Home

Wire Rope End Terminations

1. S 42 1T e Basket is cast steel e Individually magnetic particle inspected e Pin diameter and jaw opening allows wedge and socket to be used in conjuction with open swage and spelter sockets Secures the tail or dead end of the wire rope to the wedge thus eliminates loss or Punch out of the wedge e Eliminates the need for an extra piece of rope and is easily installed The TERMINATOR wed ge eliminates the potential breaking off of the tail due to fatigue The tail which is secured by the base of the clip and the wedge is left undeformed and available for reuse Incorporates Crosby s patented QUIC CHECK Go and No Go feature cast into the wedge The proper size rope is determined when the following criteria are met e 1 The wire rope should pass thru the Go hole in the wedge e 2 The wire rope should NOT pass thru the No Go hole in the wedge Utilizes standard Crosby Red U Bolt wire rope clip Wedge sockets meet the performance requirements of Federal Specification RR S 550D l TypeC ni those provisions Wedge socket terminations have an efficiency rating of 80 based on the catalog required of the contractor stre ngth of XXIP wire rope e Standard S 421 wedge socket can be retrofitted with the new style TERMINATOR wedge e Available with Bolt Nut and Cotter Pin e U S patent 5 553 360 and foreign equivalents mm S 421T Weight Stock No Weight
2. a Lo ae ee ist Stage 1192523 2nd Stage 1192541 1st Stage 1192621 2nd Stage 1192587 Die Desc Ores 3 60 25 4 14 5 toatoa 8 4 08 38 1 231 9 66 1041107 5 44 38 1 1041125 13 6 51 0 310 13 1041143 13 2 51 0 EEA 1041161 30 8 70 0 1 TORTIE 70 0 1041205 E EAEN roat2ea 2z 30 5 515 104124 102 1041269 28 29 Bulk 122 635 3 00 N h N h h O he Sz co 19 1 19 1 25 7 25 7 31 5 31 5 37 1 42 7 49 0 co co oO roe oo on h oO on N h D co O are ro D gt ro ho Nh NO N oo Ny La oo N to N oo h oO ro NO oO No oo to NMI PO Oj Go Po B Oa S ol A w gt ol o Go OO N NI co o o ow a_i roe D co ey 1041287 31 32 Bulk N O Sz ie oO on O1 oO ro 1041303 34 35 P Afo oO O on co on a ol OJ OS J on rN foe Rol olo w ho ho ho O O O on D w O X NJ o D Go N N N O tn D iN w M co Ny EE D D N O ro on 64 0 1 3 8 Open 1st Stage 1192667 2nd Stage 1192621 1 1 2 Open 1st Stage 1192649 2nd Stage 1192667 Bulk 184 975 49 2 79 5 78 7 1 3 4 Open 1st Stage 1192685 2nd Stage 1192701 57 0 92 0 90 4 2 Open 1st Stage 1192729 2nd Stage 1192747 128 63 5 64 5 102 105 2 1 4 Open 1st Stage 1192765 1191089 1191089 2nd Stage 1192783 1191043 1191043 140 7 114 2 1 2 Open 1st Stage 1191061 1191061 1195370 1195
3. A warning USE ONLY 6 X 12 DIES ON If the tonnage is lower than desired Working Load Limit turn the valve clockwise while con tinuing to press the foot pedal marked up until desired Working Load Limit is reached B If tonnage is higher than desired Working Load Limit release pressure by pressing the pedal marked down Then repeat steps 2 through 4 Swaging Machine Capacity Chart for S 501 amp S 502 Swage Sockets Swaging Machine Capacity Chart for Swage Sleeves Ferrules amp Buttons Largest mE Hydraulic Fitting Largest Fitting Allowed Swaging Die Allowed to be Hydraulic l to Be Swaged Machine Swaging Size Swaged Swaging Die mm Size Method in mm Machine Swaging size S 505 S 506 S 510 S 409 Mark Series Size Method in Sleeve Sleeve Ferrules Buttons 9 1 2 x5 Full Shank 19 Mark Series 500 Tons 4x7 500 Ton FullDie 712x gt 38 g2 14 2 A A 5x7 Progressive Le 32 i 4x7 1000 Ton Full Die 5x7 64 32 14 32 Full Shank i i 26 5x7 1000 Tons aaa 1500 Ton Full Die boars 89 32 14 32 Progressive ee 38 3000 Ton Full Die 6x12 114 32 14 32 T Largest size fitting available To Full Shank 6x12 me 5x7 Progressive 6x12 52 3000 Tons Full Shank 6x 12 52 Progressive 16 x 12 52 Copyright 2002 The Crosby Group Inc All Rights Reserved Largest size fitting available 2I NATIONAL HY
4. kg 9 No 325 1052116 217 1052125 254 42 9 1052134 298 1052143 351 7 2 63 5 1 3 8 1 1 2 1052152 424 Wire Rope WIRELock wiRELOCK wir ELock Size Required Stock K it Size No cc 1 1 8 1 1 4 28 32 1039604 1 3 8 1 1 2 35 38 1039606 2 kits required 32 Copyright 2002 The Crosby Group Inc All Rights Reserved G 517 8 517 a Mooring Sockets e Designed for today s higher strength classes of wire rope e Wide range of sizes available e 50 mm through 92 mm Wire Line e M Line socket terminations have a 100 efficiency rating based on the minimum breaking load of the wire rope e Design of bail allows for easy connection to shackles and other connecting links e Socket design utilizes features to keep cone from rotating e Available Galvanized or Self Colored G 517 S 517 M Line Mooring Sockets Dia 517 517 Each mm mm Stock No StockNo kg Pp A BJ D EJ F G 1005002 1005020 1005089 1005048 1005084 100503 88 92 1005123 1005132 127 105 203 230 298 937 355 6 1005066 Copyright 2002 The Crosby Group Inc All Rights Reserved 33 Open Spelter Sockets G 416 S 416 e Forged Steel Sockets thru 38 mm cast alloy steel 40 mm thru 100 mm e Spelter socket terminations have an efficiency rating of 100 based on the catalog strength of wire rope Ratings are based on recom mended use with6x 7 6x 19 or 6 x37 IP
5. 18 19 20 22 24 26 28 30 32 33 35 36 40 42 45 46 48 50 54 56 62 64 67 70 73 Sz h N O O co QII AIAI floiNjo OJAI NIM OO N Cg O1 ee I I CPO MIP Coy oo s 00IN1O 00 sk D orfor N gt 5 oivlola ioe k co NJ Ol Or RS S R B ABB OJN O1fFO1 OF Ory h oh N IS ol om O N z z 12 86 i N O O1 k l ioe NO eS ee COFOINPOr R IP NPRLHATO oO h oje ojo N Ol NTOIODPOPOPON AIO IOI OI INININ gt gt gt ae Koj Ke CO aJo Copyright 2002 The Crosby Group Inc 35 All Rights Reserved 36 National Steel Swaging Sleeves SIDE 1 NATIONAL SWAGE DIE GUIDE When Paging Crosia oir ne Diin inane Hinni produc yon re fae L halip The National Die Guide will assist you in selecting the proper dies to meet your swaging needs For Flemish eye wire rope splicing Designed for low temperature toughness Resists cracking when swaged equals or exceeds stainless steel sleeves Special processed low carbon steel Cold Tuff for better swageability Can be stamped for identification after swaging without concern for fractures when following these directions Use round corner stamps to a maximum depth of 0 4 mm The area for stamping should be on the side of the sleeve in the plane of the sling eye and no less than 6 mm from either end of the sleeve Standar
6. a AANARAARMRRRRNAR i No kg Oni kg C Jt Kt L T V 9 10 11 13 14 16 18 19 1035582 20 22 356 24 26 9 1035600 403 69 0 51 0 95 5 22 4 118 2 2 730 835 28 1035609 450 30 32 202 N A TERMINATOR Assembly includes Socket Wedge Pin and Wire Rope Clip 1 1 4 not available in TERMINATOR Style t Nominal NOTE For intermediate wire rope sizes use next larger sizesocket 30 Copyright 2002 The Crosby Group Inc All Rights Reserved US 422T Utility Wedge Sockets QUIC CHECK US 422T e Basket is cast steel e Cast into each socket is the name McKissick Crosby or CG its model number and its wire line range e By simply changing out the wedge each socket can be utilized for various wire line sizes Ensure correct wedge is used for wire rope size e Wedges are color coded for easy identification e Blue largest wire line size for socket e Black mid size wire line for socket e 11 mm on US4 e 14 mm on US5 e Orange smallest wire line size for socket e Cast into each wedgeis the model number of the socket and the wire line size for which the wed ge is to be used e Load pinis forged and headed on one end e US 422 wedge sockets contain a hammer pad lip to assist in proper securement of termination e Wedge socket terminations have an efficiency rating of 80 based on the catalog strength of XXIP wire rope e UWO 422 Wedges are to be used only with the US 422 We
7. e Four column wide stance which provides the operator ample working clearance between columns and a large area for in process sling storage T x g be Di iG e Vertical swage action which gives an equalized press on the fitting to produce uniform high quality e Self locating spring locks snap the shoe type dies into place for quick set up and change e The National four column wide stance Hydraulic Swaging Machines each equipped with an up acting ram have two side cylinders for fast approach and return of the main ram They come in three swaging capacities 1500 Tonnes Hydraulic Swaging Machines Approximate weight 15 6 t Overall height 2 6 m Fast advance and retract speed Automatic slow precision swaging speed e 500 tonnes 4450 kN e 1000 tonnes 8900 kN e 1500 tonnes 13350 kN Swaging Machine Capacity Chart for Swaging Machine Capacity Chart for Swage Sleeves Ferrules amp Buttons S 501 amp S 502 Swage Sockets Largest Fitting Allowed Hydraulic Largest Fitting Hvdraulic to Be Swaged Swaging Die Allowed to be ae serie Die mm Machine Swaging Size Swaged ging Size Method in mm Machine Swaging Size S 505 S 506 S 510 S 409 Size Method in Sleeve Sleeve Ferrules Buttons 500 Ton Full Shank 2 1 2 x 5 Mark Series 4x7 19 500 Ton Full Die 2 1 2 x 5 Mark Series 5 k 7 4x7 38 32 14 22 5x7 Progressive 4x7 32 5x7 1000 Ton
8. 1192845 J J ia Mall Ma la ll id ad dl dd Md DS hano BA B A e Wid al a Ga aa a a lo e a i id dl ll Kl Taca Middl Kl ald al 2 a Bianna DOA DM il Nid Middl ll ed Wd il Kd lH ll la Gl al lhl Gl al dal lM al ll a Mi Ml ll ll Nd lM Kd el Md ed M B OC 1089165 18 20 3 62 294 394 70 0 35 1 203 162 38 1 254 198 70 0 361 3 4 Socket 1192925 J 11089183 22 5 23 341 432 79 5 41 1 239 189 44 5 295 239 825 394 7 8 Socket 1192 9 J 1039209 24 26 8 07 393 505 93 5 51 0 269 216 51 0 340 269 95 5 457 1 Socket_ 119291 J 1089227 28 11 5 440 57 0 103 57 0 302 243 57 0 381 30 2 108 520 1 1 8 Socket 1192989 _ J 1089245 32 16 1 484 645 114 63 5 338 270 63 5 419 31 0 121 585 1 1 4 Socket 1193005 _ J 1089263 34 36 19 8 532 71 0 127 63 5 368 297 63 5 461 351 133 650 1 3 8 Socket 1193023 J 1042767 48 52 66 799 100 203 95 5 535 432 102 683 600 203 905 2 Socket_ 1193087 1191294 119379 1195218 Maximum Proof Load shall not exceed 50 of XXIP rope catalog breaking strength 38 Copyright 2002 The Crosby Group Inc All Rights Reserved Closed Swage Sockets QUIC CHECK S 502 e Forged from special bar quality carbon steel suitable for cold forming e Hardness controlled by spheroidize annealin
9. 140 162 187 210 235 267 282 302 314 346 570 570 63 5 760 89 0 1 1 1 39 6 44 5 51 0 63 5 76 0 89 0 102 117 127 152 165 178 229 254 274 279 287 300 318 343 33 3 38 1 47 8 57 0 66 5 79 5 95 5 105 121 137 146 165 178 197 216 229 241 254 274 318 _h 112 12 7 142 15 7 h AJN ho wo CO _ Ol 00 20 22 24 26 28 30 32 35 h aJo O1 O OIOININ N O NINININ oflailNIO NIAAA O 40 42 44 48 50 54 56 60 64 67 70 73 75 80 82 86 88 92 94 102 Cast Alloy Steel md N 89 0 O N O Opyoyoys Qoo oni EN Leo LeS gt oj ololojw D N N N O O o1 oo oo co OJo N O N oo O D O N O O x z io O1 10CO WIOMIMINMINM S No CO FOOIN ONO olojo 38 34 Copyright 2002 The Crosby Group Inc All Rights Reserved Closed Spelter Sockets G 417 S417 e Forged Steel Sockets thru 38 mm cast alloy steel 40 mm thru 100 mm e Spelter socket terminations have an efficiency rating of 100 based on the catalog strength of wire rope Ratings are based on the recom mended use with 6 x7 6 x19 or 6x 37 IPS or XIP EIP XXIP EEIP RRL FC or IWRC wire rope Closed grooved Sockets meet the performance requirements of Federal Specification RR S 550D Type B except for those provisions requir
10. INFORMATION Detailed application information will assist you in the proper installation of wire rope clips This information is most effective when provided at the point of application as well as in supporting brochures and engineering information The manufacturer must provide this specific information Generic information will not provide all the needed application instructions A formal application and warning system that attracts the attention of the user clearly informs the user of the factors involved in the task and informs the user with the proper application procedures as needed COMPETITION Ask is the clip forged Ask is an adequate cradle provided in the clip base for the wire rope Malleable cast iron clips are sometimes improperly used as replacements for forged clips Ask Do they have both fist grip and U bolt clips available Ask Do they have a full range of forged wire rope clip sizes No competitor has the full line of forged U Bolt clips and fist grip clips that Crosby has Ask Is the manufacturer s name and size of clip clearly marked Ask Do they have a traceability system that is actively used in the manufacturing process Most do not have a traceability system Ask Does each clip have the application and warning information Most competitors do not have application and warnings information with each clip thels Peas lay orour Remember CROSBY Crosby
11. StockNo Side Load Ro Size mm S 502 pe Weight 1500 3000 eieck i i Ton Ton No Description 6 x 12 6 x 12 1039825 6 015 109 12 7 35 1 19 1 6 85 54 0 127 89 0 117 1 4 Socket_ 1192845 1039843 8 034 138 19 6 41 1 2 4 865 81 0 17 0 114 180 5 16 3 8 Socket 119283 _ 103 861 910 0 33 138 19 6 41 1 2 4 10 4 81 0 17 0 114 180 5 16 3 8 Socket 1192383 _ 1039889 11 12 0 64 176 24 9 51 0 9 12 2 108 218 146 231 7 16 1 2 Socket 119281 103 05 13 0 64 176 24 9 51 0 9 140 108 218 146 231 7 16 1 2 Socket 119281 _ 103 23 14 132 220 31 8 60 5 31 8 15 5 135 287 184 295 9 16 5 8 Socket 119297 103 41 16 129 220 31 8 60 5 31 8 170 135 287 184 295 9 16 5 8 Socket 1192907 103 69 18 20 2 27 261 39 4 73 0 6 203 162 333 219 361 3 4 Socket_ 119225 J 103 87 22 3 08 303 43 2 79 0 42 9 239 189 38 1 257 394 7 8Socket_ 1192 9 103902 2426 4 72 344 5 5 92 0 52 5 269 216 445 292 457 1So ket_ 1192 1 J 103 520 28 672 382 57 0 102 8 5 30 2 243 510 324 520 1 1 8 Socket_ 1192089 103948 32 978 430 45 114 6 0 33 8 270 57 0 365 585 1 1 4 Socket_ 1193005 103966 3436 12 9 473 71 0 127 6 0 36 8 297 57 0 400 650
12. clips on each eye See Figure 5 An alternate method is to use twice the number of clips as used for a turnback termination The rope ends are placed parallel to each other overlapping by twice the turnback amount shown in the application in structions The minimum number of clips should be installed on each dead end See Figure 6 Spacing installation torque and other instructions still apply S Q SSNS OSSOS iw UO U w DEAD END LIVE END Figure 6 6 IMPORTANT Apply first load to test the assembly This load should be of equal or greater weight than loads expected in use Next check and retighten nuts to recommended torque In accordance with good rigging and maintenance practices the wire rope end termination should be inspected periodically for wear abuse and general adequacy Table 1 Clip Rope Minimum No Amount of Rope Torque Size Size of to Turn Back in in Inches mm Clips mm Nm 1 8 3 4 2 85 6 1 3 16 5 2 95 10 2 1 4 6 7 2 120 20 3 5 16 8 2 133 40 7 3 8 9 10 2 165 61 0 7 16 11 12 2 178 88 1 2 13 3 292 88 9 16 14 15 3 305 129 5 8 16 3 305 129 3 4 18 20 4 460 176 7 8 22 4 480 305 1 24 25 5 660 305 1 1 8 28 30 6 860 305 1 1 4 33 34 7 1120 488 1 3 8 36 7 1120 488 1 1 2 38 40 8 1370 488 1 5 8 41 42 8 1470 583 1 3 4 44 46 8 1550 800 2 48 52 8 1800 1017 2 1 4 56 58 8 185
13. eSocket_ NOTE Length is measured from outside end of termination mi Ji IBEAS ITV IGBMS MOPY 40 Copyright 2002 The Crosby Group Inc All Rights Reserved National Swage Duplex Sleeves S 506 e For turnback wire rope splicing e Designed for lower temperature toughness e Resists cracking when swaged equals or exceeds stainless steel sleeves e Special processed low carbon steel e Cold Tuff for better swageability e Stamp for identification after swaging without concern for fractures as per directions in National Swaging Brochure e Turnback terminations have efficiency ratings of 94 based on the catalog strength of wire rope NOTE S 506 Duplex sleeves are recommended for use with6 x 19 or 6 x 37 IPS or XIP EIP RRL FC or IWRC wire rope Before using any National Swage fitting with any other type lay construction or grade of wire rope it is recommended that the termination be destructive tested and documented to prove the adequacy of the assembly to be manufactured S 506 COLD TUFF Duplex Non Tapered Sleeves S 506 Steel Duplex Non Tapered Sleeve Specifications Press Die Data Before Swage Dimensions Stock No Max 500 Ton S 506 Rope Weight After Swage 1000 Ton Stock Size per 100 Pkg Dimensions 1500 Ton No mm Qty Cc mm Die Desc 5x7 S18 26 9 20 6 485 moma e 77 200 se 269 206 485 103839 79 Copyright 2002 The Crosby Group I
14. months Inspection Maintenance Safety s Make sure all bolts and nuts are in place and tightened to recommended torque as shown in Table A on page 56 Load block or die base plate surfaces must be to manu facturers specifications for thickness and flatness to provide complete support of the die during swaging Make sure die holder side rails are not bent or loose Clean dies and die holder surfaces Keep free of metal shavings slag grit sand floor dry etc Lubricate the four guide bushings daily with light oil Die Working Load Limit Pressure Adjustment on Lower Cylinder National 500 Ton through 1500 Ton Swaging Machines Die Working Load Limit Pressure Adjustment on 3000 Ton Swaging Machine For reducing tonnage use selector switch on front of control panel to select lower tonnage approximately 1500 Tons or 3000 Ton Follow this procedure to adjust swaging tonnage pressure on your Swaging machine Install the die holder s or die adapter with the dies to be used Bring the dies together without a part in the dies until they just touch Turn the tonnage control valve which is located on the control panel left of the tonnage gauge counter clockwise about 6 six turns or until knob no longer turns Now without a part in the dies apply pressure to the dies by pressing the foot pedal marked up A ALWAYS USE 5 X 7 OR 6 X 12 DIES AT 1500 TON SETTING TONNAGE THAT EXCEEDS 1500 TONS
15. 0 1017 2 1 2 62 65 9 2130 1017 2 3 4 68 72 10 2540 1017 3 75 78 10 2690 1627 3 1 2 85 90 12 3780 1627 If a pulley sheave is used for turning back the wire rope add one additional clip See Figure 4 If a greater number of clips are used than shown in the table the amount of turnback should be increased proportionately The tightening torque values shown are based upon the threads being clean dry and free of lubrication Copyright 2002 The Crosby Group Inc All Rights Reserved CROSBY FIST GRIP CLIPS WARNINGS AND APPLICATION INSTRUCTIONS Failure to read understand and follow these instruc tions may cause death or serious injury Read and understand these instructions before using clips Match the same size clip to the same size wire rope Do not mismatch Crosby clips with other manufactur ers clips Prepare wire rope end termination only as instructed Do not use plastic coated wire rope Apply first load to test the assembly This load should be of equal or greater weight than loads expected in use Next check and retighten nuts to recommended torque See Table 1 this page Efficiency ratings for wire rope end terminations are based upon the catalog breaking strength of wire rope The efficiency rating of a properly prepared loop or thimble eye termination for clip sizes 3 mm through 22 mm is 80 and for sizes 25 mm to 38 mm is 90 The number of clips shown see Table is based upon using RRL
16. 076 2nd Stage 1191089 1191089 1195469 1195085 146 76 0 78 5 121 119 2 3 4 Open 1st Stage 1191034 1191034 1195389 1195094 2nd Stage 1191052 1191052 1195478 1195101 162 82 5 86 0 133 126 3 Open 1st Stage 1193201 1193201 1195398 1195110 2nd Stage 1193229 1193229 1195487 1195129 1041483 87 89 2105 Bulk 356 178 98 5 394 148 147 3 1 2 Open 1st Stage 1193247 1195138 2nd Stage 1193265 1195147 1041492 93 95 2495 Bulk 81 191 103 108 160 158 3 3 4 Open 1st Stage 1191114 1195263 2nd Stage 1191132 1195272 1041508 100 3130 Bulk 406 206 111 114 173 4 Open 105 1st Stage 1191150 1195156 2nd Stage 1191178 1195165 1041526 112 4536 Bulk 457 22 124 129 195 189 4 1 2 Open 114 1st Stage 1191187 1195174 2nd Stage 1191203 1195183 1041321 37 38 1041349 44 45 1041367 50 52 510 Ww 1041385 56 57 862 Bulk 1195085 1195067 1041401 62 64 1043 Bulk O oO gt o a_i mh D 1041429 68 70 1270 Bulk 1041447 75 76 1334 Bulk Copyright 2002 The Crosby Group Inc 37 All Rights Reserved Open Swage Sockets QUIC CHECK S 50 1 e Forged from special bar quality carbon steel suitablefor cold forming e Hardness controlled by spheroidize annealing e Swage Socket terminations have an efficiency rating of 100 based on the catalog strength of wire rope e Stamp for identification after swaging without concern for fractures as per direc
17. 1 3 8 Socket_ 1193 3 103984 38 40 17 3 511 78 0 140 71 5 40 1 324 635 432 715 1 1 2 Socket_ 1193041 1191267 1193255 1195192 Maximum Proof Load shall not exceed 50 of XXIP rope catalog breaking strength Copyright 2002 The Crosby Group Inc 39 All Rights Reserved National Swage Buttons S 409 e Special processed low carbon steel Cold Tuff for better swageability Swage Button terminations have an efficiency rating of 98 based on the catalog strength of wire rope Stamp for identification after swaging without concern for fractures as per directions in National Swaging Brochure NOTE S 409 Buttons are recommended for use with 6x 19 or 6 x 37 IPS or XIP EIP RRL FC or IWRC wire rope Before using any National Swage fitting with any other type lay construction or grade of wire rope it is recommended that the termination be destructive tested and documented to prove the adequacy of the assembly to be manufactured S 409 COLD TUFF Buttons S 409 Steel Swage Button Specifications Press Die Data Before After i Stock No 500 Tons S 409 Rope Weight 1000 Tons ee Size Size Per100 i E 1500 Tons No mm C i Length Die Desc 5x7 omn TSB 3 ot 12 er se5 02 155 W8 14 Button 1191601 o9 788 8 726 24 27 o 0 388 GBistStage 1102064 _ rose SB 14 ste seo 515 i55 8 _01 0 96 se bution 1107600 KESGAN vis tio sa8 0 108 ta
18. DRAULIC SWAGING MACHINE TORQUE MAINTENANCE INFORMATION Item No Req d Description Cylinder Housing Cap Piston Tie Rod Nut Platen Guide Gland Bushing Packing Set Packing Gland Nut Packing Gland Spacer Stud Cap Screw Cap Screw Lower Bracket Upper Bronze Ring Upper Bracket Machine Screw Side Cylinder Lower Bronze Ring l gt Oel ODY T N Z YI IW A A NS ool on m lanl eg 1 sa We ca LN MOND NAANANHHPHYDYO OHH Block Stud Nut Copper O Ring Lock Nut Top of Cylinder Bottom of Packing Cavity Wf SOOO OQOQOO OWlalO Val AiR a A Table A Torque in Nm 500 t 800 t 1000 t 1500 t Swaging Swaging Swaging Swaging Maintenance Description Machine Machine Machine Machine Schedule Tie Rod Nuts Weekly Piston Bolts Monthly Packing Gland Nuts over spacers only Weekly all others hand tighten Platen Guide Bolts Weekly Packing Gland Bolts 6 Months Side Cylinder Bolts Weekly Guide Bushing Bolts Weekly 80 M Piston Pump Pistons Torque in ft Ibs Die Holder 1 4 20 UNC 13 Bolt Torque 5 16 18 UNC 15 5 8 111UNC 211 7 8 9UNC 583 56 Copyright 2002 The Crosby Group Inc All Rights Reserved
19. Full Die 4x7 64 32 14 32 5x7 1000 Ton Full Shank 4x7 26 8x7 1500 Ton Full Die 5x7 89 32 14 32 x 6x12 Progressive 4x7 38 5x7 3000 Ton Full Die 6x12 114 32 14 32 P EN 1500 Ton Full Shank 5x7 32 Largest size fitting available 6x12 Progressive 5x7 52 6x12 NOTE For special applications or conditions OOTAN a Snank ere 5o contact Crosby National at 501 982 3112 Progressive 6x12 52 Largest size fitting available Copyright 2002 The Crosby Group Inc 43 All Rights Reserved WIRELOCK RESIN FOR SPELTER SOCKETS Note For use on 416 417 amp 517 spelter sockets only e 100 termination efficiency e Temperature operating range is 54 C to 115 C e Ideal for on site applications e No hazardous molten metal e Improved fatigue life e Pouring temperature without booster pack is 9 C to 43 C e One booster pack if pouring temperature is 0 C to 9 C e Two booster packs if pouring temperature is 10 C to 0 C o Refer to WIRELOCK Technical Manual for more information WIRELOCK rs ems aT a l Ei WIRELOCK W416 7 W RELOC Socket Compound Booster W416 7 Kits Pack Approvals Kit Kits Stock Weight Each Stock Lloyd s Register of Shipping Size Per Case No kg No Det Norske Veritas DNV 100 cc 20 1039602 0 28 1039603 E A 250 cc 12 1039604 0 57 1039605 A EOE A 500 cc 12 1039606 1 15 1039607 United S
20. S or XIP EIP XXIP EEIP RRL FC or IWRC wire rope Open Grooved Sockets meet the performance requirements of Federal Specification RR S 550D Type A except for those provisions required of the contractor NOTICE All cast steel sockets 40 mm and larger are magnetic particle inspected and ultrasonic inspected Proof testing available on special order Drawing illustrates one groove used on sockets 6 mm thru 19mm Sizes 22 mm thru 38 mm use 2 grooves Sizes 40 mm and larger use 3 grooves G 416 S 416 Open Spelter Sockets Structural Dimensions Strand Rope Dia Dia G 416 S 416 mm mm Galv S C 6 7 1039628 8 10 1039646 11 13 1039664 1 02 14 16 12 13 103968 1 63 14 16 1039708 2 64 18 19 103972 4 38 20 22 103974 7 03 24 26 103976 9 75 28 103978 14 1 30 32 1039806 21 4 33 35 103982 24 9 36 40 103984 37 2 42 45 103986 59 46 48 103988 76 50 54 1041633 1041642 114 56 62 1041660 143 64 67 1041679 1041688 172 70 73 1041704 197 76 80 1041722 25 1041740 35 Qa rm 116 17 5 123 20 6 141 25 4 25 4 23 9 171 30 2 T 28 7 202 38 35 1 206 31 8 235 41 4 3 38 1 268 51 0 8 44 5 300 57 0 51 0 335 63 5 8 57 0 384 70 0 414 70 0 413 76 0 4 76 0 464 89 0 1 79 5 546 1 95 5 T 95 5 597 1 108 3 102 648 1 121 3 0 114 692 1 127 9 124 737 1 133 860 133 784 1 140 2 146 845 1 152 98 165 921 1 178 108 184 9 1 17 5 20 6 39 6 42 9 47 8 57 0 66 5 82 5 95 5 105 121 133
21. TS 1 WIRELOCK kits are pre measured and consist of two 2 containers one 1 with resin and one 1 with granular compound 2 Use the complete kit NEVER MIX LESS THAN THE TOTAL CONTENTS OF BOTH CONTAINERS 3 Each kit has a shelf life clearly marked on each con tainer and this must be observed NEVER USE OUT OF DATE KITS WIRELOCK resin in liquid state is flammable Chemicals used in this product can give off toxic fumes and can burn eyes and skin Never use out of date material Use only in well ventilated work areas Never breathe fumes directly or for extended time Always wear safety glasses to protect eyes Always wear gloves to protect hands Avoid direct contact with skin anywhere Copyright 2002 The Crosby Group All Rights Reserved STEP 8 MIXING AND POURING 1 Mix and pour WIRELOCK within the temperature range of 9 degrees to 43 degrees C Booster kits are available for reduced temperatures 2 Pour all the resin into a container containing all the granular compound and mix thoroughly for two 2 min utes with a flat paddle 3 Immediately after mixing slowly pour the mixture down one side of the socket until the socket basket is full STEP 9 CURING 1 WIRELOCK will gel in approximately 15 minutes in a temperature range 18 degrees C to 24 degrees C 2 The socket must remain in the vertical position for an additional ten 10 minutes after gel is complet
22. Wire Rope End Terminations Copyright 2002 The Crosby Group Inc 2i All Rights Reserved 26 Forged Wire Rope Clips What It Takes To Be Crosby Or Equal FORGED FOR CRITICAL APPLICATIONS The proper performance of forged clips depends on proper manufacturing practices that include good forging techniques and accurate machining Forged clips provide a greater rope bearing surface and more consistent strength than malleable cast iron clips Fist Grip clips provide a saddle for both the live and the dead end Fewer forged clips are required for each termination than with malleable cast iron clips Forged clips reduce the possibility of hidden defects that are sometimes present in malleable cast iron clips Malleable cast iron clips should only be used in non critical applications ANSI OSHA and ASTM recommend only forged clips for critical applications FULL LINE The proper application of forged clips requires that the correct type size number and installation instructions be used See APPLICATION INFORMATION below for more information Availability of a full range of sizes of forged U bolt clips and forged fist grip clips are essential for design flexibility IDENTIFICATION The clip s size manufacturer s logo and a traceability code should be clearly embossed in the forging of the clip These three elements are essential in developing total confidence in the product APPLICATION
23. ame code on each S 319SWG hook is to facilitate proper latch selection only and has no reference to the working load FIGURE 3 FIGURE 4 FIGURE 5 limit of the hook Wire Hook Required Maximum Rope Frame Swaging Die After Size I D Swage mm Code Stock No Description Dimensions 4 75 DC 1191621 3 20 Swage Button Die 10 2 6 35 FC 1192845 6 35 Swage Socket Die 11 7 7 95 GC 1191621 6 35 Swage Button Die Viet 7 95 HC 1192863 9 55 Swage Socket Die 18 0 9 55 HC 1192863 9 55 Swage Socket Die 18 0 11 1 IC 1192881 12 7 Swage Socket Die 23 1 12 7 IC 1192881 12 7 Swage Socket Die 23 1 14 3 JC 1192907 15 9 Swage Socket Die 29 5 15 9 JC 1192907 15 9 Swage Socket Die 29 5 19 1 KC 1192925 19 1 Swage Socket Die 36 1 22 2 LC 1192949 22 2 Swage Socket Die 39 4 25 4 NC 1192961 25 4 Swage Socket Die 45 7 28 6 OC 1192989 28 6 Swage Socket Die 52 1 319C Style Hook Copyright 2002 The Crosby Group Inc ol All Rights Reserved WIRELOCK WARNINGS AND APPLICATION INSTRUCTIONS Incorrect use of WIRELOCK can result in an unsafe termination which may lead to serious injury death or property damage Do not use WIRELOCK with stainless steel rope in salt water environment applications Use only soft annealed iron wire for seizing Do not use any other wire copper brass stainless etc for seizing Never use an assembly until the WIRELOCK has gelled and cured Re
24. at can be retrofitted with terminator wedges are US4 US6 and US8 See the Crosby Catalog for additional information New QUIC CHECK Go and No Go features cast into wedge The proper size wire rope is determined when the following criteria are met 1 The wire rope shall pass thru the Go hole in the wedge 2 The wire rope shall NOT pass thru the No Go hole in the wedge Important Safety Information Read and Follow Inspection Maintenance Safety Always inspect socket wedge and pin before using Do not use part showing cracks Do not use modified or substitute parts Repair minor nicks or gouges to socket or pin by lightly grinding until surfaces are smooth Do not reduce original dimension more than 10 Do not repair by welding Inspect permanent assemblies annually or more often in severe operating conditions Do not mix and match wedges or pins between models or sizes Always select the proper wedge and socket for the wire rope size Assembly Safety Use only with standard 6 to 8 strand wire rope of designated size For intermediate size rope use next larger size socket For example When using 9 16 diameter wire rope use a 5 8 size Wedge Socket Assembly Welding of the tail on standard wire rope is not recommended The tail length of the dead end should be a minimum of 6 rope diameters but not less than 6 See Figure 1 To use with Rotation Resistant wire rope special wire rope constructio
25. d Steel Sleeve terminations have efficiency ratings as follows based on the catalog strength of wire rope S 505 Termination Efficiency Size Type of Wire Rope mm IWRC FC 6 25 96 93 28 52 92 89 54 and Larger 90 87 NOTE S 505 Standard Sleeves are recommended for use with 6 x 19 or 6 x 37 IPS or XIP EIP XXIP EEIP RRL FC or IWRC wire rope Before using any National Swage fitting with any other type lay construction or grade of wire rope it is recommended that the termination be destructive tested and documented to prove the adequacy of the assembly to be manufactured Cross Section of Swaged Sleeve NOTE See Page 37 for dimensional information For additional swaging information please refer to the National Swaging Brochure Copyright 2002 The Crosby Group Inc All Rights Reserved National Steel Swaging Sleeves N 505 COLD TUFE Standard Steel Sleeves 505 Standard Steel Sleeve Specifications Press Die Data Maximum Bef ore Swage Dimensions mm z i S505 Rope Weight Swage mg Size Per 100 Dimensions mm _ kg AnA mm 50 200 500 Tons Front Load Side Load 1000 Tons 1500 Tons 1500 ton 3000 ton 1500ton 3000 ton 5x7 6x12 6x12 6x12 6x12 TH Teper 3B Teper 3B Teper 72 Teper T2 Teper 5B Taper 5B Teper 3A Taper 7B Teper Taper i SS a a
26. dge Socket Assemblies Selected sizes now incorporate the TERMINA TOR design US 422T Utility Wedge Socket Dimensions US 422T Weight Wedge i mm xno tg a _fefeloftelu s x ife ats uv Stock No t ruse io Pouar 2o oao a7 175 eas oss asa aia ns re0 sa roots iar ess ros as foes US6 16 1044354 4 26 1047365t 64 _ 241 118 381 31 8 57 0 2 0 89 0 54 0 114 76 0 142 82 5 22 4 60 5 70 0 US6 19 1044363 4 26 1047374t 64 241 118 381 31 8 57 0 2 0 89 0 54 0 114 76 0 142 82 5 22 4 54 0 67 0 US11 28 1088634 25 9 1046928 3 18 406 193 635 63 5 90 5 152 184 70 0 159 121 287 156 33 3 93 0 104 US 422T TERMINATOR Style UWO 422T TERMINATOR Style Copyright 2002 The Crosby Group Inc 31 All Rights Reserved Button Spelter Sockets e Designed for use with mobile cranes Can be used to terminate high performance rotation resistant ropes and standard 6 strand ropes e Available in six sizes from 13mm to 38mm e Button Spelter terminations have a 100 effiaency rating based on the catalog strength of the wire rope e Easy to install assembly utilizes Crosby WIRELOCK socketing compound e Sockets and buttons are re usable e Replacement buttons and sockets are available Button Spelter Sockets Wire Rope Dimensions Size SB 427 Weight in mm No
27. e 3 The socket will be ready for service 60 minutes after gelling 4 Never heat sockets to accelerate gel or curing STEP 10 RE LUBRICATION Re lubricate wire rope as required STEP 11 PROOF LOADING Whenever possible the assembly should be proof loaded All slings with poured sockets in accordance with ASME B30 9 shall be Proof Loaded 53 54 IMPORTANT SAFETY INFORMATION National Four Post Swaging Machine Operation Safety NEVER use dies that are cracked worn or abraded galled NEVER use dies that have an oversized cavity ALWAYS use a matched set of dies When swaging steel fittings DO NOT SHIM DIES Dies for steel fittings must be free to float and align one to the other When swaging aluminum fittings THE STEEL DIES MUST BE SHIMMED Shim the side of the die to ensure the proper cavity alignment for flash removal NEVER shim between the dies When Swaging Crosby National fittings use only the proper capacity swaging machine for the size of fitting used See Swaging Capacity Chart If the swaging machine capacity exceeds the die block Working Load Limit rating adjust the swaging machine ton nage to the Working Load Limit shown on the die block being used See Table 1 for die block Working Load Limit Always use the correct size and type of die for the size wire rope fitting used Always lubricate die faces and cavities with light weight oil Pr
28. e strength of the material and fatigue properties Forged Fist Grip Clips are forged and the entire clip is galvanized The double saddle design eliminates the possi bility of incorrect installation Designed as an integral part of the clip the bolts are opposite one another see G 429 example below As result the nuts can be installed in such a way as to enable the operator to swing the wrench in a full arc for ease of installation Application Information Application and warning information is available for both Crosby Red U Bolt Clips and Fist Grip Clips The Crosby Warning System is designed to attract the attention of the user clearly inform the user of the factors involved in the task and provide the user with proper application procedures Each Crosby Red U Bolt Clip and Fist Grip Clip is either bagged or tagged with appropriate application and warn ing information thus ensuring that the information is available at the point of application for each and every clip during installation Material Analysis Crosby can provide certified material mill analysis for each production lot traceable by the Product Identification Code PIC Crosby through its own laboratory verifies the analysis of each heat of steel Testing Crosby periodically audits the termination efficiencies of the Red U Bolt Clips and Fist Grip Clips Upon special request Crosby will determine the efficiencies of clip assemblies when applied to sp
29. ecial rope con structions and special applications G 450 G 429 Red U Bolt Clip Fist Grip Clip Copyright 2002 The Crosby Group Inc 27 All Rights Reserved Forged Wire Rope Clips G 450 e Each base has a Product Identification Code PIC for material traceability the name CROSBY or CG and a size forged into it e Sizes 1 8 through 2 1 2 3 mm through 76mm have forged bases e Entire Clip Galvanized to resist corrosive and rusting action e Only Genuine Crosby clips havea Red U BOLT for instant recognition e All Clips are individually bagged or tagged with proper application instructions and warning information e Clip sizes up through 1 1 2 88mm have rolled threads e Look for the Red U Bolt your assurance of Genuine Crosby Clips Crosby Clips all sizes 1 4 6 mm and larger meet the performance requirements of Federal Specification FF C 450 TYPE 1 CLASS 1 except for those provisions required of the contractor G 450 Crosby Clips Rope Std Weight Size G 450 Package Per100 mm Stock No Qty kg A B C D E 100 10 454 6 246 142 150 12 7 100 00 00 8 1010079 1 127 96 351 191 22 4 18 3 1 4 64 6f 191 790f 411 445 40 4 1 1 Bulk Bulk Bulk Bulk Bulk Bulk Bulk Bulk Electro plated U Bolt and Nuts 70 mm and 89mm base is made of cast steel 1010239 10 10 10 0 0 SS 450 Each base has a Product Identification Code PIC fo
30. ed of the contractor NOTICE All cast steel sockets 40 mm and larger are magnetic particle inspected and ultrasonic inspected Proof testing available on special order Drawing illustrates one groove used on sockets 6 mm thru 19mm Sizes 22 mm thu 38 mm use 2 grooves Sizes 40 mm and larger use 3 grooves G 417 S 417 Closed Spelter Sockets Structural Dimensions Strand i mm G 417 S 417 ra C Galv S C 039897 1039904 1 39 6 42 9 03991 03993 51 0 03995 67 0 039977 1 92 76 2 039995 3 28 92 0 04001 4 76 105 040037 6 46 114 040055 8 95 128 040073 13 24 137 040091 16 32 146 040117 25 96 171 040135 35 83 194 040153 47 62 216 041759 63 50 241 041777 99 79 273 041795 125 29 041811 142 31 76 80 041839 181 33 l 165 1041857 246 8 36 216 108 184 Diameter of pin must not exceed pin used on companion 416 socket Reference adjacent page D dimension t Cast Alloy Steel N oo 17 5 20 6 23 9 30 2 33 3 38 1 44 5 51 0 58 5 70 5 76 2 79 5 95 5 102 114 124 133 146 39 6 42 9 51 0 67 0 70 0 82 5 95 5 105 119 132 140 162 187 210 235 259 292 311 330 362 57 2 57 2 63 5 76 2 89 0 31 8 102 114 127 138 151 165 191 216 229 248 279 30 330 356 381 12 7 17 NIN AJN o gt ES 0 NID NJO oo 5 N O mh D N 7 _ k _ I _ AIR NENE 1CO co _ D _ _ 12 13 14 16
31. eight than loads expected in use Next check and retighten nuts to recommended torque See Table 1 this page Efficiency ratings for wire rope end terminations are based upon the catalog breaking strength of wire rope The efficiency rating of a properly prepared loop or thimble eye termination for clip sizes 3 mm through 22 mm is 80 and for sizes 25 mm through 89 mm is 90 The number of clips shown see Table is based upon using RRL or RLL wire rope 6 x 19 or 6 x 37 Class FC or IWRC IPS or XIP XXIP If Seale construction or similar large outer wire type construction in the 6 x 19 Class is to be used for sizes 25 mm and larger add one additional clip If a pulley sheave is used for turning back the wire rope add one additional clip The number of clips shown also applies to rotation resistant RRL wire rope 8 x 19 Class IPS XIP XXIP sizes 38 mm and smaller and to rotation resistant RRL wire rope 19 x 7 Class IPS XIP XXIP sizes 44 mm and smaller For other classes of wire rope not mentioned above we recom mend contacting Crosby Engineering at the address or telephone number on the back cover to ensure the desired efficiency rating For elevator personnel hoist and scaffold applications refer to ANSI A17 1 and ANSI A10 4 These standards do not recom mend U Bolt style wire rope clip terminations The style wire rope termination used for any application is the obligation of the user For OSHA Construc
32. ength is 5 times the Working Load Limit ID Code O is old 319 style hook Dimensions mm S 319SWG StockNo e o fF o w v x t w o ep a v aa om2 n2 725 510 160 185 200 236 0 102 160 26 48 605 510 381 a20 765 910 805 197 254 295 209 24 tor 224 BO 020 700 o55 510 E 79 6 tor 805 206 200 333 302 9 182 239 BS 705 Bis 700 510 i O 240 is 122 54 360 4 cet 33 221 287 BS 680 005 025 035 1 i en oa 249 is 140 24 360 14 cet 33 221 87 BS 680 a5 825 035 1 22 239 ana 000 47 05 5 30 5 2 Wo te 111 102 28 50 765 42 Copyright 2002 The Crosby Group Inc All Rights Reserved National Hydraulic Swaging Machines National offers the highest quality and most complete line of Hydraulic Swaging Machines specifically designed to be used to swage fittings on wire rope 3 Capacities to Fit your Requirements e 500 Tonnes e 1000 Tonnes e 1500 Tonnes The following features of National Hydraulic Swaging Machines offer a number of advantages for high production sling shops e A dual hydraulic system which combines the use of high speed and low pressure to bring dies into position and the low speed and high pressure necessary for ideal swaging control Adjustable tonnage control so tonnage can be set to match die block Working Load Limit
33. g e Swage Socket terminations have an efficiency rating of 100 based on the catalog stren gth of wire rope e Stamp for identification after swaging without concern for fractures as per directions in National Swagin g Brochure e Swage sockets incorporate a reduced machined area of the shank which is equivalent to the proper after Swage dimension Before swaging this provides for an obvious visual difference in the shank diameter After swaging a uniform shank diameter is created allowing for a QUIC CHECK and permanent visual inspection opportunity e Designed to quickly determine whether the socket has been through the swaging operation and assist in field inspections it does not eliminate the need to ooo standard production inspections which include gauging for the proper after swage dimensions or proof loading e U S Patent 5 152 630 and foreign equivalents NOTE S 502 Swage Sockets are recommended for use with 6 x 19 or 6x 37 IPS or XIP EIP X XIP EEIP RRL FC or IWRC wire rope Before using any National Swage fitting with any other type lay construction or grade of wire rope it is recommended that the termination be destructive tested and documented to prove the adequacy of the assembly to be manufactured In accordance with ANSI B30 9 all slings terminated with swage sockets shall be proof loaded S 502 Closed Swage Sockets S 502 Closed Socket Specifications Press Die Data Before Swage Dimensions
34. move any non metallic coating from the broomed area Sockets with large grooves need to have those grooves filled before use with WIRELOCK Read understand and follow these instructions and those on product containers before using WIRELOCK The following simplified step by step instructions should be used only as a guide for experienced users For full information consult our document WIRELOCK TECH NICAL DATA MANUAL WIRE ROPE USER MANUAL by AISI and WIRE ROPE MANUFACTURERS CATA LOGS STEP 1 SOCKET SELECTION 1 WIRELOCK is recommended for use with Crosby 416 417 Spelter Sockets and GS 517 2 For use with sockets other than Crosby 416 417 consult the socket manufacturer or Crosby Engineering 3 Sockets used with WIRELOCK shall comply with Federal or International CEN ISO Standards 4 WIRELOCK as with all socketing media depends upon the wedging action of the cone within the socket basket to develop full efficiency A rough finish inside the socket may increase the load at which seating will occur Seating is required to develop the wedging action STEP 2 SEIZING Seize the wire rope or strand as shown using soft an nealed iron wire i i D MIN 5D or 50d d Diameter of the largest wire WHICHEVER IS GREATER Strand Wire Rope 52 STEP 3 BROOMING 1 Unlay the strands of the wire rope and IWRC as far as the seizi
35. nc 4 All Rights Reserved Shank Hooks for Swaging QUIC CHECK Wide range of sizes available e Working Load Limit 0 35 14 tonnes e Wire Rope sizes 5mm thru 30 mm e Utilizes standard Crosby 319N shank hooks with interlocking hook tip Each hook has a pre drilled cam which can be equipped with a latch e Utilizes standard National Swage swaging dies e Forged Carbon Steel e Quenched and Tempered Heat treat process allows for ease of swaging e Design Factorof 5to 1 e Black Oxide finish on body Shank is uncoated e All hooks incorporate Crosby s patented QUIC CHECK markin gs Angle Indicators and Throat Deformation Indicators See page 87 for detailed information For use with6 X 19 or 6 X 37 IPS or XIP EIP XXIP EEIP RRL FC or IWRC wire rope Before using any Crosby fitting with any other type lay construction or grade of wire rope it is recommended that the termination be destructive tested and documented to prove the adequacy of the assembly to be manufactured Refer to swage socket or swage button instructions in the National Swage Swaging Products and Procedures Brochure for proper swaging techniques S 319SWG Shank Hooks for Swaging Required Maximum Working i Swaging Die After Swage Load Limit S 319SWG Die Diameter t Stock No Description Stock No mm 1 8 Button pt 10530200057 1 4 Button 1058080 f 083 3 8 Socket 1192863 180 3 8 Socket Minimum Ultimate Str
36. ng 2 Cut out any fiber core 3 Unlay the individual wires from each strand including the IWRC completely down to the seizing 4 Remove any plastic material from broomed area Strand Wire Rope STEP 4 CLEANING 1 The method of cleaning will depend on the lubricant and or coating on the wire 2 The methods and materials used for cleaning should comply with the current EPA regulations 3 Consult the Wire Rope Technical Board your Wire Rope supplier or the Wire Rope Manufacturer for recom mended materials and methods 4 The currently recommended Trichlorethane does not comply with the Clean Air Act of 1990 Section 611 Ozone Depletion Substances Degreaser Copyright 2002 The Crosby Group Inc All Rights Reserved STEP 5 POSITIONING OF SOCKET 1 Position socket over the broom until the wires are LEVEL with the top of the socket basket or to a minimum embedded length as shown 2 Clamp rope and socket vertically ensuring alignment of their axes 3 CAUTION DO NOT USE OVERSIZED SOCKETS FOR WIRE ROPE 30 D STRAIGHT BEFORE BEND 5D or 50d d Diameter of the largest wire WHICHEVER IS GREATER Wire Rope Strand STEP 6 SEAL SOCKET Seal the base of the socket with putty or plasticine to prevent leakage of the WIRELOCK e SS SS STEP 7 WIRELOCK KI
37. ng clean dry and free of lubrication WRONG Wedge Backward WRONG Tail Clipped to live Line Rope Backward Figure 2 Operating Safety Apply first load to fully seat the Wedge and Wire Rope in the socket This load should be of equal or greater weight than loads expected in use Efficiency rating of the Wedge Socket termination is based upon the catalog breaking strength of Wire Rope The efficiency of a properly assembled Wedge Socket is 80 During use do not strike the dead end section with any other elements of the rigging Called two blocking Copyright 2002 The Crosby Group Inc All Rights Reserved WEDGE SOCKET WARNING AND APPLICATION INSTRUCTIONS 9 421 US 422 Important Safety Information Read and Follow Inspection Maintenance Safety Always inspect socket wedge and pin before using Do not use part showing cracks Do not use modified or substitute parts Repair minor nicks or gouges to socket or pin by lightly grinding until surfaces are smooth Do not reduce Original dimension more than 10 Do not repair by welding Inspect permanent assemblies annually or more often in severe operating conditions Do not mix and match wedges or pins between mod els or sizes Always select the proper wedge and socket for the wire rope size Assembly Safety Use only with standard 6 to 8 strand wire rope of Loads may slip or fall if the Wedge Socket is not pro
38. ns with 8 or more outer strands ensure that the dead end is welded brazed or seized before inserting the wire rope into the wedge socket to prevent core slippage or loss of rope lay The tail length of the dead end should be a minimum of 20 rope diameters but not less than 6 See Figure 1 Properly match socket wedge and clip See Table 1 to wire rope size Align live end of rope with center line of pin See Figure 1 Secure dead end section of rope See Figure 1 Tighten nuts on clip to recommended torque Table 1 Do not attach dead end to live end or install wedge backwards See Figure 2 Use a hammer to seat Wedge and Rope as deep into socket as possible before applying first load Loads may slip or fall if the Wedge Socket is not properly installed A falling load can seriously injure or kill Read and understand these instructions before installing the Wedge Socket Do not side load the Wedge Socket Apply first load to fully seat the Wedge and Wire Rope in the socket This load should be of equal or greater weight than loads expected in use Do not interchange wedges between S 421T and US422T or between sizes FIGURE 1 A TAIL LENGTH Standard 6 to 8 strand wire rope A minimum of 6 rope diameters but A minimum of 20 rope diameters but not less than 150 mm not less than 150 mm Clip Size The tightening torque values shown are based upon the threads bei
39. ogressive swaging of fittings must be done in ac cordance with procedure shown in Swaging Prod ucts and Procedures booklet Only open channel dies are to be used Stop swaging when the cavity side of both dies touch Make sure part is swaged to the recommended after swage dimensions See Crosby General Catalog or National Swage Brochure Die Guide or Die Chart If a swage fitting other than a Crosby National is used determine adequacy of the termination by a destruc tive pull test All swage sockets must be swaged with socket head adjacent to the socket relief largest radius on the die For special applications or conditions contact Crosby National Misuse of swaging machine can result in serious injury or death READ UNDERSTAND AND FOLLOW all the information in this warning document and the instructions shown in Swaging Products and Procedures booklet before operating the swaging machine Swaging machine operators must be trained in accordance with the information supplied by The Crosby Group Inc The swaging ma chine owner is responsible for the training and the safe operation of the swaging ma chine Do not swage oversize parts Only swage parts of the proper design material and hardness If misused dies and or die holders may break PROTECT YOURSELF AND OTHERS Always stay away from the sides of the swaging machine during swaging operations and alert others in your work area Keep head hand
40. ond clip firmly but do not tighten Proceed to Step 3 Figure 1 Figure 2 Copyright 2002 The Crosby Group Inc All Rights Reserved 3 When three or more clips are required space additional clips equally between first two take up rope slack tighten nuts on each U Bolt evenly alternating from one nut to the other until reaching recommended torque SSC Figure 3 NOTE D TREAD DIAMETER airy ma 1 CLIP BASE WIDTH 4 If a pulley sheave is used in place of a thimble add one additional Fist Grip Fist Grip spacing should be as shown Figure 4 5 WIRE ROPE SPLICING PROCEDURES The preferred method of splicing two wire ropes together is to use inter locking turnback eyes with thimbles using the recom mended number of clips on each eye See Figure 5 An alternate method is to use twice the number of clips as used for a turn back termination The rope ends are placed par allel to each other over lapping by twice the turn back amount shown in the application instruc tions The minimum number of clips should be installed on each dead end See Figure 6 Spacing installation torque and other instruc tions still apply Q g SSSSSSSSSS 6 Sf A Dy Nf Vo yy gt ia XJ XI Ww Ww DEAD END La LIVE END Figure 6 6 IMPORTANT Apply first load to tes
41. or RLL wire rope 6 x 19 or 6 x 37 Class FC or IWRC IPS or XIP XXIP If Seale construction or similar large outer wire type con struction in the 6 x 19 Class is to be used for sizes 25 mm and larger add one additional clip If a pulley sheave is used for turning back the wire rope add one additional clip The number of clips shown also applies to rotation resistant RRL wire rope 8 x 19 Class IPS XIP XXIP sizes 38 mm and smaller and to rotation resistant RRL wire rope 19 x 7 Class IPS XIP XXIP sizes 38 mm and smaller For other classes of wire rope not mentioned above we recom mend contacting Crosby Engineering at the address or telephone number on the back cover to ensure the desired efficiency rating The style of wire rope termination used for any application is the obligation of the user For OSHA Construction applications see OSHA 1926 251 1 Refer to Table in following these _ a lt instructions Turn back specified ee amount of rope from thimble or loop Apply first clip one base width from dead end of rope Tighten nuts evenly alternating from one nut to the other until reaching the recommended torque 2 When two clips are required apply the second clip as near the loop or thimble as possible F Tighten nuts evenly alternating un til reaching the recommended torque When more than two clips are required apply the second clip as near the loop or thimble as possible turn nuts on sec
42. perly installed A falling load can seriously injure or kill Read and understand these instructions before installing the Wedge Socket Do not side load the Wedge Socket Do not interchange Crosby wedge socket wedge or pin with non Crosby wedge socket wedge or pin Apply first load to fully seat the Wedge and Wire Rope in the socket This load should be of equal or greater weight than loads expected in use Do not interchange wedges between S 421 and US 422 or between sizes Length Wrong designated size For intermediate size rope use next larger size socket For example When using 9 16 diameter wire rope use a 5 8 size Wedge Socket Assembly Welding of the tail on standard wire rope is not recommended The tail length of the dead end should be a minimum of 6 rope diameters but not less than 6 Align live end of rope with center line of pin See Figure 1 Secure dead end section of rope See Figure 1 DO NOT ATTACH DEAD END TO LIVE END See Figure 2 Use ahammer to seat Wedge and Rope as deep into socket as possible before applying first load Touse with Rotation Resistant wire rope special wire rope constructions with 8 or more outer strands ensure that the dead end is welded brazed or seized before inserting the wire rope into the wedge socket to prevent core slippage or loss of rope lay The tail length of the dead end should be a minimum of 20 rope diameters but not less
43. provides forged Red U Bolt Clips and forged Fist Grip Clips which meet or exceed Federal Specification Number FF C 450 and are considered the industry standard Only Crosby provides forged Red U Bolt Clips from 1 8 to 3 1 2 and forged Fist Grip Clips from 3 16 through 1 1 2 The 3 1 2 base is a steel casting Crosby clearly embosses its logo the size and the Product Identification Code PIC into all Crosby Red U bolt Clip bases and Fist Grip clips Crosby s traceability system is actively used throughout the manufacturing of forged clips The material analysis for each heat of steel is verified within our own laboratory Crosby provides detailed application and warning information for all forged clips Each clip is individually bagged or tagged with the application and warning information Testing and evaluation of special applications can be performed upon special request When buying Crosby you re buying more than product you re buying Quality Copyright 2002 The Crosby Group Inc All Rights Reserved Crosby Value Added Full Line Crosby provides both forged Red U Bolt Clips and forged Fist Grip Clips Forged Crosby Red U Bolt Clips have forged bases on all sizes except 3 1 2 the 3 1 2 base is a steel casting The entire clip is galvanized to resist corrosive and rusting action Clip sizes 1 8 through 1 1 2 have U Bolts with rolled threads which enhance th
44. r material traceability the name CROSBY or CG and a size forged into it Entire clip is made from 316 Stainless Steel to resist corrosive and rusting action All components are Electro Polished All Clips are individually bagged or tagged with proper application instructions and warning information Std Weight Dimensions SS 450 Package Per 100 Stock No Qty kg 28 Copyright 2002 The Crosby Group Inc All Rights Reserved Fist Grip Wire Rope Clips NEW STYLE e Bolts are an integral part of the saddle Nuts can be installed in such FIST GRIP FIST GRIP CLIPS a way as to enable the operator to swing the wrench ina full arc for CLIPS 5MM 16MM nsialiahon 19 MM 38 MM e All sizes have forged steel saddles e All Clips are individually bagged or tagged with proper application instructions and warning information e Assembled with standard heavy hex nuts ao e Entire clip is Galvanized to resist corrosive and rusting action l Fist Grip wire clips meet or exceed the performance requirements of FederalSpecification FF C 450 Type III Class 1 except for those provi sions required of the contractor G 429 Package Per 100 mm mmy Stock No Qty kg c f d TE GN 8 mws 0 _ 7 n9 9 25 s3 7 _ AOD Sizes through 16mm incorporate New Style design Copyright 2002 The Crosby Group Inc 29 All Rights Reserved S 421T Wedge Sockets QUIC CHECK
45. r pin or bolt nut and pin may be mended that the termination be destructive tested and docu used for lifting personnel mented to prove the adequacy of the assembly to be Hook must always support the load The load must manufactured never be supported by the latch Use only Crosby shank hooks designed exclusively for Never exceed the Working Load Limit WLL of the swaging wire rope and hook system A visual periodic inspection for cracks nicks wear gouges Read and understand National Swage Swaging and deformation as part of a comprehensive documented Products and Procedures manual before swaging inspection program should be conducted by trained person the hook nel in compliance with the schedule in ANSI B30 10 For hooks used in frequent load cycles or pulsating loads the hook should be periodically inspected by Magnetic Particle or Dye Penetrant Never use a hook whose throat opening has been increased or whose tip has been bent more than 10 degrees out of plane from the hook body or is in any other way distorted or bent Note A latch will not work properly on a hook with a bent or worn tip Never use a hook that is worn beyond the limits shown in Figure 1 Remove from service any hook with a crack nick or gouge Hooks with a crack nick or gouge shall be repaired by ZONE A REPAIR NOT REQUIRED grinding lengthwise following the contour of the hook pro ZONE B 10 OF ORIGINAL DIMENSION vided that the red
46. s and body away from moving swaging machine and die parts Consult die manufacturer for correct use of their product Adjust swaging machine tonnage to the Working Load Limit WLL tonnage shown on the die block being used If the Working Load Limit is not legible refer to Die height amp width and corresponding Working Load Limit See Table 1 Failure to do so can result in serious injury or death TABLE 1 Die Size Working Load Limit Height x Width WLL 2 x 3 1 2 200 Ton Mark Series 2 1 2 x 4 200 Ton National 2 1 2 x 5 500 Ton Mark Series 4 x 7 1 200 Ton Mark Series 5 x 7 1 500 Ton National 6 x 12 3 000 Ton National Note These Working Load Limits are for Crosby National Die Blocks only The Working Load Limits of die blocks from other manufacturers may vary Copyright 2002 The Crosby Group Inc All Rights Reserved Inspect the rods for corrosion Use 000 emery cloth or steel wool to maintain a high polish surface Do not increase the hydraulic system pressure above the factory preset pressure of 6500 psi for 500 ton 1000 ton and 1500 ton swaging ma chines 5000 psi for 3000 ton swaging machine Under ordinary operating conditions drain and clean reservoir every two 2 years Filters inside of the reservoir should be cleaned every time the reservoir is drained and cleaned The Racine tell tale suction filter should be cleaned every six 6
47. t the assembly This load should be of equal or greater weight than loads expected in use Next check and retighten nuts to recommended torque In accordance with good rigging and maintenance practices the wire rope end termination should be inspected periodically for wear abuse and general adequacy Table 1 Clip Rope Minimum Amount of Rope to Torque Size Size No of Turn Back in in Inches mm Clips mm Nm 3 16 5 2 100 40 7 1 4 6 7 2 100 40 7 5 16 8 2 127 40 7 3 8 9 10 2 133 61 0 7 16 11 12 2 165 88 1 1 2 13 3 279 88 1 9 16 14 15 3 323 176 5 8 16 3 342 176 3 4 18 20 3 406 305 7 8 22 4 660 305 1 24 25 5 940 305 1 1 8 28 30 5 1040 488 1 1 4 32 34 6 1400 488 1 3 8 36 6 1570 678 1 1 2 38 40 7 1980 678 If a pulley sheave is used for turning back the wire rope add one additional clip See Figure 4 If a greater number of clips are used than show in the table the amount of turnback should be increased proportionately The tightening torque values shown are based upon the threads being clean dry and free of lubrication 47 Q WEDGE SOCKET WARNINGS AND APPLICATION INSTRUCTIONS C Extended Wedge Socket Assembly U S Patent No 5 553 360 RG D S lo S 421T amp US 422T TERMINATOR NOTE Existing Crosby S 421 Wedge Sockets can be retrofitted with the New Terminator Wedge The Only existing US 422 Wedge Sockets th
48. tates a 1000 cc 12 1039608 2 08 1039609 American Bureau of Shipping 2000 cc 12 1039610 4 08 1039611 Guide to amount of WIRELOCK Required Wire Rope WIRELOCK Wire Rope WIRELOCK Size Required Size Required cc cc 6 7 9 44 700 U S Department 8 17 48 700 of Transportation 9 10 17 51 1265 United States 11 35 54 1265 Coast Guard 13 35 56 1410 NATO Numbers ie ae pe eal 100cc 8030 21 902 1823 16 92 oe LLE 250cc 8030 21 902 1824 20 86 67 1830 500cc 8030 21 902 1825 22 125 70 2250 1000cc 8030 21 902 1826 26 160 76 3160 Witnessed and tested by American Bureau of Shipping 28 210 82 3795 AB eee 32 350 88 4920 Approximate U S Measurements 36 350 94 5980 250cc s Kit 1 Cup 500cc s Kit 1 Pint 7 i ue as 1000cc s Kit 1 Quart Copyright 2002 The Crosby Group Inc All Rights Reserved CROSBY CLIPS WARNINGS AND APPLICATION INSTRUCTIONS PEN pi di tN G 450 SS 450 Red U Bolt 316 Stainless Steel Failure to read understand and follow these instructions may cause death or serious injury Read and understand these instructions before using clips Match the same size clip to the same size wire rope Prepare wire rope end termination only as instructed Do not use with plastic coated wire rope Apply first load to test the assembly This load should be of equal or greater w
49. than 6 See Figure 1 Tail Length Standard 6 to 8 strand wire rope A minimum of 6 rope diameters but not less than 6 i e For 1 rope Tail Length 1 x 6 6 Rotation Resistant Wire Rope A minimum of 20 rope diameters but not less than 6 i e For 1 rope Tail Length 1 x 20 20 Figure 1 Figure 2 Operating Safety Apply first load to fully seat the Wedge and Wire Rope in the socket This load should be of equal or greater weight than loads expected in use Efficiency rating of the Wedge Socket termination is based upon the catalog breaking strength of Wire Rope The efficiency of properly assembled Wedge Socket is 80 During use do not strike the dead end section with any other elements of the rigging Called two block ing Copyright 2002 The Crosby Group Inc 49 All Rights Reserved CROSBY SHANK HOOKS FOR SWAGING S 319SWG WARNING AND APPLICATION INSTRUCTIONS Loads may disengage from hook if proper procedures are not followed A falling load may cause serious injury or death See OSHA Rule 1926 550 g for personnel hoisting by cranes or derricks A Crosby 319 hook with a PL S 319SWG hooks are recommended for use with 6 x 19 or Latch attached when secured with bolt nut and rope Before using any National Swage fitting with any other S 319N hook with an S 4320 Latch attached when type lay construction of grade of wire rope it is recom secured with cotte
50. tion applications see OSHA 1926 251 1 ee SSE TY Refer to Table in following SS RRA these instructions Turn back specified amount of rope from thimble or loop Apply first clip one base width from dead end of rope Apply U Bolt over dead end of wire rope live end rests in saddle Never saddle a dead horse Tighten nuts evenly alter nate from one nut to the other until reaching the recommended torque 2 Figure 1 2 f a hn tn et ee eee y Sa 1 SSS RL D Figure 2 When two clips are required apply the second clip as near the loop or thimble as possible Tighten nuts evenly alternating until reaching the recommended torque When more than two clips are required apply the second clip as near the loop or thimble as possible turn nuts on second clip firmly but do not tighten Proceed to Step 3 46 a When three or more clips are required space additional clips equally between first two take up rope slack tighten nuts on each U Bolt evenly alternating from one nut to the other until reaching recommended torque Figure 3 E D TREAD DIAMETER 4 m D NOTI If a pulley sheave ae is used in place of a thimble add one additional clip Clip spacing should be as shown Figure 4 5 WIRE ROPE SPLICING PROCEDURES The preferred method of splicing two wire ropes together is to use inter locking turnback eyes with thimbles using the recom mended number of
51. tions in National Swagin g Brochure e Swage sockets incorporate a reduced machined area of the shank which is equivalent to the proper after Swage dimension Before swaging this provides for an obvious visual difference in the shank diameter After swaging a uniform shank diameter is created allowing for a QUIC CHECK and permanent visual inspection opportunity e Designed to quickly determine whether the socket has been through the swaging operation and assist in field inspections it does not eliminate the need to T standard production inspections which include gauging for the proper after swage dimensions or proof loading e U S Patent 5 152 630 and foreign equivalents NOTE S 501 Swage Sockets are recommended for use with 6 x 19 or 6x 37 IPS or XIP EIP X XIP EEIP RRL FC or IWRC wire rope Before using any National Swage fitting with any other type lay construction or grade of wire rope it is recommended that the termination be destructive tested and documented to prove the adequacy of the assembly to be manufactured In accordance with ANSI B30 9 all slings terminated with swage sockets shall be proof loaded S 501 Open Swage Sockets S 501 Open Socket Specifications Press Die Data Before Swage Dimensions StockNo SideLoad Rope Size Weight 1500 3000 mm im i Ton Ton mm Description 6x12 6x12 1089021 6 7 0 24 122 127 35 1 17 5 6 54 0 175 10219 38 1 117 1 4 Socket
52. uced dimension is within the limits shown ZONE C 5 OF ORIGINALK DIMENSION in Figure 1 ZONE D SEE MIMIMUM THREAD SIZE CHART FIGURE 1 50 Copyright 2002 The Crosby Group Inc All Rights Reserved Never repair alter rework or reshape a hook by welding heating burning or bending Never side load back load or tip load a hook See Figure 2 The use of a latch may be mandatory by regulations or safety codes e g OSHA MSHA ANSI ASME B30 insurance etc Note When using latches see instructions in Understanding The Crosby Group Warnings for further information Always make sure the hook supports the load See Figure 3 The latch must never support the load See Figure 4 Side Load Back Load Tip Load When placing two 2 sling legs in hook make sure the angle from the vertical to the outermost leg is not greater than 45 WRONG degrees and the included angle between the legs does not exceed 90 degrees See Figure 5 FIGURE 2 For angles greater than 90 degrees or more than two 2 legs a master link or bolt type anchor shackle should be used to attach the legs of the sling to the hook See ANSI ASME B30 10 Hooks for additional information In accordance with ANSI B30 9 all slings terminated by swag ing shall be proof tested S 319SWG hooks are designed to be a component of a system and therefore rated based on the working limit of the system of which they are attached The fr

Wire Rope End Terminations

Contents

Download Pdf Manuals

Related Search

Related Contents