated capacity, the EWI is designed to disappear before the sling fails. The sling inspector now has a GO/NO-GO inspection device rather than relying on a subjective handover-hand inspection to make an educated guess if the load bearing core yarns are in good condition. This safety system is available for High Performance K-Spec® Fiber Roundslings or polyester roundslings fabricated by authorized Patent #7,661,737 Foreign Patents Pending SLINGMAX® Dealers.

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

PAD EYE TESTER - HYDRAULIC Testing of the hardware, slings and hoist are commonplace before making a lift. However, testing the connection from which the hoist is hanging is rarely part of the prelift testing. This pad eye tester weighs as little as forty ty pounds and attaches directly to the pad eye in the ceiling deck, or bulkhead. Test with up to 25 tons of force to verify that the pad eye will hold to the surface. This idea came from a discussion with riggers in a shipyard who had been involved in accidents when pad eyes broke from their welds and the rigging gear and load dropped.

G-LINK CONNECTORS The magic of one piece hardware that does so many things. You can use it on Twin-Path ® , web and single path roundslings, for attaching hooks or rings, connecting two slings together, as sliding choker connection, as an adjustable sling, as a choke lock connection or to shorten a sling’s reach.

SPARKEATER ® SYNTHETIC SLINGS SE When you have a hot environment up to 300°F, use a Sparkeater ® to lift the load without marring the surface of the lifted piece. This is the only high performance, high temperature synthetic sling commercially available.

TWIN-PATH® ADJUSTAB JUST LE JUSTAB BRIDLE SLING TPXA or TPA This tool is an aid to finding the center of gravity. When the load is lifted the ring moves over the COG to balance and level the object. ob

FIBER OPTIC INSPECTION FO All Twin-Path ® slings have the Fiber Optic inspection. The condition of the internal core yarn can be inspected by checking the continuity of the fiber optic cable. The fiber optic cable will conduct light using natural, overhead or flashlight sources.

SHACKLE PIN PADS The Shackle Pin Pad is the Slingmax ® Solution to the problem of sharp edges on the pin-side of a shackle. This pad is easy to connect and easy to remove.

CORNERMAX RNERMAX® PAD TWIN-PATH® TWO LEG BRIDLES TL Simply the lightest and strongest synthetic bridles in the world today. These ese are perfec r t rfec to rreplace ace existing chain and wire rope bridles. This makes the Twin-Path ® Two Leg Bridle extremely versatile on the job.

The CornerMax ® cut protection device prevents an edge on the load from touching the sling. In fact the edge doesn’t even touch the CornerMax ® protector! This protector will handle the most extr extreme circumstances lifting steell and concr concrete. CornerMax® Pads are proven, tested— sling protection ion from Slingmax® for straight 90° edgess.

TWIN-PATH® EYE & EYE SYNTHETIC SLING EE Usually an eye and eye sling is made from a roundsling with a sleeve over it to form the eyes at each end. But our TPXCEE is a single-bodied sling with integrated eyes. It can be manufactured using either K-Spec® core yarn or polyester.

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CORNERMAX X® SLEEVE The CornerMax ® sleeve is the latest in rigging protection from Slingmax ® Rigging Solutions. This sleeve will protect a synthetic sling from cutting on edges that are curved or irregular.

Outrigger Pads Features • These durable pads/blocks have a variety of uses: • Pile Driving Companies • Mobile Cranes • Wellhead Servicing Companies • Service Trucks • Water Well Drilling Trucks • Coiled Tubing Units • Service Rigs • Concrete Pumpers • Pads for Tractor Trailer Units • Wireline • Recreational Vehicles • Ladder Firetrucks • Snubbing Units • Utility Companies • Rental Companies • Sign Companies • Tire Shops • Round - Square & Heavy Duty Blocking, each in a range of sizes. • Produced with ¾” standard fir plywood. This grade of plywood is guaranteed against blows, large core voids and veneer peeling up. The plywood is cut to size, glued with polyurethane waterproof glue, cross-grained, pressed in a 50,000lb press and screwed from both sides to penetrate 90% of the pad. • Polyurethane is a waterproof and water cured glue that absorbs into the plywood creating an incredibly strong bond.

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Crane Users Guide Let us show you the ropes

t takes more than the right wire ropes to operate your cranes. It also takes the right knowledge and experience. When you know the ropes – that is, how to choose, use and maintain each of the many types of ropes – you’ll know how to assure maximum service lif and performance for each crane life application.

When it comes to showing you the ropes, no one does it like Union, a WireCo WorldGroup brand. As the largest producer of wire rope, we offer everything you need for your crane’s wire rope needs. Nine WireCo WorldGroup manufacturing operations and eight distribution centers in North America, plus manufacturing facilities in Germany, Portugal and China, give our customers unparalleled support and global reach. Union can deliver the right wire ropes for your machine and application no matter where your worksite may be. All the more reason to call us.

This crane user’s guide is only one example. On the following pages, you’ll gain valuable information to help you: CHOOSE THE RIGHT T WIRE ROPES. Knowing the ropes starts by understanding the wide variety of wire ropes available for your many needs. This guide contains practical information to help you. CARE AND MAINTAIN WIRE ROPES.

You can help assure maximum service life and performance by following the proper care and maintenance procedures – including regular inspections – outlined in this guide. IDENTIFY AND PREVENT COMMON PROBLEMS IN THE FIELD.

This guide also tells you how to recognize and prevent some of the more common causes of wire rope damage during handling, installation and usage.

Broad range. Best manufacturer. Unmatched support.

t Union, n, we understand the crane marketOur years of climbing on the cranes with you, combined with the latest metallurgical practices and unique design capabilities,

have enabled us to continue to innovate and provide the most cost effective line of crane ropes in the world Union is part of the global leader in manufacturing, engineering and distributing wire rope, wire rope assemblies, high carbon wire, and electromechanical cable: WireCo WorldGroup up We apply thorough design and manufacturing controls – including complete material traceability ity And we are the only manufacturer in the world that is QPL

Systems ms So buy from the best…WireCo WorldGroup up – The world is our worksite

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Crane Users Guide Choosing the right wire rope for your application

ith each application, your choices of wire ropes can be many. How do you know which one works best for you? Ropes include a combination of characteristics that give them specific performance abilities. Before you choose, it pays to look closely at each rope’s special characteristics.

BENEFIT OF FEWER OUTSIDE WIRES PER STRAND

ABRASION RESISTANCE > Increases with larger wires. > Decreases with smaller wires. BENEFIT OF MORE OUTSIDE WIRES PER STRAND

FA GUE FATI RESISTANCE > Decreases with larger wires. > Increases with smaller wires.

NO SINGLE WIRE ROPE CAN DO IT ALL All wire ropes feature design characteristic tradeoffs. In most cases, a wire rope cannot increase both fatigue f resistance and abrasion resistance. For example, when you increase e ffatigue resistance by selecting a rope with more wires, the rope will have less abrasion resistance because of its greater number of smaller outer wires. When you need wire rope with greater abrasion resistance, one choice is a rope with fewer (and larger) outer wires to reduce the effects of surface wear. But that means the rope’s fatigue resistance will decrease. That’s why you need to choose your wire rope like you would any other machine. Very carefully. carefully You must consider all operating conditions and rope characteristics. THE BASIC CHARACTERISTICS OF WIRE ROPE How do you choose the wire rope that’s best suited for your job? Following are the most common characteristics to be considered when selecting a rope for an application. STRENGTH Wire rope strength is usually measured in tons of 2,000 lbs. In published material, wire rope strength is shown as minimum breaking force or nominal (catalog) strength.

These refer to calculated strength figures that have been accepted by the wire rope industry. When placed under tension on a test device, a new rope should break at a figure equal to – or higher than – the minimum breaking force shown for that rope. The published values apply to new, unused rope. A rope should never operate at – or near – the minimum breaking force. The minimum breaking force of the rope must be divided by the design factor required for the application to determine the maximum load allowed on the rope. During its useful life, a rope loses strength gradually due to natural causes such as surface wear and metal fatigue. FATIGUE RESISTANCE Fatigue resistance involves fatigu f e of the wires that make up a rope. To have high ffatigue resistance, wires must be capable of bending repeatedly under stress – for example, as a loaded rope passes over a sheave during operation. Increased fatigue resistance is achieved in a rope design by using a large number of wires. It involves both the wire properties and rope construction. In general, a rope made of many wires will have greater fatigu f e resistance than a same-size rope made of fewer, larger wires because smaller wires have greater ability to bend as the rope passes over sheaves or around drums. To overcome the effects of fatigue, ropes must never bend over sheaves or drums with a diameter so small as to bend wires excessively. ely There are precise ely. recommendations for sheave and drum sizes to properly accommodate all sizes and types typ of ropes.

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Crane Users Guide Every rope is subject to metall ffatigue from bending stress while in operation, and therefore the rope’s strength gradually diminishes as the rope is used.

Peening usually occurs on drums, caused by rope-to-rope contact during spooling of the rope on the drum. It may also occur on sheaves.

CRUSHING RESISTANCE Crushing is the effect of external pressure on a rope, which damages it by distorting the cross-section shape of the rope, its strands or core – or all three.

Peening causes metal fatigue, which in turn may cause wire e ffailure. The hammering – which causes the metal of the wire to flow into a new shape – realigns the grain structure of the metal, thereby affecting itss ffatigue resistance. The out-of-round shape also impairs wire movement when the rope bends.

Crushing resistance therefore is a rope’s ability to withstand or resist external forces, and is a term generally used to express comparison between ropes. When a rope is damaged by crushing, the wires, strands and core are prevented from moving and adjusting normally during operation. In general, IWRC ropes are more crush resistant than fiber core ropes. Regular lay ropes are more crush resistant than lang lay ropes. 6-strand ropes have greater crush resistance than 8-strand ropes or 19-strand ropes. Flex-X® ropes are more resistant than standard roundstrand ropes. RESISTANCE TO METAL LOSS AND DEFORMATION Metal loss refers to the actual wearing away of metal from the outer wires of a rope, and metal deformation is the changing of the shape of outer wires of a rope. In general, resistance to metal loss by abrasion (usually called “abrasion resistance” refers to a rope’s ability to resistance”) withstand metal being worn away along its exterior. This reduces strength of a rope.

RESISTANCE TO ROTATION When a load is placed on a rope, torque is created within the rope as wires and strands try to straighten out. This is normal and the rope is designed to operate with this load-induced torque. However this torque can cause both However, single part and multiple part hoisting systems to rotate. Load-induced torque can be reduced by specially designed ropes. In standard 6- and 8-strand ropes, the torques produced by the outer strands and the IWRC are in the same direction and add together. XLT4 ropes use the torque created by the strand lay and the rope lay to minimize the total rope torque. In rotation-resistant ropes, the lay of the outer strands is in the opposite direction to the lay of the inner strands, thus the torques produced are in opposite directions and the torques subtract from each other.

“SQUARED ENDS” > Typical example of breaks due to fatigue.

“CRUSHING” Typical example of external pressure on a wire rope.

CROSS-SECTION > OF A WORN WIRE Original > cross-section Worn surface

CROSS-SECTION OF A PEENED WIRE > Original cross-section > Peened surface

The most common form of metal deformation is generally called “peening” – since outside wires of a peened rope appear to have been “hammered” along their exposed surface.

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Crane Users Guide Wire rope recommendations for crane applications

et us show you the ropes you’ll need to keep your cranes working. On the following charts, you’ll see the wire ropes we recommend for your many different applications. Your specific application may vary vary, of course, and that’s why you can depend on a world leader such as Union to help you choose the right rope.

Important note when changing ropes: Mobile Cranes: When changing wire ropes, ensure the minimum breaking force is equal to or higherr than the rope it replaces If you change from a standard rope to a rotation-resistant rope, the required design factor willl changeASME B305 B30 requires res a design factor of 35 for standard ropes and a design factor of 50 for rotation-resistant n-resistant ropes Tower Cranes: When changing wire ropes, ensure the minimum breaking force is equal to or higherr than the rope it replaces ASME B303 B30 requires a design factor of no less than 5 for all load hoist ist ropes Anytime you change the construction or grade of the rope on a crane, ensure the crane’s load

CRAWLER AND TRUCK CRANES APPLICATION

RECOMMENDED

ROPE

COMMENTS

Main hoist rope

Starlift Xtra Flex-X 19 regular lay XLT4™ * Flex-X® 6 regular lay IWRC 6 x 26 regular lay IWRC 6 x 25 regular lay IWRC

Characteristics needed are resistance to bending fatigue, resistance to crushing and resistance to wear Flex-X 6 provides the best combination of necessary characteristics, plus higher strength If block rotation is a problem and the drum is grooved, Starlift Xtra or XLT 4 is recommended For smooth drums, Starlift Xtra or Flex-X 19 should be considered

Auxiliary hoist rope

Starlift Xtra Flex-X 19 XLT4* 19 x 7 8 x 25 Resistwist

Rotation resistance is a primary concern in an auxiliary hoist and for applications utilizing grooved drums, both Starlift Xtra and XLT4 are recommended For smooth drum applications, Starlift Xtra should be considered Both of these ropes may be used with a swivel For less demanding applications, Flex-X 19 provides p a good combination of rotation resistant properties and resistance to crushing

Boom hoist rope

Flex-X 9 Flex-X 6 regular lay IWRC Flattened strand 6 x 26 regular lay IWRC

The primary characteristic needed in a boom hoist rope is resistance to drum crushing Flex-X 9 is best suited to handle this situation Flex-X 6 also works well in many boom hoist applications equipment, it generally will not perform as well as those listed here

Tag line

6 x 19 regular lay IWRC 6 x 36 regular lay IWRC

Most standard construction ropes will perform in this application

* See XLT4 details on page 9

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

Crane Users Guide

CLAMSHELLS AND GRAPPLES APPLICATION

RECOMMENDED

ROPE

Holding line and closing line

Flex-X® 6 IWRC 6 x 26 regular lay IWRC

Boom hoist and tag line

Referto Crawler Crane Section

COMMENTS These applications need a solid combination of resistance to fatigue and abrasion better than conventional ropes

TOWER CRANES APPLICATION

RECOMMENDED

ROPE

COMMENTS

Hoist rope

Starlift Xtra

Rotation resistance is necessary for block stability in long block fall distances incurred with tower cranes Starlift Xtra is recommended for this application and may be used with a swivel

Trolley rope

Flex-X 7CC 7-Flex 6 x 36

Fatigue resistance and resistance to wear are important for trolley ropes Flex-X 7CC offers the best combination of these characteristics making it the best choice for trolley ropes

Boom hoist rope

Flex-X 9 Flex-X 6 regular lay IWRC Flattened strand 6 x 26 regular lay IWRC

The primary characteristic needed in a boom hoist rope is resistance to drum crushing Flex-X 9 is best suited to handle this situation Flex-X 6 also works well in many boom hoist applications Alternate lay ropes may perform as well as those listed here

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Crane Users Guide Wire ropes for rotational stability

opes that provide load stability can often provide the best and most economical service in specific applications when you choose, handle and use them properly.

Contra-helically laid, rotation-resistant ropes are different from standard ropes because they’re designed to reduce rope torque. Modes of ffailure ailure and wear for rotation-resistant ropes can differ from those for standard rope constructions. The very nature of these ropes requires special handling, selection and usage not encountered with standard constructions. These ropes are susceptible to kinking, crushing and unbalancing in the form of “core pops” and “birdcages” if used or handled improperly. Use care to avoid operational practices that can possibly lead to these conditions. There are different types of rotationresistant ropes, categorized by their resistance to rotation. Category 1 rotationresistant rope (Starlift ift Xtra) has at least 15 if outer strands, has three layers of strands (over a center) and has little or no tendency to rotate, or, if guided, transmits little or no torque. It can be used with a swivel. Because Category 1 rotation resistant ropes are manufactured with little or no preforming, it is critical to not remove the welded ends. If the welded ends are removed the rope can become unbalanced. Category 2 rotation-resistant rope (Flex-X 19 and 19 x 7) has 10 or more outer strands, has two or more layers of strands (over a center) and has a significant resistance to rotation. Category 3 rotation-resistant rope (8 x 19 RTW) has no more than 9 outer strands, has two layers of strands (over a center) and has limited resistance to rotation. For best performance, Category 2 and 3 rotation-resistant ropes should not be used with a swivel.

STARLIFT XTRA™ Starlift Xtra, a Category 1 rotationresistant rope, features a unique design that minimizes the torque and rotation of the rope at normal load ranges of zero to 20% of the rope’s minimum breaking force (MBF). In addition, Starlift fft Xtra is engineered to give you maximum strength per diameter while also achieving superior fatigue resistance. These factors combine to give you the maximum service life when you have long block falls or load control is critical. Unlike other rotation-resistant ropes, swivels can be used in your system with Starlift Xtra. Starlift Xtra wire rope has one off the highest strength-to-diameter ratios on the market. ASME B30.5 Mobile and Locomotive Cranes requires a design factor of 3.5 for 6-strand hoist ropes. The same standard requires a design factor of 5.0 for rotation-resistant ropes. The MBF of Starlift fft Xtra is such that even with the 5.0 design factor,r,r it has lifting capacities that equal or exceed 6-strand XIP ropes utilizing a 3.5 design factor. Other ropes of similar construction do not provide this benefit. The characteristics off Starlift Xtra enhance its performance in multiplelayer spooling as well. The lang lay construction, coupled with the special design features, provide excellent resistance to abrasion that occurs at kickover areas in drum spooling. The rope construction combined with the compacted strand design of Starlift if ift Xtra results in a rope cross-section of very high density. yy. This feature provides increased resistance to crushing.

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

Crane Users Guide XLT4

operation. Where there is multiple layer spooling, the base layers on the drum must be under tension to assure proper spooling and to avoid “pull-in” of the upper layers. The tension on these lower layers ensures that the rope is both tight against adjacent wraps and tight around the drum which establishes a solid foundation ion ffor the upper layers.

XLT 4 ropes are specially designed to provide very low torque, a high minimum breaking force and high resistance to wear in multi-layer spooling. Under load, XLT 4 generates near-zero torque, matching or surpassing the stability of Category 1 35 x 7 class rotation-resistant ropes. Yet, thanks to its unique design, XLT 4 is not classified as a “rotation-resistant” rope. It can be used with or without a swivel as a mobile crane hoist rope at design n ffactors as low as 3.5 to 1.

XLT4 SPECIFICATIONS NOMINAL DIAMETER

NOMINAL DIAMETER

MINIMUM BREAKING FORCE

APPROX WEIGHT

INCHES

MILLIMETERS

TONS OF 2000 LBS

LBS /FT

12 1/2 14

15.8 17.7 21.4

0.45 0.51 0.61

9/16 5/8 16

22.3 27.4 27.8

0.65 0.79 0.79

19 3/4 22

39.0 39.2 52.0

1.1 1.1 1.5

7/8 23 24

53.0 56.8 61.7

1.5 1.6 1.8

1 26 28

68.9 72.1 83.3

2.1 2.1 2.4

1-1/8

86.7

2.6

XLT 4 rope’s compact construction keeps more steel in contact with sheaves and drums for unmatched resistance to crushing and wear – for lower maintenance, less downtime and longer service life. With the rope’s high capacity capacity, lifts may be feasible using fewer parts of line – boosting the speed, efficiency and productivity of crane work. Because of its unique construction, XLT 4 performs best on grooved drums that are larger than the minimum required D/d and where the entire b ted to loading in normal bjec length of the rope is subjec

ROTATION-RESISTANTCRANE ROPES SPECIFICATIONS MINIMUM BREAKING FORCES IN TONS OF 2,000 POUNDS CATEGORY 1 STARLIFT XTRA Diameter Millimeter

Approx. Minimum Weight Breaking Force lbs / ft

CATEGORY2 FLEX-X® 19 Diameter Approx. Minimum Inches Weight Breaking lbs / ft Force

3/16 1/4 5/16

CATEGORY3 8 X 19 XIP®

19 X 7 XIP®

Approx. Weight lbs / ft

Minimum Breaking Force

Diameter Inches

Approx. Weight lbs / ft

Minimum Breaking Force

0 064 0 113 0 177

1 57 2 77 4 30

3/16 1/4 5/16

0 18

4 63

3/8 7/16 1/2

0 43 0 49

11 2 14 6

0 25 0 35 0 45

6 15 8 33 10 8

3/8 7/16 1/2

0 26 0 36 0 47

6 63 8 97 11 6

9/16

0 65

18 5

0 58

13 6

9/16

0 60

14 7

16 19

0 85 1 22

30 6 42 9

5/8 3/4

0 78 1 16

22 7 32 4

0 71 1 02

16 8 24 0

5/8 3/4

0 73 1 06

18 1 25 9

22 25 4 26

1 65 2 19 2 30

57 2 75 9 79 2

7/8 1 1 1/8

1 58 2 05 2 57

43 8 56 9 71 5

1 39 1 82 2 30

32 5 42 2 53 1

7/8 1 1 1/8

1 44 1 88 2 39

35 0 45 5 57 3

28 30 32

2 67 3 08 3 50

91 6 105 119

1 1/4 1 3/8 1 1/2

2 83 3 43 4 08

65 1 78 4 92 8

1 1/4 1 3/8 1 1/2

2 94 3 56 4 24

705 849 100

NOTE: These strengths apply only when a test is conducted with When in use, the strengths of these ropes may be

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Crane Users Guide Flex-X 7CC, a container crane rope that guarantees a lift in productivity.

ontainer crane hoist and trolley ropes are subjected to the stressful combination of bending fatigue and abrasion from operating over a series of intricate sheaves and drums. Union has developed Flex-X 7CC, a wire rope for container cranes that’s so revolutionary it’s guaranteed to provide you with wit a significant lift in service life when n compared compare with standard ropes. FLex-X 7CC will operate longer – no matter what load conditions condition you put it under. A combinatio ombination of superior design and manufacturing technique techniqu helps reduce metal fatigue, internally and externally, while helping to extend exten the lif of sheaves and life an drums.

FLEX-X 7CC SPECIFICATIONS NOMINAL DIAMETER

APPROX WEIGHT

MINIMUM BREAKING FORCE

INCHES

LBS./FT.

TONS OF 2000 LBS.

1/2 9/16 5/8

0.50 0.63 0.80

15.3 19.3 22.7

3/4 7/8 1

1.13 1.55 2.01

32.4 43.8 56.9

1-1/8 1-1/4 1-3/8

2.54 3.14 3.80

71.5 87.9 106

FLEX-X 7CC

FLEX-X 7CC LASTS LONGER. Flex- 7CC’s longer service Flex-X rvice lif life will result in lower maintenance costs due to fewer rope changes. chang All ropes rop gradually lose strength due to wear wea and fatigue but test data has proven that Flex-X 7CC has superior fatigue life over standard rope. With Wit the ropes subjected subjecte to the same operating conditions (load and sheave diameter), condition the chart at right righ illustrates how Flex-X 7CC’s service exceeded standard rope by 46% 46 when both ropes reached 80% of the standard standar rope’s strength.

FLEX-X EX 7CC EX-X

STANDARD

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

Crane Users Guide Wire rope weights and minimum breaking force for cranes. The Flex-X ® process compacts each strand, which improves the rope’s strength, stability, abrasion resistance, fatigue resistance and crushing resistance.

STANDARD 6 X 19 CLASS AND 6 X 36 CLASS CRANE ROPES.

he 6 x 19 classification of wire ropes includes standard 6-strand round strand ropes with 16 through 26 wires per strand. The 6 x 36 classification of wire ropes includes standard 6-strand round strand ropes with 27 through 49 wires per strand. Although their operating characteristics vary, vary all have the same weight per foot and the same minimum breaking force, size for size.

These characteristics make Flex-X 6 an excellent choice for the main hoist rope for mobile cranes and the hoist rope on most overhead cranes. Flex-X 9, specifically designed for boom hoist applications, features compacted strands and swaging for extra drum crushing resistance

6 X 19 & 6 X 36 CLASS SPECIFICATIONS

IWRC / FLEX-X 6 AND FLEX-X 9 / FLATTENED STRAND ROPES MINIMUM BREAKING FORCES IN TONS OF 2,000 2, POUNDS. 6 X 19 AND 6 X 36 CLASS IWRC XIP®

Diameter

XXIP®

COMPACTED STRAND FLEX-X® 6

FLEX-X® 9

Approx. Minimum Approx. Minimum Weight Breaking Weight Breaking lbs. / ft. Force lbs. / ft. Force

Approx. Weight lbs. / ft.

Minimum Breaking Force

3/16 1/4 5/16

0.116 0.18

3.40 5.27

3/8 7/16 1/2

0.26 0.35 0.46

7.55 10.2 13.3

8.30 11.2 14.6

0.32 0.41 0.55

8.8 11.9 15.3

9/16 5/8 3/4

0.59 0.72 1.04

16.8 20.6 29.4

18.5 22.7 32.4

0.70 0.86 1.25

19.3 22.7 32.4

0.95 1.35

7/8 1 1 1/8

1.42 1.85 2.34

39.8 51.7 65.0

43.8 56.9 71.5

1.67 2.18 2.71

43.8 56.9 71.5

1.85 2.40 3.05

1 1/4 1 3/8 1 1/2

2.89 3.50 4.16

79.9 96.0 114

87.9 106 125

3.43 4.25 5.01

87.9 106 125

1 5/8 1 3/4 1 7/8

4.88 5.67 6.50

132 153 174

146 169 192

2 2 1/8 2 1/4

7.39 8.35 9.36

198 221 247

217 244 272

Inches

FLATTENED STRAND Approx. Weight lbs. / ft.

Minimum Breaking Force

26.2 37.4

0.74 1.06

21.7 31.0

50.6 65.7 82.7

1.46 1.89 2.39

41.9 54.4 68.5

2.95 3.57 4.25

84.0 101 119

4.99 5.79

140 161

NOTE: Many wire ropes are also available in PFV, a plastic impregnated rope design from Union.

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Crane Users Guide Guidelines for installation and maintenance. WHEN YOU’RE INSTALLING WIRE ROPE, THERE’S A PRIMARY CONCERN: Getting the rope on the equipment without trapping any twist that may have been induced during handling or installation.

THE PREFERRED TECHNIQUE FOR INSTALLING ROPE ONTO ACRANE. 1. UNLOAD ROPE PROPERLY AND RELIEVE ANY TWISTS.

Pull the rope off the shipping reel or unroll it from a shipping coil as shown. (If done improperly, you may kink the rope, which will result in permanent damage to the rope.) Then lay the rope on the ground in a direct line with the boom. This helps release any twist in the rope.

Unreel rope from a shaft supported by two jacks. Uncoil rope by rolling it along ground like a hoop. 2. ATTACH ROPE’S END TO DRUM. Pull the

rope over the point sheave and attach the end to the drum. Before making any end attachment, be sure the rope strands are free to adjust. (In other words, make sure the end of the rope is not welded together.) 3. WIND ROPE ONTO DRUM SLOWLY AND CAREFULLY. At this point, it isn’t

necessary to provide additional load other than the weight of the rope being pulled across the ground.

4. SPOOL FIRST LAYER TIGHTLY.

Make sure the foundation layer is spooled tightly.

It’s essential on smooth-faced drums that the first layer is spooled with wraps tight and close together since the first layer forms the foundation for succeeding layers. If need be, use a rubber lead or brass mallet (but never rubber, a steel hammer hammer) to tap the rope in place.

5. SPOOL MULTIPLE LAYERS WITH SUFFICIENT TENSION. It’s very important

to apply a tensioning load to the ropes during the rope breaking-in process. (If not, the lower layers may be loose enough that the upper layers The result of improper become wedged tensioning is a “pulling in” of into the lower the rope. layers under load, which can seriously damage the rope.) The tensioning load should range from 2 to 3% of the rope’s minimum breaking force. 6. FOR ROPES IN MULTI-PART SYSTEMS:

Reeve the traveling block and boomtip sheaves so Incorrect Correct the rope spacing is maximized and the traveling (hook) block hangs straight an and level to help assure block stability. stability Avoid deadending the rope at the traveling block if possible. 7. CHECK ROPE FOR TWIST. With the rope

slack, pull enough rope out to allow it to hang in a loop (right). If the rope hangs without twisting together, there is no Twist in rope No twist twist in the rope. If the rope twists together (left), the rope has twist in it. Follow steps shown on next page to relieve twist from the rope.

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

Crane Users Guide BREAKING IN YOUR NEW WIRE ROPE.

RELIEVING TWIST.

After installation, you should properly break in your rope, which allows the rope’s component parts to adjust themselves to your operating conditions.

To relieve twist that may be trapped in a rope spooled directly off a reel to the drum, raise the boom to its highest position while letting out the rope until the rope almost touches the ground. Let the rope hang free without added load while standing clear. When twist is fully relieved, proceed with rigging the crane.

With the boom fully raised – and fully extended if you’re using a hydraulic boom – attach a light load at the hook and raise it a few inches off the ground. Allow to stand for several minutes. Then cycle the load between the full “up” and “down” positions several times. Stand back and watch the drum winding and rope travel for any potential problems. After making the lifts with a light load, increase the load and cycle it up and down a few times. This procedure will train the rope and help assure smooth operation during its useful life. Ideally, you should run these loads with reeving that lets you place the loads on the block with all rope off the drum except the last three wraps. If this isn’t possible, alternate methods must be used to assure proper tensioning of the rope on the drum.

LUBRICATE ROPES OFTEN FOR LONG LIFE.

To properly maintain your rope, the first place to check is for obvious signs of abuse from other parts of the rope system. But the biggest part of maintenance involves regular lubrication to prevent corrosion and to reduce friction between the rope’s components as well as the friction between rope and sheaves or drums. Your rope receives internal lubricant at the factory factory, actory, but it’s not enough to last the rope’s entire life due to constant bending over sheaves and drums. The need to keep ropes properly lubricated can’t be overemphasized. CLEAN ROPES FIRST.

RIGGING IN TIGHT QUARTERS.

If you can’t lay the new rope out on the ground before rigging – and you need to pull it directly from the reel – further steps are necessary. necessary First, you should mount the reel on a shaft through flange holes and on jack stands, making sure you spool as illustrated below. While unspooling, do not allow the reel to “free-wheel.” l. Brake l.” the reel by applying pressure to a flange. Never apply braking pressure to the rope on the reel – or pass the rope rope between blocks of wood or other material.

Remove excess dirt, rock dust or other materials that can prevent field-applied lubricants from properly penetrating into the ropes. LUBRICATE USING ONE OF TWO METHODS.

One is called manual lubrication such as spray or drip systems that apply lubricant when you want. You can also swab or paint lube into your moving rope by hand, or pour lube onto your rope as it passes a certain point. The other is called automatic lubrication that drips or sprays lube onto your rope as it passes over a sheave at preselected intervals.

WHAT LUBRICANT SHOULD YOU USE? There are two lubricants you should not use Never apply heavy grease to the rope because it can trap excessive grit and dust, which can externally damage the rope or be forced inside, causing hidden damage Nor should you apply used “engine oil” because it contains materials that can damage your rope The kind and amount of lubricant will vary according to the type and use of your wire rope But the lubricant should have these traits: > Penetrate to the rope core The best way is to apply at a place where the rope bends, such as over a sheave, exposing the wires and strands to provide a better opening to the core > Contain enough adhesive to wires in the rope and the spaces around the wires > Be free of acids and alkalis > Resist corrosion > Stay put without being easily washed away

Install from reel top over the point sheave.

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Crane Users Guide How to inspect your wire ropes.

espite their durability and strength, wire ropes used on cranes will wear out and need to be retired from service. That’s why regular inspection is so crucial to your long-term success. It’s important to appoint a qualified trained person to conduct the inspection and understand the mechanics of inspection. This section offers you general guidelines, but for more detailed information, please consult our Techreport 107.

FOCUS ON YOUR ROPE’S CRITICAL POINTS.

While you’re required to inspect the entire rope length, we recommend you pay particular attention to the critical points of a wire rope. These are the points subject to greater internal stresses, greater external forces or are more susceptible to damage. Rope deterioration normally occurs more quickly at these points, so it pays to expand your inspection in these important areas: PICK-UP POINTS. These are sections of

HOW OFTEN TO INSPECT.

Obviously, the more you use a wire rope, the more often you need to inspect it. According to the ASME standards, owners or users are required to visually inspect all wire ropes at least once every day when in use. A qualified, trained person should be appointed to conduct the inspection. That person is also required to periodically inspect all wire ropes and keep a written record, noting any damage and recording when ropes are replaced. This will give you a basis for judging the proper time to replace your ropes. We recommend you set up a longrange inspection program, including examination of ropes removed from service.

ropes repeatedly placed under stress when you apply the initial load of each lift ift such as those sections contacting the if sheaves or on the drums. END ATTACHMENTS. Attachments at the

dead end and drum restrict the free movement of wires, normally leading to broken wires that are more difficult to detect. Inspect with an awl to expose them, and if you find more than one broken wire, replace the rope or cut off the affected area and reattach the fitting. Corrosion can be more prevalent in this area. Be sure to also inspect the fitting itself. DRUMS. Check for signs of wear that

could damage wire rope. For grooved drums, inspect the grooves for smoothness and absence of corrugation. For smooth drums, check for wire rope corrugation. It’s also important to verify that the required minimum number of dead wraps remain on the drum and to check the condition of the drum flanges. SHEAVES. The grooves on sheaves usually

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

Crane Users Guide SHEAVES. The grooves on sheaves usually

wear smaller over time. With a groove gauge, check each sheave for proper groove size and contour, as well as smoothness. Grooves that are too small or tight can cause pinching and increased wear while grooves that are too wide can cause flattening of the rope – both of which can reduce your rope’s life. Any application that has both ends of the rope on a drum (typically overhead cranes and boom hoists) has an “idler” sheave at the center of the rope. The rope at this point must be pulled off the sheave and inspected closely for crown

and valley broken wires at each periodic inspection. HEAT EXPOSURE. Watch for evidence of

heat exposure which can damage the rope and its lubricant. Any contact with an electrical arc such as welding is reason for removal of the entire rope. Never use the rope as the ground for an arc welder. ABUSE POINTS. Check for “bright” spots where ropes are subjected to abnormal scuffing and scraping. Look for any condition that causes the rope to be asymmetrical.

HOW TO FIND BROKEN WIRES. One of the most common signs of rope deterioration is broken wires, normally the outside wires at the crowns of the strandsDuring your inspection, it’s very important to search for broken wires, especially the areas of the rope in contact with sheaves and drums when loads are picked up

> It’s important to remember there are minor – sometimes major – differences among applications, even on machines with similar designs That’s why it takes the judgment of a trained, knowledgeable inspector to choose the critical points on each rope application for closer inspection

Typical valley wire breaks.

Typical crown wire breaks. 1 sheaves Clean the grease from the rope with a cloth – a wire brush, if necessary – so you can see any breaks 2 Flex the rope to expose any broken wires hidden in the valleys between the strands 3 Visually check for any broken wiresOne way is to run a cloth along the rope to check for possible snags 4 With an awl, probe between wires and strands and lift any wires that appear loose Evidence of internal broken wires may require a more extensive rope examination

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Crane Users Guide When to replace your ropes.

ccording to the ASME B30.5 standard for mobile cranes, there are no precise rules to determine the exact time to replace rope because so many variables are involved. Once a rope reaches a specified removal criteria, it may be allowed to operate to the end of the work shift, based on the judgement of a qualified person. The rope should be replaced after that work shift at the end of the day – or at the latest prior to the equipment being used by the next work shift.

The following required standards established by ASME B30.5 that provide specific reasons to replace wire ropes. BROKEN WIRES. For running ropes including XLT 4 ropes, replace when you see six randomly distributed broken wires in one lay – or three broken wires in one strand in one lay.

ONE BROKEN WIRE EXTENDING FROM ROPE’S CORE. When you see one outer

wire broken at the point of contact with the rope’s core which has worked its way out or looped out from the rope structure, you’ll need to conduct additional inspection of that section of rope. EXTENSIVE E ROPE WEAR. W hen wear

reaches one-third the original diameter of the outside individual wires, it’s time to replace the rope. ROPE DISTORTION. N. Replace any rope with evidence of kinking, crushing, birdcaging or any other damage resulting in distortion of the rope structure. HEAT DAMAGE. Because heat exposure can damage the rope and its lubricant, always remove ropes damaged by heat from any cause.

For rotation resistant ropes categories 1, 2 and 3, replace when you see two randomly distributed broken wires in six rope diameters – or four randomly distributed broken wires in 30 rope diameters. Broken wire removal criteria apply to wire ropes operating on steel sheaves and drums. The user should contact the sheave, drum or crane manufacturer for broken wire removal criteria for wire ropes operating on sheaves and drums made of material other than steel.

SUPERIOR PRODUCTS, EXCEPTIONAL SERVICE

Crane Users Guide

REDUCTIONS IN NOMINAL DIAMETER.

Replace any rope when its measured diameter has decreased more than 5% below its nominal diameter. WHAT REPLACEMENT ROPE TO USE.

Your replacement rope should have a minimum breaking force at least as great as the original rope furnished or recommended by the crane manufacturer. Any deviation from the original size, grade or construction must be specified by the wire rope manufacturer, crane manufacturer or a qualified person. See pages 6-7.

Always measure the largest dimension when measuring your rope.

WHAT ABOUT IDLE ROPES? All wire

ropes that have been idle for one month or longer due to shutdown or storage of the crane on which they’re installed should be inspected according to ASME standards before you place them in service. Make sure an authorized person inspects for all types of rope deterioration.

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Proper method of measuring ropes with odd number of outer strands, using caliper with plates.

Crane Users Guide How to identify and correct three common problems in the ﬁeld. HOW TO DETERMINE THE PROPER DIRECTION OF DRUM WINDING. Overwind left to right, use right lay rope.

Right lay Overwind

Underwind right to left, use right lay rope.

Right lay Underwind

Overwind right to left, use left lay rope.

Left lay Overwind

Underwind left to right, use left lay rope.

DRUM SPOOLING: A TIGHT SITUATION FOR CRANE OPERATORS.

hen you’re installing a new rope onto a crane, there’s a primary objective: spool the rope onto the equipment tightly without trapping any twist in the rope on the drum. (See installation guidelines for details.)

For multiple-layer spooling, it’s essential to get the first layers of rope spooled with sufficient tension. Particularly with smooth-faced drums, the first layers must be tight with each wrap snug against the preceding wrap. Since the first layer provides the “grooving” for upper layers, wraps must be placed tightly together. If not, wraps in upper layers will pull down between wraps already on the drum, which can cause crushing damage and reduced rope strength and service life. When you encounter spooling problems, check the following list to identify the possible cause. If any of these are incorrect, the result can include open (or loose) spooling, random spooling or stacking of rope against drum flanges. DRUM ALIGNMENT.

Before spooling, make sure the drum is level and at right angles to the boom. Many drums are mounted on the frame so that adjustment can be made in alignment. DRUM WINDING.

Left lay Underwind

Wire rope should wind onto the smooth-faced drum as shown. Make sure you wrap the rope left or right and over or under as recommended.

USE OF A SWIVEL.

Except for Category 1 rotation-resistant ropes and XLT 4 , a swivel end termination will let the rope lay lengthen when loaded. As the rope spools onto a drum, the unlaid rope travels over the point sheave and accumulates between the drum and point sheave. This leads to block rotation, erratic spooling, unbalancing and decreased rope service. Category 1 rotation resistant ropes and XLT 4 may be used with a swivel without these concerns. FLEET ANGLE.

One of the most important factors in proper winding of rope on drums. For smooth-faced drums, this angle should be between 1/2° and 1-1/2”. For grooved drums, it should be between 1/2” and 2”. Fleet angles larger than these can cause spooling problems and the rope to rub against the flanges of the sheave – plus may lead to rope crushing and abrasion on the drum. Fleet angles smaller than these may cause the rope to pile up at the flanges. POINT SHEAVE.

When more than one sheave is in use at the boomtip, make sure the lead line presents the optimum fleet angle to the drum.

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Crane Users Guide GROOVED DRUMS.

Groove spacing must be adequate to prevent the rope from crowding out adjacent wraps as the rope spools across the drum. In addition, groove spacing must not be excessive, which can allow wraps of the next layer to pull down between wraps of the previous layer, causing abrasion and crushing.

IMPROPER INSTALLATION.

When a rope has been installed in such a way that twist has been introduced into the rope, spooling problems can result. (See installation guidelines for details.)

DRUM FLANGES.

RISER STRIPS AND KICK PLATES.

Flanges should be perpendicular to the drum face and not worn, deformed or spread outward. These conditions can cause spooling problems at the changeof-layer point as additional layers are spooled.

If spooling problems persist after you’ve considered the above conditions, try using riserr strips and kick plates. For details on these accessories, check with your crane manufacturer or call Union for technical service.

Rope unbalance: a problem of unequal proportions .

lso called “wavy rope,” unbalance is an indication or result of abnormal movement of strands in an operating rope. It usually involves two or more outer strands of rope rising out of position, standing higher than remaining strands with no apparent cause or evidence of external physical force. Anytime you see an unbalanced rope, you should increase your rope inspection frequency. Find out the cause and correct the problem before you install your next rope.

The causes. Unbalance often shows up in the middle of a rope system where you don’t expect it. It’s usually caused by “milking” of the rope – in other words, a lay change in the rope. The causes are many: swivels, small diameter sheaves, improper-sized or worn sheave grooves or sheave misalignment, to name a few. Standard 6-strand regular lay ropes are generally more resistant to unbalance than other ropes.

How to correct unbalance problems. There are several practices you can implement to minimize rope unbalance problems. These include: ELIMINATE SWIVELS AT DEAD ENDS. A swivel end termination will lengthen the lay in the rope when

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loaded, which can cause an unbalance in the rope. REMOVE WELDED ENDS OF ROPES. Where a rope has been torch cut, make sure the strands are free to adjust before the rope is clamped or seated in an end termination. However, this does not apply to Flex-X 35. Leave the welded ends on Flex-X 35

CROSS-SECTION VIEWS OF THREE SHEAVE GROOVE CONDITIONS.

LOOK FOR ANY SHEAVE MISALIGNMENT. Misalignment of sheaves in multi-part reevings and improperly aligned idler sheaves can also contribute to unbalance problems. ASSURE PROPER GROOVE CONTOURS. Use a groove gauge to inspect sheave and drum grooves for proper contour. If sheave grooves are too small or are worn deeper and narrower by an old rope, they’re too tight for new ropes. If grooves are too wide, the ropes tend to ﬂatten out and become oval-shaped. Any of these conditions can restrict strand movement and cause twist to build up in the rope.

Using a gauge, A is correct,B is too tight and C is too loose.

CONSIDER A 6-STRAND ROPE CONSTRUCTION. Standard 6-strand regular lay ropes are less susceptible to unbalance than other ropes . REMOVE ANY TWIST IN ROPE. See rope installation guidelines for details.

Crane Users Guide Block rotation: a very entangling problem.

lso called cabling, block rotation occurs when multipart reeving twists together at a certain height, entangling the parts of rope between the traveling block and boomtip. It can happen with little warning, making it virtually impossible ible to lif lift or lower a suspended load. Twisted hoist lines can bring a construction project to a sudden halt, resulting in downtime.

– Use larger diameter traveling block sheaves to increase the rope spacing. As the diameter of the traveling block sheave increases, the chances for block rotation are reduced. – Use the outer (farthest apart) sheaves – traveling block and boom. – Dead-end the rope at the boomtip to increase the spread between the wire rope parts.

But the good news is this. You can minimize block rotation through proper installation and handling, as well as take corrective measures THE KEY ISUNDERSTANDING TORQUE.

Every wire rope – regardless of type, classification, grade or manufacturer – will develop torque when loaded. Torque is normal and natural, caused by the way wire ropes are made. Wires are first laid together in a spiral to form strands, then several strands are laid together in a spiral to form the rope. When loaded, wires and strands try to straighten out, thus creating torque. Another source of torque is any change in the rope lay length. This is normally caused by “milking” or rotation at the end of the rope. USE THE SHORTEST FALL LENGTH POSSIBLE.

Torque in a rope affects the tendency of the traveling block to rotate. Thus, it’s important to minimize any torque. HOW TO HELP REDUCE BLOCK ROTATION.

There are at least seven different operating practices you can use to minimize block rotation on your crane. CHANGE THE RIGGING GEOMETRY. This

includes the following operating practices:

The length off ffall, or the distance from the pick point to the point sheaves, is critical. Longer ffall lengths are less stable and more likely to lead to block rotation. AVOID ODD-PART REEVING. An even number

of parts is more stable. USE TAGLINES ON LIFTS. Attach a tagline to restrain the load block and keep the load from rotating.

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Crane Users Guide USE A DIFFERENT ROPE CONSTRUCTION.

Standard 6-strand ropes do not provide any rotation resistance. There are different levels of rotation resistance that can be obtained from specialty ropes. For maximum block stability use Starlif Starlift Xtra or XLT 4 . Both XLT 4 and Starlift Xtra ropes are also used in single part hoisting. There are other specialty ropes that provide some rotation resistance. Our Flex- 19 and 19 x 7 ropes are Category 2 Flex-X rotation-resistant ropes. Flex-X 19 is very resistant to crushing in multiple layer spooling and is frequently used in multipart hoisting applications.

The trapped unlaying causes twist in the rope, which leads to block rotation, erratic spooling, unbalancing and decreased rope service. Remove the swivel from the rope termination and follow steps to remove twist from the rope to optimize rope service. CHECK SHEAVE ALIGNMENT AND GROOVE SIZE. Improper sheave alignment or

groove size can “milk” the lay in a rope and cause torque.

USE A SWIVEL ONLY WITH CATEGORY 1 ROPES. XLT 4 and Category 1 ropes, due

to their special design, may be used with a swivel. Other wire ropes should not be used with a swivel. With standard ropes, Category 2 (Flex-X 19 and 19 x 7) rotation-resistant rope and Category 3 (8 x 25) rotation-resistant rope, a swivel in an end termination will allow rotation in a direction that unlays the outer strands when the rope is loaded. This can cause a reduction in rope strength, unbalance in the rope and spooling problems. While the rope rotation only occurs between the swivel and the first sheave, the unlaid rope travels over the sheave as the load is lifted and introduces unlaying to the section of the rope beyond the sheave. This unlaying becomes trapped and will not come out of the rope when n the load is removed.

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Crane Users Guide How to evaluate block stability due to rigging geometry.

ndustry testing has been conducted to help you assess the block stability of your rigging configuration and rope selection. The bands on this graph approximate the block stability for four types of wire ropes in multi-part systems:

– 6-strand, right regular lay lay, IWRC – Category 3 (8-strand, rotation-resistant) – Category 2 (19-strand, rotation-resistant) – Category 1 (Starlift (Starlif Xtra, rotationresistant) or XLT 4

Four independent variables are used in pairs to locate a reference point on the graph that indicates the stability of the lift being made. The ratios used include: L/S = Length of fall (ft) ÷ Spacing of the rope (ft) L = Length of fall measured from the centerline of the point sheave to the centerline of the traveling block sheave as shown in the diagram am

Starlift Xtra, Category 1 XLT4

S = Average diagonal spacing of the rope at the boom point and the traveling block sheaves as shown in the diagram D/d = (D)Average pitch diameter of point and block sheaves (in (in) ÷ (d) nominal rope diameter (in)

Flex-X 19,

For 2-part reeving, S = average pitch diameter of point and block sheave For 3-part reeving, S = 2/3 of 2-part For 4-part reeving, S = diagonal distance of rope parts

The band for XLT4 and Category 1 rotationresistant ropes is based on torque values The bands for 6-strand, Category 2 and Category 3 rotation-resistant ropes were developed

For 5-part reeving, S = 4/5 of 4-part

conducted by Wire Rope Technical Board and the Power Crane and Shovel Association

When the reference point on the graph lies above the appropriate band, block rotation will probably occur. If the reference point lies below the band, then the lift will probably be stable without block rotation. If the point lies within the band, block b rotation is uncertain.

For 6-part reeving, S = diagonal distance of rope parts For 7-part reeving, S = 6/7 of six-part system jointly conducted by Wire Rope Technical Board and the Power Crane and Shovel Association io

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Crane Users Guide

Warning

Before installing wire rope in your applications, always read and follow the warning label we attach to each reel.

WARRANTY

on the condition that the published strengths apply only to new, unused rope, that the mechanical equipment on which such products are used is properly designed and maintained, that such products are properly stored, handled, used and maintained, and properly inspected on a regular basis during the period of use Seller shall not be liable under any circumstances for consequential or incidental damages or secondary charges including being incorporated in or becoming coming a component of any other product

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