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WIRE ROPE END TERMINATIONS

1. NOTE Length is measured from outside end of termination Copyright 2012 The Crosby Group LLC 43 All Rights Reserved Button Terminations 1 7 S 409 Button Terminations 1 8 1 through 7 8 14 See page 45 for larger sizes Buttons are swaged in open channel dies Refer to the chart on page 43 for proper die selection To swage the button use the following procedure Step 1 Slide wire rope through button until the end of the wire rope protrudes a minimum of 1 8 rope diameter from the end of the button After swaging the rope should be about flush with the button end Step 3 1st pass allow dies to remain open approximately 1 2 the distance from the time initial contact is made between the button and dies Open dies and rotate fitting 45 to 90 degrees Step 5 4th pass if sharp flashing does not occur close dies Open dies and rotate fitting 45 to 90 degrees Step 2 Lubricate both die cavities and lower die face See page 43 for proper die selection Step 4 2nd and 3rd passes allow dies to remain open approximately 1 2 the distance from the time initial contact is made between the button and dies Open dies and rotate fitting 45 to 90 degrees between passes Step 6 5th and 6th passes Rotate fitting 45 degrees 1 8 turn Close dies to round fitting Open dies and rotate fitting 45 to 90 degrees between passes Open dies and ch
2. 20 LOAD KN 9 10 1 6 x 36 I W R C 0 0 1 2 3 4 MOVEMENT mm Fig Il Movement within the socket under load for the two extreme angles and the standard 140 taper 88 Copyright 2012 The Crosby Group LLC All Rights Reserved Resin Socketing of Steel Wire Rope The mechanism of this movement and wedging action were investigated by looking at the distribution of pressure through the socket This showed that approximately two thirds of the total pressure within the socket was concentrated in the bottom third of the socket Whilst pressure at the top of the socket was very low indeed It is necessary to explain why any movement is possible within the socket and to link it with the pressure distribution findings above When the resin is first poured into the socket there is a perfect match between the shape of the socket and the resin cone Once the resin has cured however shrinkage occurs and in an exaggerated form the effect is as below Fig III Exaggerated Relationship between Cone and Socket after the Resin has cured Figure Ill When the load is applied to the rope any adhesion of the resin to the socket will shear and the cone which is now slightly smaller will begin to engage the socket wall at the neck of the socket thereby generating pressure Although it still retains a high modulus the resin in contact with the socket is subject to plastic deformation and some flow is possible allowing mo
3. Dross The impurities that form on top of the molten metal EIP Extra Improve Plow Steel A grade of wire rope End Termination The treatment at the end or ends of a length of wire rope usually made by forming an eye or attaching a fitting and designed to be the permanent end termination on the wire rope that connects it to the load Eye or Eye Splice A loop with or without a thimble formed at the end of a wire rope Fatique Rated Tested to a minimum standard of 20 000 cycles at 1 5 times the Working Load Limit Will meet the requirements of the Euronorm standards for fatique FC Fiber Core Cord or rope of natural or synthetic fiber used as the axial member of a strand Fist Grip Wire Rope Clips Fitting for clamping parts of wire rope to each other to form an eye or splice Crosby G 429 Fist Grip Clips Flashing Occurs when sleeve or socket material flows out into the area between the die faces See picture Flemish Eye A mechanical splice termination formed by unlaying the end of the rope body into two parts and forming an eye by looping the two parts in opposite directions and laying the rope back together A swaged metal sleeve secures the ends to the body of the sling See page 26 Full Die A process where the complete fitting is inserted into the die and swaged following specific swaging procedures for the product Full Shank A process where the full shank length of the fitting
4. For elevator personnel hoist and scaffold applications refer to ANSI A17 1 and ANSI A10 4 These standards do not recommend U Bolt style clips Copyright 2012 The Crosby Group LLC All Rights Reserved Maritime The maritime standards are divided into the following categories Ship Repairing Shipbuilding Ship Breaking Longshoring and Gear Certification Vessel Gear and Shore Based Gear The use of wire rope clips to form eyes in wire rope and wire rope slings is allowed in Ship Repairing Shipbuilding and Ship Breaking In Longshoring Subpart F 1918 52 Specific requirements a 2 reads Wire rope clips or knots shall not be used to form eyes in or join sections of preventer guys Also 1918 52 Specific Requirements c 3 reads Eyes in the ends of wire rope cargo falls shall not be formed by knots and in single part falls shall not be formed by wire rope clips In gear certification Subpart D 1919 24 Limitations on use of wire rope c reads Eyes in the ends of wire rope cargo falls shall not be formed by knots and in single part falls shall not be formed by wire rope clips ASME B30 26 Saddles shall be forged steel Each wire rope clip saddle shall have forged or die stamped markings by the manufacturer to show 1 Name or trademark of manufacturer 2 Size Crosby clips exceed ASME B30 26 identification requirements Shock loading should be avoided per ASME B30 26 See ASM
5. Load misapplied in direct contact with the wedge can dislodge the wedge amp cause loss of load 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 wedge between S 421 and US 422 or between sizes 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 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 blocking Do not allow a direct load to contact the wedge rev 4 104 Copyright 2012 The Crosby Group LLC All Rights Reserved SUP
6. 131 119 94 718 94 116 278 3 21 275 2 00 76 1 1053057 98 484 48 100 144 163 150 131 870 113 141 347 3 92 3 25 2 50 _ 1 2 12 13 1053066 98 484 55 100 144 163 150 131 870 113 141 347 3 92 3 25 2 50 _ 3 4 18 1053003 155 754 80 150 2 26 263 241 188 1263 163 222 5 25 6 00 4 25 4 00 Copyright 2012 The Crosby Group LLC 51 All Rights Reserved 1053048 3 8 Socket 1192863 4 4 5 7 M 7 9 O i 9 3 DZ CROSBY SHANK HOOKS FOR SWAGING WARNINGS AND APPLICATION INSTRUCTIONS S 319SWG S 319SWG hooks are recommended for use with 6 x 19 or 6 x 36 IPS or XIP EIP XXIP EEIP RRL FC or IWRC wire rope Before using any National Swage fitting with any other type lay construction of 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 Use only Crosby shank hooks designed exclusively for swaging A visual periodic inspection for cracks nicks wear gouges and deformation as part of a comprehensive documented inspection program should be conducted by trained personnel 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 op
7. Give conscious victims water and induce vomiting Seek medical attention SECTION VII PRECAUTIONS FOR SAFE HANDLING AND USE Steps to take in case material is released or spilled Evacuate personnel not equipped with proper protective clothing and devices Ventilate the area of the spill Keep spill from incompatible materials it may come in contact with Waste Disposal Method Dibenzoyl Peroxide Submerge excess in minimal volume of water treat small volumes at a time in 10 Sodium Hydroxide solution dispose of slurry in sanitary landfill Large quantity spills should be absorbed in minimal quantities of Vermiculite dry sand or earth Dispose of in sanitary landfill Precautions to take in handling and storing Do not attempt to capture Dibenzoyl Peroxide in material such as wood paper or other combustible material See also section V Incompatibilities Other Precautions Store in a cool well ventilated area away from excessive heat and sources of ignition Do not smoke around WIRELOCK booster packs SECTION VIII CONTROL MEASURES Respiratory Protection Specify type gt 0 5 Half Face Air Purifying Respirator lt 5ppm gt 5 Full Face Air Purifying Respirator lt 2 5ppm gt 2 5 Powered Air Purifying Respirator lt 50ppm gt 50 Supplied Air Pressure Demand lt 500ppm Self Contained Breathing Apparatus gt 500ppm Cartridge Type Dust Mist Ventilation Local Exhaust Dilution
8. RRL FC or IWRC wire rope NOTE See page 24 for dimensional Cross Section of Before using any National Swage fitting with any other type lay information Swaged Sleeve 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 National QUIC PASS Swaging System me The Next Generation in Swaging Systems The QUIC PASS swaging system allows Flemish style wire rope terminations to be swaged in only two passes This is accomplished while maintaining currently published efficiency ratings and utilizing National Swage S 505 Standard COLD TUFF Steel Sleeves e Allows the swaging process to be completed in just two passes resulting in a 50 75 reduction in the number of passes required with conventional swaging systems e Allows the dies to close completely with each pass resulting in e An increase in overall swaging process efficiencies the job can be performed quicker e A reduction in the complexity of swaging the concern for excess flashing between dies has been eliminated e A reduction in training time needed for operators more user friendly e The finished sleeve has a Hex appearance that provides a QUIC CHECK look to determine if the termination has been swaged and provides a flat surface that allows for ease of I D stamping on the finished sleeve For additional swaging in
9. Step 5 1st pass Place sling eye in the vertical plane and close dies completely Open dies and rotate fitting one flat 60 Oozing of the oil from between the die faces will indicate when dies are fully closed Step 7 Open dies and check for proper after swage dimensions Use a National QUIC PASS No Go Gauge to check the after swage dimensions to ensure that it has been swaged to the proper dimension When swaged properly the gauge will slide up and down the full length of the sleeve on all three sets of opposing flats See page 18 for proper use of No Go Gauges Note Use only No Go Gauges designed for QUIC PASS systems Copyright 2012 The Crosby Group LLC All Rights Reserved Step 2 Construct 7 Flemish Eye See page 28 man for assembly instructions s Step 4 Oil lubricate both cavities top and bottom and lower die face as well as the sleeve See page 24 for proper die selection Oil lubrication is critical in order to obtain proper after swage dimensions and performance Step 6 2nd pass Close dies completely Dies must be fully closed in both passes before swaging is complete Swage Fittings Sockets Swaging Methods for S 501 and S 502 National S 501 and S 502 Carbon Steel Swage Sockets are designed for swaging in National dies These swage fittings are designed to be used on one 1 part of 6 X 19 or 6 X 36 IPS or XIP EIP RRL FC or IWRC wi
10. in 1 4 8 1 2 8 4 8 1 319C Style Hook Copyright 2012 The Crosby Group LLC All Rights Reserved a PEA n ri Side Load WRONG AA Back Load WRONG WRONG Figure 2 Top Load 7 Figure 3 Required Swaging Die 1192845 1 4 Swage Button Die 3 1 1 8 Swage Button Die Figure 4 Figure 5 Maximum After Swage Dimensions 1191621 1 4 Swage Button Die 1192863 3 8 Swage Button Die 1192863 3 8 Swage Button Die 53 Swage Hook Terminations 346 1 S 319SWG Swage Hooks 3 16 through 1 See page 55 for larger sizes S 319SWG Swage Hooks are swaged in specially designed National Swage dies with a relief and extra length All hooks should be swaged full shank To swage the hook use the following procedure Step 1 For proper insertion mark rope using Column F Dimension on page 51 Step 3 Lubricate both die cavities and lower die face See page 51 for proper die selection Step 5 2nd pass allow dies to remain open approximately Y the distance from time initial contact is made between hook and dies Rotate fitting 45 to 90 degrees Step 2 Slide rope into hook until it is fully inserted in the shank Inspect mark for full insertion Step 4 1st pass allow dies to remain open approximately 1 2 the distance from time initial contact is made between hook and dies Rotate fitting 45 to 90 degrees Ste
11. the POSWU group WIRE ROPE END User s Manual Featuring Application and Installation Procedures for National Swage Fittings Crosby Spelter Sockets Crosby Mooring Sockets Crosby Wedge Sockets Crosby Wire Rope Clips WIRELOCK Socketing Resin Table of Contents Wire Rope End Termination User s Manual SPS all MMO el UL OM yas aseatrcericrssarsanetdetasearciantinoste taanersatananuasasines utaniun E 1 General Cautions and WaMMINGS w si c scc ce00sccedecenedcgesvaiied caenedesdcusessdadaeecentasiegeccteasandcedsundedesdeneeddedenedesagusvereeseeeesdbedessdoosesess 2 LS TNT ONS site orca ntiestvnce cote aidiraastteherlaw Vance vibe otc che tii densa p inte xine a aa dank VisiwiuasaMiihiwadene adee vey smaeseinprs aieas 3 5 SACS TSUNEO YS sessin ceim vines treasury E dea ates learn orcs E odie Oatecios nehe den isuluatintectesn ce 7 56 Swaging Machines Sleeves Sockets Buttons Hooks Die Selection Swaging Instructions IOSD SCHON TOMI ONS esd ce cance sets ecc tere EE E E 57 67 Spelter Sockets Button Sockets Mooring Sockets WIRED aeoea RE ERE E S E EA E E 69 95 Preparation Pouring Testing Approvals MSDS Wedge Socket Terminations ssiscesacsssidnesesahinesugsnetsitevamentadivnaaase nsisvenastivadidentinentdidamaaeustsitsinnsshsieieabsiassgivenncuseuitena alchaitasstabe tales 97 106 Preparation Pouring Testing Approvals MSDS WV IS TODS OS aee a E E 107 116 U Bolt Fist Grip all the C
12. B C D E F J K L M 5 8 3 4 16 19 1052415 45 10 3 1052116 1052318 9 44 3 88 153 138 144 66 175 4 28 38 3 43 7 8 1 _ 22 26 1052433 82 29 2 1052134 1052336 12 88 5 48 2 03 2 00 2 00 89 2 44 5 62 62 4 52 Wirelock Requirements Size Required WIRELOCK Kit Size cc Stock No cc 68 34 1619 6o 1039602 100 2 kits required 66 Copyright 2012 The Crosby Group LLC All Rights Reserved Button Spelter Sockets CROSBY SPELTER BUTTON SB 427B APPLICATION INSTRUCTIONS This procedure is provided to give instructions for installation of wire rope into the Crosby SB 427B Spelter Button using WIRELOCK socketing material or zinc socketing material Additionally instructions regarding the reuse of spelter buttons are included The spelter button is part of a socket assembly that includes a socket basket pin cotter pin and button If there are any questions regarding these instructions please contact The Crosby Group LLC at 918 834 4611 and request technical assistance NOTE Many high performance ropes require special attention to prevent rope damage during cutting seizing and brooming in preparation for the speltering operation Attention to the special instructions is required to insure proper termination efficiency Consult rope manufacturer for specific details Installation Install button on the rope so that the live
13. Go 00 O oO a_i h oO O O a_i 220 00 276 00 313 00 400 00 31 00 3 3 4 4 t94 102 1005 1041857 1041866 542 00 33 25 Diameter of pin must not exceed pin used on companion 416 Socket Reference adjacent page D dimension t Cast Alloy Steel ioe oo N NO po Po Po cO 01 Co ho olon o1 M c O er re co O1 ho on a_i a_i on ro AJ D o o gt N Gl N o h N M O1 7 joy NO ol a_i a i N ol CO Ol O A NO ol N NO ol a_i AA NO ol a_i 62 Copyright 2012 The Crosby Group LLC All Rights Reserved Crosby Mooring Sockets Speltering Methods for G 517 Mooring Sockets Crosby Mooring Sockets are designed to be used in marine applications where attachment to shackles and connecting links is required Efficiency When properly fabricated all Crosby Mooring Sockets have a termination efficiency of 100 percent based on the minimum breaking force of the wire rope see table on page 58 Ratings for Crosby Mooring Sockets are based on recommended use with 6 x 7 6 x 19 or 6 x 36 IPS or XIP EIP XXIP EEIP RRL FC or IWRC wire rope Strand constructed with minimal number of wires e g 1 x 7 requires special consideration that socket basket be five 5 times the strand diameter or fifty 50 times the wire diameter whichever is the greater Before using any Crosby fitting with an
14. Mechanical General Other Preferred Chemical resistant made from materials not affected by contact with any of the individual mix components Protective Gloves i l Check with suppliers for suitable type s Eye Protection Splash goggles and face shield if mixing WIRELOCK Other Protective Equipment Impervious covering such as aprons and sleeves to cover bare skin or Clothing Work Hygienic Practices Avoid prolonged contact with Dibenzoyl Peroxide and any of the individual WIRELOCK mix components on bare skin Do not continue to wear clothing that becomes contaminated Also maintain personal protective equipment daily with thorough cleaning and rinsing Store PPE in a dry location safe from continued exposure 56 Copyright 2012 The Crosby Group LLC All Rights Reserved Resin Socketing of Steel Wire Rope Appendix B Resin Socketing of Steel Wire Rope J M Dodd B Sc Millfield Enterprises 16 Shelley Road Newburn Industrial Estate Newburn Newcastle upon Tyne NE15 9RT England The concept is not new The first published data on this topic were produced in the early sixties In essence these two papers by Doherty and Campbell stated that a resin filled socket under either static tension tensile or fluctuating tension fatigue could offer strengths that were comparable with those of the rope itself There is a dearth of information on socketing and the mechanisms by which it works
15. Step 4 2nd pass allow dies to remain open approximately 1 2 the distance from the time initial contact is made between the sleeve and dies Open dies and rotate fitting 45 to 90 degrees Step 6 4th pass If sharp flashing does not occur close dies Open dies and rotate fitting 45 to 90 degrees Step 2 Lubricate both die cavities and lower die face Step 3 1st pass allow dies to remain open approximately 1 2 the distance from the time initial contact is made between the sleeve and dies Open dies and rotate fitting 45 to 90 degrees Step 5 3rd pass allow dies to remain open approximately 1 2 the distance from the time initial contact is made between the sleeve and dies Open dies and rotate fitting 45 to 90 degrees Step 7 5th and 6th pass Close dies to round fitting Open dies and rotate 45 to 90 degrees between passes Open dies and check for proper after swage dimensions See Page 17 for proper use of No Go Gauges Additional swaging may be required to provide smooth finish and achieve proper after swage dimensions Dies must be fully closed before swaging is complete Copyright 2012 The Crosby Group LLC All Rights Reserved 49 Swage Fittings Hooks Swaging Methods for S 319SWG National S 319SWG carbon steel shank hooks are designed for swaging in National dies These swage fittings are designed to be used on one 1 part of 6 X 19 or 6 X
16. The preferred method would be a slow heat ina temperature controlled oven If a torch rosebud is used the heat spot shall be monitored with a tempil stick or a temperature indicator to prevent localized heating from exceeding the 850 F 450 C limit B To remove a WIRELOCK cone heat the surface of the socket button to 350 F 177 C Do not exceed the 850 F 450 C limit for any localized hot spot Leave for 5 10 minutes then drive the cone out with a hammer and drift Selection of Sockets and Buttons for Reuse 1 Use only sockets buttons that do not show discoloration from excessive heating or any signs of welding 2 Select only sockets buttons that have been cleaned and have passed a Magnetic Particle Inspection by a qualified technician Level Il ASNT SNT TC 1A 88 per ASTM E709 Acceptance criteria shall be per ASTM E125 Types II VIIl Degree 1 No cracks are acceptable 3 Select only sockets buttons that do not show any signs of overloading or wear on the socket or pin ie elongated pin holes undersized pins etc 4 Select sockets buttons that are free from nicks gouges and abrasions Indications my be repaired by lightly grinding until surfaces are smooth provided they do not reduce the dimensions by more than 10 of the nominal catalog dimension 5 Select sockets buttons that are not distorted bent or deformed Note Sockets Buttons having any of the indications as outlined above 1 5 shall not
17. Wire Rope Clips NEW STYLE e Entire clip is galvanized to resist corrosive and rusting action FIST GRIP FIST GRIP e Based on the catalog breaking strength of wire rope Crosby wire rope CLIPS CLIPS clips have an efficiency rating of 80 for 3 16 7 8 sizes and 90 for 3 4 1 1 2 3 16 5 8 sizes 1 through 1 1 2 G e Bolts are an integral part of the saddle Nuts can be installed in such a Fo way as to enable the operator to swing the wrench in a full arc for fast installation T gt e All sizes have forged steel saddles e All clips are individually bagged or tagged with proper application i instructions and warning information e Meets or exceeds all requirements of ASME B30 26 including l ai l identification ductility design factor proof load and temperature J requirements Importantly these wire rope clips meet other critical i in wi i e e e Er ye ed performance requirements including fatigue life impact properties and the performance requirements of S Federal Specification material traceability not addressed by ASME B30 26 FF C 450 Type II Class 1 except for those provisions required o the contractor For additional information see Crosby General Catalog G 429 Fist Grip Clips a a ene sep See Rope Size G 429 Package Per 100 in Stock No Qty bs C D E G N 1010471 100 233 40 94 38 141 144 a S a aS e a 15 86 181
18. may increase the load required to seat and wedge the cone within the socket They should be avoided whenever possible and a proof load applied not exceeding 60 of MBL if they must be used Alternatively they should be filled in with clay prior to placing the socket on the rope Copyright 2012 The Crosby Group LLC All Rights Reserved 12 WIRELOCK poured sockets should not be used in environments of strong caustic or acid solutions WIRELOCK is not affected by oils or grease or salt water 13 WIRELOCK is by design a compressive resin Therefore when removed from the socket a WIRELOCK cone if hit by a hammer may shatter In a socket even under extreme loads or shockloads the WIRELOCK cone remains solid and 100 efficient 14 The shelf life of WIRELOCK is eighteen 18 months check label before use from the date of manufacture Worldwide Agency Approvals Y Lloyds Register of Shipping Y Det Norske Veritas Y American Bureau of Shipping Y United States Coast Guard Y Registro Italiano Navale Y Germanischer Lloyd STANDARD CONSIDERATIONS ASME B30 9 All slings terminated with sockets shall be proof loaded The proof load shall be a minimum of 2 and a maximum of 2 1 2 times the single leg vertical hitch rated load The proof load should be that specified by the wire rope or fitting manufacturer s recommendation provided that it is within the above specified proof load range When sockets are
19. placing oil on the die faces and cavities When swaging the oozing of the oil from the die faces will indicate when the dies are closed At this point stop swaging Avoid Excess Flashing Flashing occurs when sleeve material flows out into the area between the die faces Once formed additional passes will not eliminate flashing They will only fold back the flash and develop a permanent mark in the material and possibly create a crack Flashing is not an issue with QUIC PASS system as each pass requires full closure of the dies To avoid excess flashing do the following e Select proper dies e Make sure that dies are in good condition and properly lubricated e Apply lubricant such as a light hydraulic oil to both d die cavities and the lower die face e Follow swaging instructions on pages 27 35 CORRECT EXCESS FLASHING 22 Identification Stamping For identification purposes National COLD TUFF swage products can be impression stamped after swaging Properly done there should be no concern for fractures initiating from such impressions To stamp S 505 Sleeves e Use round corner or low stress stamps Stamp to maximum depth of 0 015 in 1 64 e Stamp in area on the side of the sleeve in the plane of the sling eye and no less than 0 250 in 1 4 from either end of the sleeve NOTE WHEN USING NATIONAL QUIC PASS DIES THE FINISHED SLEEVE HAS A HEX APPEARANCE THAT
20. the minimum recommended design factor is 3 See OSHA and ASME for full information 59 Crosby Spelter Sockets Speltering Methods for G amp S 416 and 417 Sockets Crosby Spelter Sockets are available in both the closed and open design These types of poured sockets are generally used as a straight tension member They are commonly used on crane boom pendant lines and applications that require an anchoring system to be connected mechanically to a structure such as on bridges and roof systems They are also occasionally used on crane hoist lines to connect to a crane block or overhaul ball Efficiency When properly fabricated all Crosby Spelter Sockets have a termination efficiency of 100 percent based on the minimum breaking force of the wire rope see table on page 58 Ratings for Crosby Spelter Sockets are based on recommended use with 6 x 7 6 x 19 or 6 x 36 IPS or XIP EIP XXIP EEIP RRL FC or IWRC wire rope Strand constructed with minimal number of wires e g 1 x 7 requires special consideration that socket basket be five 5 times the strand diameter or fifty 50 times the wire diameter whichever is the greater 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 Installation Information General Overview 1 Th
21. time initial contact is made between hook and dies Rotate fitting 45 to 90 degrees Step 6 3rd pass If sharp flashing does not occur close dies Open dies and rotate fitting 45 to 90 degrees QUIC CHECK Step 7 4th pass Close dies to round Y fitting Open dies and check termination for proper after swage dimensions See page 17 for proper use of No Go Gauges Note Limited swaging capacity may require the use of progressive swaging See page 41 Additional swaging may be required to provide smooth finish and achieve proper after swage dimensions Dies must be fully closed before swaging is complete Copyright 2012 The Crosby Group LLC 55 All Rights Reserved Swage Terminal Assemblies Fatigue Life Relative Fatigue Life of Termination Assemblies The chart below indicates the relative fatigue life of wire rope termination assemblies utilizing Crosby swage fittings The findings are based upon the fatigue testing of assemblies under controlled laboratory conditions The chart is for comparison only not to determine the specific fatigue life values Refer to product section in this brochure to find the termination efficiency rating for each particular swaging product Efficiency is calculated as a ratio of the ultimate strength of the termination assembly compared to the minimum breaking force of the wire rope A rating is given for both Type and Type II products Relative Fatigue Lif
22. 26 66 3 25 1 06 1 88 2 38 1 8 6 1 12 5 1 1047459 15 0 1 60 6 1047468 12 5 16 34 9 19 _9 19 9 19 9 45 9 45 11 26 11 26 12 77 12 77 15 94 15 94 3 56 3 56 19 19 19 45 45 0 59 0 59 1 26 1 26 2 77 2 77 5 94 5 94 6 34 6 34 6 96 1 81 1 63 6 96 1 81 1 63 US11T_ 1 1 4 32 1044453 Non TERMINATOR Style Copyright 2012 The Crosby Group LLC 101 All Rights Reserved S 423T SUPER TERMINATOR Wedge sockets meet the performance requirements of Federal P RR S 550D Type C except those provisions require of the contractor Meets the erformance requirements of EN13411 6 2003 For additional information see Crosby General Catalog 102 e Wedge socket terminations have a minimum efficiency rating on most high performance high strength compacted strand rotation resistant wire ropes of 80 based on the catalog breaking strength of the various ropes e Patent Pending design eliminates the difficulty of installing high performance wire rope into a wedge socket termination e Proper application of the Super TERMINATOR eliminates the first load requirement of conventional wedge socket terminations e S 423TW Wedge Kit can be retrofitted onto existing Crosby S 421T TERMINATOR Wedge Sockets e Wedge and accessories provided with a zinc finish e Meets the performance requirem
23. 376 IPS or XIP EIP RRL FC or IWRC wire rope These products are designed to be used with inch size 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 Cold Swaging Process Cold swaging is a process which causes considerable movement and work hardening of the steel in the fitting Exerting extreme pressures the swaging machine forces the steel to flow into the crevices between the wires and strands of the wire rope At the same time the swaging machine forces the material to flow plastically along the length of the wire rope These are a few of the reasons swaging Is done in multiple passes in a well lubricated die Protecting Dies and Swaging Machine When the die lands touch each other effective swaging stops Additional swaging adds needless wear and strain on the dies and swaging machine We recommend placing oil on the die faces and cavities When swaging the oozing of the oil from the die faces will indicate when the dies are closed At this point stop swaging Avoid Excess Flashing Flashing occurs when socket material flows out into the area between the die faces Once formed additional passes will not eliminate flashing They will only fold back the flash and develop a permanent mark in the material and possibly cre
24. 75 294 267 Assembled with standard heavy hex nuts 9 16 5 8 14 16 1010550 3 4 18 20 1010578 1010596 Sizes through 5 8 incorporate New Style Design 1010612 Copyright 2012 The Crosby Group LLC 113 All Rights Reserved Wire Rope Clip Information Fist Grip Clip Installation Procedures WIRE ROPE CLIPS BASIC REQUIREMENTS r n AAN FOR PROPER SS SSSR SSS _ TERMINATION lt TURNBACK SELECT PROPER SIZE e a ee 6 CLIPS AND TURNBACK PLACE CLIPS ON IN PROPER SEQUENCE TORQUE ALL CLIPS EVENLY WITH A TORQUE WRENCH APPLY FIRST LOAD AND RE TORQUE WITH A TORQUE WRENCH POH651 Turnback is measured from the end of the rope to the base of the eye or to the thimble This part of the rope is often referred to as the dead end or dead horse Since the Fist Grip clip utilizes two saddles you do not have to be concerned with workers saddling the dead horse The table below defines the information required for each wire rope clip to achieve maximum efficiency Table 1 Amount of Minimum Rope to Torque Clip Size Rope Size No of Turn Back in in in Clips Ft Lbs in in In 3 16 4 1 4 a ae 5 16 se 3 8 7 16 7 16 dt 12 3 4 130 13 1 2 130 ches A A 5 1 2 11 3 4 16 225 7 8 6 1 37 1 1 8 1 1 4 1 3 8 500 1 1 2 7 500 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 us
25. 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 perform 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 6 x 36 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 In accordance with ASME B30 9 all slings terminated with swage sockets shall be proof loaded S 502 Closed Swage Sockets S 502 Closed Swage Socket Specifications Swager Die Data Before Swage Dimensions _StockNo Side Load in 502 1500 3000 Stock ae im Die Ton Ton KA in EE EN in Description 6x 12 6x 12 1039325 1 4 _ 33 4 28 EEJ z6 I REEN 46 1 4Socket_ 1192845 J l e a a S a 1039361 3 8 9 10 72 5 42 78 1 62 88 41 3 25 68 450 71 5 16 3 8Socket 1192863 1039389 7 16 11 12 142 6 88 1 01 2 00 1 07 49 4 31 87 5 75 91 7 16 1 2Socket 1192881 1039405 1 2 13 142 6 88 101 2 00 1 07 55 4 31 87 5 75 91 7 1
26. Die Data t QUIC PASS system not available for 12mm 20mm 24mm and 36mm wire rope sizes Before Swage Dimensions in Maximum Rope Size W After 500 Tons Front Load Side Load do O1 N Ql O N ro O N O1 N yN O1 sa yN N O NS o wN war oja _ iN N oo Ol O N ro oo h O oo ee 1041205 20 1041223 7 8 1041241 1 25 26 9 Q O i Swage 1000 Tons S 505 pa Pkg Dimensions Die 1500 Tons 1500 Ton 1500 Ton 3000 Ton Stock No n mm Qty in Description 5x7 6x12 6x12 1 3 4 Open 1041349 1 3 4 44 45 Bulk 3 84 1 94 1 97 3 13 3 10 1st Stage 1192685 DAE en 7 pet ie trfaro a0 2nd Stage 1192701 Bane 2 Open 1041367 2 50 52 1132 Bulk 8 50 4 38 2 25 2 25 3 63 3 56 1st Stage 1192729 2nd Stage 1192747 1041385 2 1 4 56 57 1936 Bulk 9 56 5 03 2 50 2 53 4 03 1st Stage 1192765 1191089 1191089 2nd Stage 1192783 1191043 1191043 1195067 2 1 2 Open 2nd Stage 1191089 1191089 1195469 1195085 2 3 4 Open 1041429 2 3 4 68 70 2800 Bulk 11 50 5 75 3 00 3 09 4 75 4 70 1st Stage 1191034 1191034 1195389 1195094 2nd Stage 1191052 1191052 1195478 1195101 1041447 75 76 2940 Bulk 12 00 3 25 3 38 5 00 4 96 1st Stage 1193201 1193201 1195398 1195110 2nd Stage 1193229 1193229 1195487 1195129 3 1 2 Open 2nd Stage 1193265 1193265 1195147 1041492 3 4 93 95 5500 Bulk 15 00 7 50 4 06 4 25 6 31
27. Hi after unlaid The rope ends to be socketed ul should be of sufficient length 3 2 D so that the end of the unlaid mM F wires from the strands will be at the top of the socket basket Seizing should be placed at a distance from the end equal to the length of the basket of the socket 1 Unlay the individual strands and fully broom out the wires of the wire rope and IWRC as far as the seizing The wires should be separated but not straightened 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 e 90 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 your Wire Rope supplier or Wire Rope manufacturer for recommended material and methods Follow the solvent supplier s recommendations for cleaning the broomed end i Thy E 1 h i i h li i hy i s wl 1 d a il d d r i ij oy j w j y Fi a 4 f p 4 NK 7e fa Degreaser rev 2 Copyright 2012 The Crosby Group LLC All Rights Reserved 1 STEP 5 POSITIONING OF SOCKET Position socket over the broom until it reaches the seizing on the wire rope The wires should be LEVEL with the top of the socket basket Clam
28. RRL Right Regular Lay Rope Strands of wire rope laid to the right with the wire in each strand laid to the left Right Regular Lay is recommended for use with Crosby National Swage Products Seale The name for a type of strand pattern that has two adjacent layers laid in one operation with any number of uniform sized wires in the outer layer and with the same number of uniform but smaller sized wires in the inner layer Shock Load A force that results from the rapid application of a force Such as impacting or jerking or rapid movement of a static load A shock load significantly adds to the static load Socket Generic name for a type of rope fitting used to terminate wire rope such as wedge socket spelter socket or swage socket Crosby 416 amp 417 Spelter Sockets Crosby 501 amp 502 Swage Sockets Crosby SB 427 Button Sockets Crosby 421T amp 423T Wedge Sockets and McKissick 422 Wedge Sockets 4 Copyright 2012 The Crosby Group LLC All Rights Reserved Spring Back A condition that occurs when swaging a fitting to form a termination whereby the material moves out a small amount when the dies are open Swaging Cold Pressing The process of mechanically forming a fitting onto the eye or end of wire rope Static Load The load resulting from a constant applied force or load Swaged Fitting Fitting into which wire rope can be inserted and then permanently attached by cold pressing swaging the s
29. Retention Wire Wire Rope Assembly with Round Pin Assembly with Bolt Nut S 423TW Dia and otter Pin and Cotter Pin Wedge Kit S 423T weigh Each S 423TB Weight Each S 423TW Weight Each es cnn StockiNes is Stock No Stock No E seg e a soe ooo ee 11 8 28 1035169 571 25 9 1035254 579 25 9 1034054 199 90 Kit contains Wedge Wire Rope Clip and Bolts Tensioner Tensioner Bolt and Secondary Retention Wire S 423T pe rea a yes ape epepetr jeja jr peaje rpo 3 4 18 19 1035132 9 88 5 20 1 50 1 38 3 25 4 81 2 44 5 37 14 69 1 40 2 62 66 3 63 88 765 3 02 Nominal NOTE For intermediate wire rope sizes use next larger size socket The S 423T Super TERMINATOR wedge is designed to be assembled only into the Crosby S 421T TERMINATOR Socket Body IMPORTANT The S 423TW for sizes 5 8 through 1 1 8 14mm through 28mm will fit respective size standard Crosby S 421T Basket The 1 1 4 30 32mm S 423TW will only fit the Crosby S 421T 1 1 4 basket marked with TERMINATOR Copyright 2012 The Crosby Group LLC All Rights Reserved WEDGE SOCKET WARNINGS AND APPLICATION INSTRUCTIONS Extended Wedge Socket Assembly U S Patent No 5 553 360 and Canada Patent No 2 217 004 C be Q WR 421T US 422T TERMINATOR NOTE The design of the basket for the S 421T 1 1 4 TERMINATOR Wedge Socket does not allow proper fit to the old styl
30. Rights Reserved 2 COLD TUFF virtually eliminates the cracking during the swaging process especially at extremely low temperatures 3 The steel microstructure created from the COLD TUFF heat treatment process reveals a uniform structure in the Crosby fittings that result in Charpy impact values averaging up to ten times greater than those of competitive products Un retouched Photomicrographs of Sleeve Original Magnification 500x Crosby COLD TUFF Heat Treatment The uniform microstructure of the COLD TUFF process results in superior ductility and toughness properties Competitor s Heat Treatment The non uniform microstructure may lack proper ductility and toughness required for swaging and use 4 The improved steel microstructure provides increased resistance to cracks that can occur during the sling building process Cracks are initiated at stress risers 5 Crosby COLD TUFF sleeves dramatically reduce the effects of stress risers that can occur during swaging where the cold worked sleeve makes contact with the wire Stress risers are not detectable through visual inspection Potential Stress Riser Area Swaged Sleeve Cross Section 6 Because of the higher Charpy values found in Crosby COLD TUFF sleeves stress risers caused by stenciling are not detrimental 7 Crosby or CG and COLD TUFF are clearly stenciled on every sleeve we make legible even after swaging lea
31. Sleeves using the QUIC PASS Swaging System QUIC PASS dies for National S 505 Standard Steel Sleeves 1 4 thru 1 1 2 are provided with one cavity National S 505 1 4 thru 1 1 2 sleeves are designed to be swaged in either National standard dies or National QUIC PASS dies The QUIC PASS Swaging System for a National 500 Ton Swaging Machine includes the QUIC PASS dies QUIC PASS die holders a special guide post system and QUIC PASS No Go Gauges The QUIC PASS die holder will also work with National 5 x 7 standard swaging dies The special guide post system is not required on National Swaging machines larger than 500 Tons QUIC PASS dies for other makes of swaging machines are available QUIC PASS Swaging procedures for other makes of swaging machines are the same as shown below Use only National S 505 Standard Steel Sleeves National S 505 Standard Steel Sleeves when used with the QUIC PASS Swaging System are only recommended for use with one 1 part 6 X 19 or 6 X 36 IPS or XIP EIP XXIP EEIP RRL IWRC wire rope Before using any National Swage QUIC PASS Swaging System 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 Step 1 Slide S 505 Standard Steel Sleeve over the wire rope Step 3 Slide S 505 sleeve fully over ends of wire rope to total sleeve depth
32. T40 1 31436 R1792 T40 3 31436 R1792 T40 5 average be Professor B G Clarke Head of Department Weight 101 3 102 2 102 7 104 0 103 2 103 0 Min Stress MPa 0 0 0 0 Copyright 2012 The Crosby Group LLC All Rights Reserved Height after grind mm 37D 37 5 37 3 3 5 37 37 5 Max Stress MPa 58 3 60 6 61 2 Width 39 1 39 1 39 1 39 6 39 6 39 6 0 243 0 263 0 234 Avery 250kN Compression Testing Machine Depth 39 6 39 6 39 6 39 6 39 6 39 6 Mean Strain Modulus of Elasticity N mm 1 20E 04 1 17E 04 1 27E 04 1 21E 04 Density Compressive Load Strength Mg m kN MPa 1 74 180 6 116 7 1 76 187 8 121 3 L77 189 6 122 5 L7 203 5 129 8 1 75 196 7 125 4 L 191 0 121 8 1 76 124 1 niwed A w 21 317 RECEIVED 15 MAR 1989 Telephone 0191 222 6000 Fax 0191 222 6502 81 82 UNIVERSITY OF NEWCASTLE loa BGC AEB 21st September 1995 Department of Civil Engineering Cassie Building University of Newcastle Millfield Enterprises Ltd Newcastle upon Tyne NE1 7RU 16 Shelley Road United Kingdom Newcastle upon Tyne Head of Department NE15 ORT Professor B G Clarke Compression Test of Resin Cubes 40mm nominal cubes were supplied The specimens were cooled by immersing them in a mixture of dry ice and acetone The temperature was monitored using a similar control specimen containing a thermistor A specimen was placed between two platen
33. additional swaging adds needless wear and strain to the dies and swaging machine For the proper after swage dimensions see the section in this publication for the specific product you are swaging Key Facts About Swaging 1 There are a many styles of terminations that can be made in the end of wire rope using swage fittings The choice of the style is dependent upon the application and the task 2 The Working Load Limit rating of the termination wire rope combination is not entirely a function of the fitting being used Therefore the listing of the working load ratings is not within the scope of this literature Refer to the Wire Rope Technical Board s Wire Rope Sling User s Manual for these values 3 It is important that the proper components be used to make a termination For a specific style wire rope termination you must choose the correct size and type of fitting and its corresponding swaging die 4 The information displayed in this brochure is based upon using only a one 1 part 6 X 19 or 6 X 37 FC IPS or IWRC EIPS Right Regular Lay Wire Rope 5 National Swage fittings are designed to be used with inch and metric size wire ropes as designated in this manual and the Crosby general catalog 6 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 ass
34. approximately 100 KIT SIZES 100 cc 250 cc 500 cc 1000 cc 2000 cc 3000 cc Other sizes available to order The specific gravity of WIRELOCK is 1 73 Therefore 1000 cc s will weigh 1 73 kilos or 3 81 Ibs 250 cc s will weigh 1 73 x 250 0 43 kilos or 0 95 Ibs 1000 WIRELOCK Wire Rope Assemblies are 100 efficient when used with steel wire rope galvanized wire ropes and stainless steel wire ropes We do not advise the use of stainless steel wire rope in a salt water marine environment without regular inspection In the presence of an electrolyte i e sea water electrolytic degradation of the stainless steel wire rope can occur This phenomenon known as crevice corrosion will impair the integrity of the rope in the region near to the neck of the socket Crevice corrosion also occurs when white metal is used for socketing Zinc should not be used to socket stainless steel rope However the onset of crevice corrosion in resin sockets appears to be faster than when white metal is used Other rope types do not exhibit this behavior WIRELOCK is approximately 20 the weight of zinc Copyright 2012 The Crosby Group LLC All Rights Reserved WIRELOCK Socketing Compound WAAL Typical example of the swelling of stainless steel rope due to crevice corrosion 5 The strength of WIRELOCK in its cured state is not adversely affected by cold temperatures 6 WIRELOCK must be mixed an
35. be inserted into the socket without damaging the rope For detailed explanation of Resin Socketing of Steel Wire Rope see Page 88 4 Preparation of Broom 4 1 The rope is secured in a vice directly below the seizing to allow the strands to be unlaid to the seizing They should be bent outwards to an included angle not exceeding 90 degrees Fig 1 4 2 Internal leakage of resin in ropes 3 75mm in diameter and larger can occur because of gaps between strands and the IWRC Independent Wire Rope Core These gaps should be sealed before brooming by pushing small plugs of the sealing compound down into the served portion 4 3 If the rope has a fiber core it should be cut out insuring that the remaining fiber core extends 1 2 rope diameter into the bottom of the socket In the case of fiber cores resin is the preferred socketing medium Unlay wire rope so that angle does not exceed 90 Fig 1 4 4 lf the rope has an IWRC the IWRC shall be completely unlaid to form part of the broom 4 5 All the wires in each strand and in the IWRC must be unlaid completely down to the seizing to form a broom being careful not to disturb or change the lay of the wires and strands under the seizing band The wires should not be straightened Brooming is one of the most critical parts of any socketing operation Note The wires must be unlaid from the end of the rope to the seizing because a good fill of resin must occur to the b
36. between S 421T and US422T or between sizes Do not assemble an old style 1 1 4 S 421W wedge into an S 421T 1 1 4 TERMINATOR basket Do not assemble an old style UWO 422 Wedge into a US 422T TERMINATOR basket Figure 2 Tail Length Standard 6 to 8 Strand Wire Rope Rotation Resistant Wire Rope A minimum of 6 rope diameters but A minimum of 20 rope diameters not less than 6 but not less than 6 TABLE 1 Clip Size Torque Ft Ibs The tightening torque values shown are based upon the threads being clean dry and free of lubrication D WRONG Tail Clipped to Live Line WRONG Wedge Backward Figure 3 WRONG Rope Backward Operating Safety e 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 e 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 e During use do not strike the dead end section with any other elements of the rigging called two blocking 103 WEDGE SOCKET WARNINGS 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 Re
37. dies to remain open approximately Y the distance from the time initial contact is made between the sleeve and dies Rotate fitting 45 to 90 degrees Step 15 7th pass If sharp flashing does not occur close dies Rotate fitting 45 to 90 degrees Step 10 2nd pass allow dies to remain open approximately Y the distance from the time initial contact is made between the sleeve and dies Rotate fitting 45 to 90 degrees Step 12 4th pass allow dies to remain open approximately 1 2 the distance from the time initial contact is made between the sleeve and dies Rotate fitting 45 to 90 degrees Step 14 6th pass allow dies to remain open approximately Y the distance from the time initial contact is made between the sleeve and dies Rotate fitting 45 to 90 degrees Step 16 8th and 9th pass Close dies to round fitting Open dies and rotate fitting 45 to 90 degrees between passes Open die and check for proper after swage dimensions See page 17 for proper use of No Go Gauges Additional swaging may be required to provide smooth finish and achieve proper after swage dimensions Dies must be fully closed in 2nd stage die before swaging is complete 34 Copyright 2012 The Crosby Group LLC All Rights Reserved QUIC PASS Swaging Procedures for Flemish Eye Terminations QUIC PASS Swaging Procedures Flemish Eye Terminations for 1 4 thru 1 1 2 S 505
38. ee ee 2 13 0 O 1 50 138 2 44 5 28 12 36 241 140 263 66 3 63 6 1 1 75 4 31 2 25 5 44 2 62 6 13 Nominal NOTE For intermediate wire rope sizes use next larger size socket The S 423T Super TERMINATOR Wedge is designed to be assembled only into the Crosby S 421T TERMINATOR socket body IMPORTANT The S 423TW for sizes 5 8 through 1 1 8 14mm through 28mm will fit respective size standard Crosby S 421T Basket The 1 1 4 30 32mm S 423TW will only fit the Crosby S 421T 1 1 4 basket marked with TERMINATOR 100 Copyright 2012 The Crosby Group LLC All Rights Reserved US 422T Utility Wedge Sockets QUIC CHECK US 422T e Basket is cast steel and individually Magnetic Particle Inspected e Wedge socket terminations have an efficiency rating of 80 based on the catalog strength of XXIP wire rope e Wedges are color coded for easy identification e Blue largest wireline size for socket e Black mid size wireline for socket e 7 16 on US4 e 9 16 on USS e Orange smallest wireline size for socket e Cast into each socket is the name McKissick Crosby or CG its model number and its wireline range e By simply changing out the wedge each socket can be utilized for various wireline sizes Ensure correct wedge is used for wire rope size Most sizes now incorporate the e Cast into each wedge is the model number of the socket and the wi
39. effects of stress risers Un retouched Photomicrographs of Sleeve Original Magnification 500x The Mark Of Quality Is On Every National Sleeve Crosby COLD TUFF Crosby or CG and COLD TUFF are clearly stenciled on every Heat Treatment sleeve we make legible even after swaging leaving no Une Eee eu mi o uci question as to the quality or the manufacturer of the COLD TUFF process results in superior ductility and toughness properties Crosby COLD TUFF and National Swage Fittings Competitor s Heat Treatment The non uniform microstructure may lack proper ductility and A toughness required for swaging t p J ro u p yes and use www thecrosbygroup com P 0 Box 3128 Tulsa OK 74101 E mail crosbygroup thecrosbygroup com e 918 834 4611 Fax 918 832 0940 WIRELOCK RLS Table of Contents General Information cccccceeeeeceeeeeeeeeeeeeesees 70 71 Reuse Of Socket cccccecccesceccececceeeesaeeeseesesaneesaaees 77 Warning on Correct Application FANG 9 0 1 2 ee eee a eee ene ke Senter eee tame 78 Of WIRELOCK 0 ees ceestecteeeeeeeteee teen tteeteenteentten 73 NATO NUMDE SS 0 ccccecceeseeseeceeeessesecassaseessesevarenseees 78 Safety and Health Precautions for Guide to Amount of WIRELOCK Required 79 Using WIRELOCK 0000 ccccccceeeeeeeeeeeeeeeeanees 73 Properties of WIRELOCK ccccccceeeeeeeeeeeeeees 80 Selection Of S
40. for the specific product you are swaging alt Figure 2 i7 QUIC PASS No Go Gauges As a further aid QUIC PASS No Go gauges are available for checking the sleeve s dimensions after swaging is complete e Gauges are made of hardened alloy steel and machined to strict tolerances e Gauge can be used to verify that all sleeves have been swaged properly e After Swage dimensions not within the maximum limits may result from worn dies or improper swaging techniques QUIC PASS No Go Gauges Sleeve and Size StockNo No Go Gauge for S 505 1 4 7 8 1923705 No Go Gauge for S 505 1 1 1 4 1923712 No Go Gauge for S 505 1 3 8 1 1 2 1923714 B Z NATIONAL S 505 SLEEVE GAGE 1 4 7 8 Stock No 1923705 3 4 NATIONAL QUICPASS S 505 SLEEVE Stock No 1923712 PAT 6 035 692 NATIONAL 74 QUCLASS 505 SLEEVE bi 11 2 PAT 6 035 692 Stock No 1923714 Use a National QUIC PASS No Go Gauge to check the after swage dimensions to ensure that it has been swaged to the proper dimension When swaged properly the gauge will slide up and down the full length of the sleeve on all three sets of opposing flats QUIC PASS Maximum After Swage Dimensions LS Maximum After Swage Dimension in a ET 1 4 3 4 7 8 1 5 16 3 8 ooa ooo o a E 8 855 EE Important Safety Information e Crosby does not reco
41. is inserted into the die and swaged following specified swaging procedures for the product IPS Improved Plow Steel Wire Rope A grade of wire rope A term for a steel wire cold drawn with a tensile strength of 225 000 to 295 000 P S I IWRC Independent Wire Rope Core A wire rope used as an axial member of a larger wire rope Lang Lay The type of rope in which the lay of the wires in the strand is in the same direction as the lay of the strand in the rope The crowns of the wires appear to be at an angle to the axis of the rope Copyright 2012 The Crosby Group LLC 3 All Rights Reserved Lay a the manner in which the wires in a strand or the strands in a rope are helically laid b the distance measured parallel to the axis of the rope or Strand in which a strand or wire makes one complete helical convolution about the core or center In this connection Lay is also referred to as Lay Length or Pitch Lay of Rope See b above for definition BOSSA ONE LAY OF ROPE Marlin Spike A tapered steel pin used in wire rope splicing Open Socket A wire rope fitting that consists of a basket and two ears with a pin See Wedge Socket Spelter Socket Swage Socket or Button Socket PS Plow Steel Wire rope steel that contains 0 5 to 0 95 percent carbon P S I Pressure pounds per square inch Poured Socket A socket attached by means of zinc or resins Progressive Swaging A process w
42. length Small size sockets through 1 should be swaged full shank To swage the socket use the following procedure Step 1 For proper insertion mark rope using Column F Dimension on page 37 38 Step 3 Lubricate both die cavities and lower die face See pages 37 and 38 for proper die selection Step 5 2nd pass allow dies to remain open approximately Y the distance from time initial contact is made between socket and dies Rotate fitting 45 to 90 degrees Step 2 Slide rope into socket until it is fully inserted in the shank Inspect mark for full insertion Step 4 1st pass allow dies to remain open approximately 1 2 the distance from time initial contact is made between socket and dies Rotate fitting 45 to 90 degrees Step 6 3rd pass If sharp flashing does not occur close dies Open dies and rotate fitting 45 to 90 degrees Y Step 7 4th and 5th pass Close dies to round fitting Open dies and rotate 45 to 90 degrees between passes Open dies and check termination for proper after swage dimensions See page 17 for proper use of No Go Gauges Additional swaging may be required to provide smooth finish and achieve proper after swage dimensions Copyright 2012 The Crosby Group LLC All Rights Reserved 39 Swage Socket Terminations 114 amp Larger S 501 and S 502 Swage Sockets 1 1 8 and larger See page 39 for smaller sizes S 501 a
43. line marked on the button to ensure correct length of engagement with socketing material and allow installation of pulling eye Socketing Using WIRELOCK Resin Material Seizing cleaning brooming and preparation of wire rope and pouring of WIRELOCK is to be carried out per instructions provided in the Wire Rope End Terminations User s Manual see pages 73 77 in this document and WIRELOCK Warnings and Application Instructions located on the WIRELOCK Product or in the Crosby General Catalog Socketing using Zinc Spelter Material Seizing cleaning brooming and preparation of the wire rope and pouring of zinc is to be carried out in accordance with recommendations of the Wire Rope User s Manual 3rd Edition Appendix C or other approved procedures Copyright 2012 The Crosby Group LLC All Rights Reserved Before operation of the wire rope assembly it is recommended that all poured sockets whether with zinc or resin be proof loaded to seat the cone Reuse of Crosby Button Sockets Crosby allows the reuse of sockets so long as recommended procedures are followed Refer to Page 59 for recommended procedures for reuse of Crosby Spelter Sockets Key Facts About Wire Rope Button Sockets 1 Can be used to terminate high performance rotation resistant ropes and standard 6 strand ropes 2 Easy to install assembly utilizes Crosby WIRELOCK socketing compound Sockets and buttons are reusable Repla
44. mast stays suspended roofs bridges mining and offshore mooring systems Efficiency When fabricated properly WIRELOCK wire rope assemblies are 100 efficient based on the minimum breaking force of the wire rope WIRELOCK is designed to be used with steel wire rope galvanized wire ropes and stainless steel wire ropes Installation Information Socketing Using WIRELOCK Resin Material Seizing cleaning brooming and preparation of wire rope and pouring of WIRELOCK is to be carried out per instructions provided in the WIRELOCK Technical Data Manual located in this manual on Page 73 77 and the WIRELOCK Warnings and Application Instructions located on the WIRELOCK Product or in the Crosby General Catalog Before operation of the wire rope assembly it is recommended that all poured sockets whether with zinc or resin be proof loaded to seat the cone Facts about WIRELOCK 1 WIRELOCK is designed to gel change from a liquid to a solid in approximately 20 minutes at 65 F 18 C To ensure that the kits are not adversely affected by storage they should be stored in a dry place at a temperature of between 50 F and 75 F 10 C and 24 C and away from any source of 70 direct heat WIRELOCK like all polyester resins is temperature sensitive An increase in temperature of 15 F 10 C shortens the gel time by approximately 50 A decrease in temperature of 15 F 10 C lengthens the gel time by
45. met the challenge of making swage fittings including sleeves sockets and buttons more reliable during adverse swaging conditions At that time sleeves tended to crack during the swaging process especially at lower temperatures Our research in materials and the development of a unique thermal process resulted in the development of COLD TUFF swage fittings This name was derived from the ability of these new materials to cold flow plastically a definition of swaging in the presence of a notch at extremely low temperatures The success of COLD TUFF swage fittings in overcoming problems encountered in swaging has revolutionized the industry The result of the COLD TUFF process has made National Swage fittings stronger National S 505 Standard Steel sleeves have outperformed stainless steel sleeves on wire rope eye terminations in the classic 90 degree angle between the rope legs of sling eye test and for a fraction of the cost of a stainless steel sleeve Also COLD TUFF swage products can be impression stamped after swaging for identification purposes Properly done there should be no concern for fractures initiating from such impressions Specific recommended stamping procedures can be found in each product section Key Facts About Swaging 1 Crosby s proprietary COLD TUFF heat treat process has made swaging more reliable during the demanding conditions of swaging Copyright 2012 The Crosby Group LLC All
46. or resin to create the termination Poured sockets are used in many wire rope and structural strand termination applications where a high strength permanent end attachment is required Crosby Spelter Sockets are available in both the closed and open design see Figure 1 and Figure 2 above These types of poured sockets are generally used as a straight tension member They are commonly used on crane boom pendant lines and on applications that require an anchoring system to be connected mechanically to a structure such as on bridges and roof systems They are also occasionally used on crane hoist lines to connect to a crane block or overhaul ball Crosby Mooring Sockets See Figure 3 are designed to be used in marine applications where attachment to shackles and connecting links is required Crosby Button Sockets see Figure 4 are designed to terminate all types of running ropes used on mobile cranes to connect a hoist line to a crane block or overhaul ball The common thread among all these products is the method used to terminate the rope WIRELOCK see Figure 5 is a resin compound offered by Crosby that when properly used creates a 100 efficient termination Zinc is also used to terminate spelter type sockets with the same resultant efficiency Efficiency Efficiency ratings for wire rope end terminations are based upon the minimum breaking force of wire rope When properly fabricated all Crosby Spelter Sockets hav
47. plane of the rope no less than 0 250 in 1 4 from either end of the sleeve Copyright 2012 The Crosby Group LLC All Rights Reserved National Swage Buttons S 409 e Swage Button terminations have an efficiency rating of 98 based on the catalog strength of wire rope e Special processed low carbon steel e COLD TUFF for better swageability e Stamp for identification after swaging without concern for fractures See page 42 IGEMS JY aeng aog Fi NOTE S 409 Buttons are recommended for use with 6 x 19 or 6 x 36 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 Swager Die Data S 409 Stock No Before After Swage Dimensions Swage Dimensions i n in Stock No 500 Tons After Swage E Die 1500 Tons Ibs Dimensions Description 5x7 2 1 4 4 68 1 88 1133 7 1 06 1 41 9 10 o 113 163 50 431 189 70 18 20 2 2 i Le 5 O 5 vi 1040251 55B 1 4 67 O 8 910 3 18 20 7 8 22 220 200 3 27 _ 436 1istStage 1192505 0 4 81 11 8 1stStage 1192523 4 57 1040439 14 SB 3 5 6 1 1 1 1 2 5 42 56 1 13 88
48. restricts the movement of the live end Shock loading should be avoided See ASME B30 26 for full information 99 S 421T Wedge Sockets QUIC CHECK filial a TYPE APPROVED ia Ea n Wedge sockets meet the performance requirements of Federal Specification RR S 550D Type C except those provisions required of the contractor For additional information see Crosby General Catalog Dia 421T StockNo A B e Wedge socket terminations have an efficiency rating of 80 based on the catalog strength of XXIP wire rope e Meets or exceeds all requirements of ASME B30 26 including identification ductility design factor proof load and temperature requirements Importantly these sockets meet other critical performance requirements including fatigue life impact properties and material traceability not addressed by ASME B30 26 e Type Approval and certification in accordance with ABS 2006 Steel Vessel Rules 1 1 17 7 and ABS Guide for Certification of Cranes e Basket is cast steel and individually Magnetic Particle Inspected e Pin diameter and jaw opening allows wedge and socket to be used in conjunction with closed swage and spelter sockets e 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 e The TERMINATOR Wedge eliminates the po
49. rotate fitting 45 to 90 degrees Step 12 4th pass If sharp flashing does not occur close dies Open dies and rotate fitting 45 to 90 degrees between each pass 4 pe T A S ki A L gt P A 1 Wi T A D Step 13 5th and 6th pass Close dies to round fitting Open dies and rotate fitting 45 to 90 degrees between each pass Open dies and check termination for proper after swaging dimensions See page 17 for proper use of No Go Gauges Additional swaging may be required to provide smooth finish and achieve proper after swage dimensions Dies must be fully closed in 2nd stage die cavity before swaging is complete 32 Copyright 2012 The Crosby Group LLC All Rights Reserved Flemish Type Wire Rope Sling Eyes 2 amp Larger Flemish Eye Terminations for 2 and larger National S 505 Sleeves For other sizes see pages 29 32 National Standard Steel Sleeve dies are provided with a 1st stage die and 2nd stage dies National S 505 Standard Steel Sleeves 1 1 8 and larger require swaging in the 1st stage dies and completing the swage in 2nd stage dies in a National Hydraulic Swaging Machine 1st STAGE Step 1 Slide Sleeve over rope Assemble Flemish Eye See page 28 for assembly instructions Step 3 Lubricate both die cavities and lower die face See page 24 for proper die selection Step 5 2nd pass allow dies to remain open approximately 1 2 the distance from the
50. rubber containing copper or with oxidizers Other Precautions Store in a cool well ventilated area away from heat sunlight naked lights and other sources of ignition Do not smoke around WIRELOCK SECTION VIII CONTROL MEASURES Respiratory Protection Specify type gt 50 Half Face Air Purifying Respirator lt 500ppm gt 500 Full Face Air Purifying Respirator lt 2500ppm gt 2500 Powered Air Purifying Respirator lt 5000ppm gt 5000 lt 50 000ppm gt 50 000ppm Org Vap Chem Supplied Air Pressure Demand Self Contained Breathing Apparatus Cartridge Type Ventilation Local Exhaust Dilution Mechanical General Other Preferred For Process Enclosures Chemical resistant made from materials not affected by contact with any of the individual mix components Protective Gloves Check with suppliers for suitable type s Eye Protection Splash goggles and face shield if mixing components Other Protective Equipment l l Impervious covering such as aprons and sleeves to cover bare skin or Clothing Work Hygienic Practices Avoid prolonged contact on bare skin Do not continue to wear clothing that becomes contaminated Also maintain personal protective equipment daily with thorough cleaning and rinsing Store reusable PPE in a dry location safe from continued exposure to WIRELOCK 84 Copyright 2012 The Crosby Group LLC All Rights Reserved gt oo M
51. terminations National Swage a member of The Crosby Group LLC provides the highest quality fittings and equipment available for fabricating swaged wire rope terminations In addition National Swage also provides valuable knowledge about the swaging process that is a result of the combination of many years of extensive testing and on the job training After Swage Dimensions One of the important considerations in producing a quality termination is the overall diameter of the fitting after the swaging process is complete Since all dies wear and the swaged fitting used in terminations have spring back the results of swaging should be checked periodically to determine the wear condition of the die as well as to ensure the fitting is swaged to proper dimensions In addition to worn dies not achieving the proper after swage dimension can also be due to the die not being fully closed during swaging Dies showing excessive wear should be replaced Copyright 2012 The Crosby Group LLC All Rights Reserved The effective swaging that dies can accomplish stops when the die lands touch each other Any continued swaging adds needless wear and strain on the dies and swaging machine By placing a light oil on the die faces and in the cavity the dies will be lubricated as well as protected The oozing of the oil from the faces of the dies as they touch will indicate when the dies have closed At this point stop the swaging cycle Again
52. that the purchaser is thoroughly familiar with the safe and proper use and application of the product Responsibility for the use and application of the products rests with the user The Crosby Group disseminates product warnings and end user application information through various channels In addition Crosby provides formal product training seminars and our engineering personnel are readily available to answer your technical questions For more information read the Crosby General Catalog refer to Crosby s web site www thecrosbygroup com or contact your Crosby Distributor or Crosby direct at 918 834 4611 Failure of the product can occur due to misapplication abuse or improper maintenance Product failure could allow the load to become out of control resulting in possible property damage personal injury or death There are numerous government and industry standards that cover products made by Crosby This catalog makes no attempt to reference all of them We do reference the standards that are most frequently asked about Ratings shown in Crosby Group literature are applicable only to new or in as new condition products Load Limit ratings indicate the greatest force or load a product can carry under usual environmental conditions Shock loading and extraordinary conditions must be taken into account when selecting products for use in a system In general the products displayed in Crosby Group literature are used as pa
53. the broomed area Non Crosby 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 be used only as a guide for experienced trained users For full information consult our document WIRELOCK TECHNICAL DATA MANUAL API AMERICAN PETROLEUM INSTITUTE RECOMMENDED PRACTICE 9B ISO standards WIRE ROPE MANUFACTURERS CATALOGS and WIRE ROPE SLING USERS MANUAL THIRD EDITION 94 STEP 1 SOCKET SELECTION WIRELOCK is recommended for use with Crosby 416 417 Spelter Sockets Structural strand requires a socket with the basket length approximately five 5 times the strand diameter or fifty 50 times the wire diameter what ever is greater to achieve 100 efficiency Consult The Crosby catalog for proper selection of Wire Rope or Structural Strand sockets For use with sockets other than Crosby 416 417 consult the socket manufacturer or Crosby Engineering Sockets used with WIRELOCK shall comply with Federal or International CEN ISO Standards 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 MEASURE re Be enath Hi asket Leng AND SEIZE
54. time initial contact is made between sleeve and dies Rotate fitting 45 to 90 degrees Step 7 4th pass allow dies to remain open approximately 1 2 the distance from the time initial contact is made between sleeve and dies Rotate fitting 45 to 90 degrees Copyright 2012 The Crosby Group LLC All Rights Reserved Step 2 Slide sleeve fully over ends of wire rope Step 4 1st pass allow dies to remain open approximately 1 2 the distance from the time initial contact is made between sleeve and dies Rotate fitting 45 to 90 degrees Step 6 3rd pass allow dies to remain open approximately 1 2 the distance from the time initial contact is made between sleeve and dies Rotate fitting 45 to 90 degrees Step 8 5th and 6th pass If sharp flashing does not occur close die Open dies and rotate fitting 45 to 90 degrees between passes 33 Flemish Type Wire Rope Sling Eyes 2 amp Larger 2nd Stage Lubricate both die cavities and bottom die face See page 24 for die selection Step 9 1st pass allow dies to remain open approximately Y the distance from the time initial contact is made between the sleeve and dies Rotate fitting 45 to 90 degrees Step 11 3rd pass allow dies to remain open approximately 1 2 the distance from the time initial contact is made between the sleeve and dies Rotate fitting 45 to 90 degrees Step 13 5th pass allow
55. 1 8 and above Swaging 1 1 8 and larger Standard Steel S 505 sleeves on Flemish Eye terminations requires using 2 sets of open channel dies 1st stage and 2nd stage for each size Beginning with the 1st stage die and finishing with the 2nd stage die will achieve proper after swage dimensions Dies for S 505 Sleeves 1 1 8 and larger are single cavity with open channel Refer to page 24 of the Wire Rope End Termination User s Manual for proper die selection Using S 505 Sleeves with Metric Ropes Although Crosby National S 505 Standard Steel sleeves are designed to be used with most metric ropes there are selected intermediate sizes of metric ropes that when swaged in standard National dies utilizing Crosby National S 505 sleeves do not achieve required after swage dimensions and efficiencies To ensure all 505 sleeves achieve the required efficiency when used with metric ropes Crosby provides special National swaging dies to be used in conjunction with selected size metric ropes These new dies will produce the required efficiencies and after swage dimensions The table found on Page 24 of the Wire Rope End Termination User s Manual identifies the new dies that are required to properly swage the selected intermediate size wire ropes not covered in the standard product offering found on Page 25 of the manual Copyright 2012 The Crosby Group LLC All Rights Reserved Dies for 6mm through 26mm except 12mm 20mm an
56. 12 The Crosby Group LLC 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 Product 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 When placing two 2 sling legs in hook make sure the angle from the vertical to the outermost leg is not greater than 45 degrees and the included angle between the legs does not exceed 90 degrees See Figure 5 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 swaging 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 frame code on each S 319SWG hook is to facilitate proper latch selection only and has no reference to the working load limit of the hook Hook Frame I D Code Wire Rope Size in o 1191621 o n S
57. 192943 26 17 80 15 47 2 00 3 69 2 00 1 07 8 63 2 00 13 38 1 07 3 68 180 1Socket_ 1192961 25 25 17 35 2 25 4 06 2 25 1 19 9 75 2 25 15 00 1 19 4 18 2 05 1 1 8 Socket_ 1192989 l 35 56 19 20 2 53 4 50 2 50 1 34 10 81 2 50 16 50 1 27 4 64 2 30 1 1 4 Socket_ 1193005 l 1039263 1054122 1 3 8 34 36 43 75 21 10 2 81 5 25 2 50 1 46 11 88 2 41 18 13 1 46 5 25 2 56 1 3 8 Socket 1193023 l 1 1 2 38 4 A 48 52 146 2 31 15 Maximum Proof Load shall not exceed 50 of XXIP rope catalog breaking strength Assembly with bolt nut and cotter pin Copyright 2012 The Crosby Group LLC 37 All Rights Reserved National Closed Swage Sockets QUIC CHECK S 502 e Forged from special bar quality carbon steel suitable for cold forming e Swage socket terminations have an efficiency rating of 100 based on the catalog strength of wire rope e Hardness controlled by spheroidize annealing e Stamp for identification after swaging without concern for fractures See page 36 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
58. 24 1041633 1041642 262 00 25 50 5 3 18 7580 2 12 25 8 563 1041679 1041688 380 00 29 00 5 75 5 3 1 4 3 3 8 82 86 2 3 4 2 7 8 722 1041697 1041704 434 00 30 88 6 25 5 50 se se eee 3 318 778 1041718 1041722 563 00 33 25 6 75 6 00 saaa Fomio ers toat7at 1041740 783 00 36 25 750 700 4 25 Cast Alloy Steel h O1 O N No O1 O1 u O h Se h a g 2 a _ 2 2 h O co N N O1 N Ol Ql O Aj oe oe N O1 O N O O 00 oe oO O O O1 _ NO z _ La co oloo a au K O o 9 on po Olo W N T VID aN Alw olu olo olo ol oo Po ao PO Ol No Jo N ra O a ho lO oo O1 G CO h h oo h h N _ O1 oo oo N N Nh O1 O1 gt oO O1 O O O gt N O O1 O O Se N N N O1 O1 moh a Kee gt 1 co 00 MIDIO KIOD NIN on Po O N on O h l ON OJO NMIN NIO O1 AJA y O1 PO Sa sla O1 OJo ays OJO OJN AJA N AJN h h oO I N o N N ol wj jr 3 0 wlo NJD 02 Go On ho ad o n NIOD Qjo Ojo mY 91 01 O a N o O O 01 oo eS eS o u Go 2 0 0 ojojo NI O gt D ylolalaja aj ojojojo h o N on olojen Ll2 la on alec O AJ j olalolo Ol O O O w
59. 59 PEL and TLV Levels are in parts per million ppm SECTION Ill PHYSICAL CHEMICAL CHARACTERISTICS Specific Gravity 0 9 O pes lt D Boiling Point 145 C Melting Point 31 C approx H 0 1 Vapor Density 3 6 Evaporation Rate 0 49 Vapor Pressure 4 5 Air 1 Butyl Acetate 1 mm Hg At 20 C Solubility in Water Insoluble to slightly soluble Miscible in Alcohol and Ether Appearance and Odor Sweet aromatic odor at low concentrations SECTION IV FIRE AND EXPLOSION DATA Flash Point 31 C approx Flammable Limits LEL UEL 1 1 6 1 Unusual Fire and Explosion Hazards SECTION V REACTIVITY DATA Stability Unstable X oratonen Styrene may explode in its container if its polymerizing inhibitors are not in proper mix concentration Stable mute Strong Oxidizing materials such as Peroxides Strong Acids and Aluminum Chloride may cause fire and explosions MAZAO HE COMPOSMON Carbon Monoxide Carbon Dioxide or By products Hazardous Polymerization May occur X Conditions to Avoid Styrene Avoid Peroxides Strong Acids Aluminum Chloride Will not occur SECTION VI HEALTH HAZARD DATA Route s of Entry Yes Yes Yes Health Hazard Acute amp Chronic mnaauong A amp C om A amp C Carcinogenicity NTP No IARC Monographs No OSHA Regulated No Styrene Irritation To Eyes Nose Throat Skin Skin rash with chronic exp Incompatibility M
60. 6 1 0 56 119 144 150 75 100 91 75 163 194 113 88 191 228 34 94 2 06 2 50 Copyright 2012 The Crosby Group LLC All Rights Reserved A 6 2 38 44 06 75 88 94 Wire Rope Clip Information U Bolt Clip Installation Procedures WIRE ROPE CLIPS BASIC REQUIREMENTS x x FOR PROPER Ta S TERMINATION SELECT PROPER SIZE SN CLIPS AND TURNBACK PLACE CLIPS ON IN PROPER SEQUENCE TORQUE ALL CLIPS EVENLY WITH A TORQUE WRENCH APPLY FIRST LOAD AND RE TORQUE WITH A TORQUE WRENCH POH651 Turnback is measured from the end of the rope to the base of the eye or to the thimble This part of the rope is often referred to as the dead end Since the U Bolt Clip has a single saddle you must be concerned about workers saddling the dead horse The table below defines the information required for each wire rope clip to achieve maximum efficiency Amount of Minimum Rope to No of Turn Back i in Inches Torque Clip Size i in in 1 8 3 16 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 1 1 8 1 1 4 7 1 3 8 7 1 1 2 1 5 8 1 3 4 2 2 1 4 2 1 2 2 3 4 10 3 10 3 1 2 12 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 clea
61. 6 1 2 Socket 1192881 1039423 9 16 14 2 92 8 59 127 2 38 128 61 5 38 114 725 1 16 9 16 5 8 Socket 1192907 J 1030441 5 8 16 285 859 127 2 38 128 68 5 38 114 725 1 16 9 16 5 8 Socket 1192907 1039469 3 4 18 20 5 00 10 25 1 56 2 88 149 80 6 44 133 863 1 42 3 4Socket_ 1192925 1030487 7 8 22 6 80 11 87 172 3 12 173 94 750 153 10 09 155 7 8Socket_ 1192943 1039502 1 24 26 10 40 13 56 2 00 3 62 2 11 1 07 8 63 178 1150 180 1Socket_ 1192961 1039520 1 1 8 28 14 82 15 03 2 25 4 00 2 37 1 19 9 75 2 03 12 75 2 05 1 1 8 Socket 1192989 1039548 1 1 4 32 21 57 16 94 2 53 4 50 2 62 1 34 10 81 2 25 14 38 2 30 1 1 4 Socket 1193005 1039566 1 3 8 34 36 28 54 18 59 2 81 5 00 2 62 1 46 11 88 2 29 15 75 2 56 1 3 8 Socket 1193023 Maximum Proof Load shall not exceed 50 of XXIP rope catalog breaking strength Rope Size Rope Size 38 Copyright 2012 The Crosby Group LLC All Rights Reserved Swage Socket Terminations 1 4 1 S 501 and S 502 Swage Sockets 1 4 through 1 See page 40 41 for larger sizes S 501 and S 502 Swage Sockets are swaged in specially designed National Swage dies with a relief and extra
62. 6 23 1st Stage 1191114 1195263 2nd Stage 1191132 1195272 100 4 Open 1041508 4 105 6800 Bulk 16 00 8 13 4 38 4 50 6 81 1st Stage 1191150 1195156 2nd Stage 1191178 1195165 4 1 2 Open 1041526 4 1 2 112 114 10000 Bulk 18 00 9 13 4 88 5 06 7 66 7 45 1st Stage 1191187 1195174 2nd Stage 1191203 1195183 24 Copyright 2012 The Crosby Group LLC All Rights Reserved 1195085 3 1 2 3 Intermediate Metric Die Chart Sleeve and Swaging Die Requirements for Intermediate Sizes of Metric Wire Rope i Standard Round Dies S 505 Metric Maximum Stock No Size Size 1st Stage Die 2nd Stage Die Dimension 1041143 1 2 12 190881 5x7 Double Cavity 960 990 1041223 7 8 20 1190901 5x7 Double Cavity 4 570 1 620 1041241 1 24 1190921 5x7 Double Cavity 1830 1880 1041401 22 60 1192809 5x7 1190981 5x7 4310 4 370 1041401 2 2 6o 1191061 6x12 1190991 6x12 4 310 4 370 1041483 3 1 2 80 1198247 6x12 ngno 6x12 5 380 5 450 QUIC PASS system not available for these metric rope sizes Copyright 2012 The Crosby Group LLC 25 All Rights Reserved Flemish Type Wire Rope Sling Eyes Introduction Flemish type wire rope sling eyes are formed by looping an eye see information on pages 27 28 for forming eye properly and cold swaging a steel sleeve on the rope at the base of the loop Swaging bonds the ends of the rope strands i
63. 75 WIRELOCK and the rope should conform to the temperature at 7 Use of Heat which the WIRELOCK has been stored for the last 7 1 Do nol apply heat to sockets to accelerate the curing 24 hours When the sockets rope and WIRELOCK process prior to pouring The application of external are stored at normal room temperature 65 to 70 F or heat may cause the resin to gel before it reaches the 18 to 21 C booster packs must not be used even if bottom of the socket and lead to assembly failure the ambient temperature is below 48 F 9 C If u Used sockets cleaned out by heating see Appendix temperature is above 95 F 35 C the WIRELOCK D should be allowed to cool to room temperature kit should be refrigerated for two hours before use before reuse 6 4 Itis possible to combine various kit sizes to achieve Hot sockets must not be used any required volume e g 2500 cc 1 x 1000 cc i 8 Pouring plus 3 x 500 cc etc In this case all of the liquid resin should be placed in the mixing container and then 8 1 Once the WIRELOCK is mixed it should be poured immediately Fig 7 into the socket to all of the powder added to it or vice versa before mixing Always mix all of the resin with all of the ensure good penetration preferably down the side powder Never mix less than the total contents of of the socket to allow air to escape all cans aeee e i i SWIRELOCK 7 gt Some kits can be mixed in the or
64. 88 250 175 10 306 284 200 384 3 50 Copyright 2012 The Crosby Group LLC All Rights Reserved i 1 1 Pie a oe Max After Swage Dimensions in Stock No 500 Tons 1000 Tons 1500 Tons 5x7 Die Description Turnback Terminations 5446 5 Turnback Eye Terminations using 5 16 through 5 8 S 506 sleeves utilize the open cavity of the S 505 Standard Steel Sleeve die on a National Hydraulic Swaging Machine See page 49 for larger sizes Each S 505 Standard Steel Sleeve die contains 2 cavities open and tapered To form the eye and swage the termination use the following procedure Step 1 Slide the end of the rope through the sleeve and turn back the wire rope end through the S 506 Duplex Steel Sleeve and adjust the rope to form the proper eye size Allow approximately 1 one rope diameter to extend past the end of the sleeve This will provide for elongation of the fitting during swaging See page 47 for proper die selection Step 3 1st pass allow dies to remain open approximately 1 2 the distance from time initial contact is made between sleeve and dies Open dies and rotate fitting 45 to 90 degrees Step 5 3rd pass If sharp flashing does not occur close dies Open dies and rotate fitting 45 to 90 degrees Step 2 Lubricate both die cavities and lower die face Step 4 2nd pass allow dies to remain open approxima
65. ABLE CAST IRON CLIPS SHALL NOT BE USED ASME B30 5 POH651AA 108 Key Facts About Wire Rope Clips 1 The proper performance of forged clips depends on proper manufacturing practices that include good forging techniques and accurate machining 2 Forged clips U bolt and Fist Grip styles provide a greater rope bearing surface and more consistent strength than malleable cast iron clips 3 Fist Grip clips provide a saddle for both the live and the dead end 4 Fewer forged clips U bolt and Fist Grip styles are required for each termination than with malleable cast iron clips 5 Forged clips U bolt and Fist Grip styles reduce the possibility of hidden defects that are sometimes present in malleable cast iron clips 6 Malleable cast iron clips should only be used in non critical applications ASME OSHA and ASTM recommend only forged clips for critical applications 7 All Clips are individually bagged or tagged with proper application instructions and warning information User must become familiar with instructions attached to the product 8 Crosby wire rope clips can be reused after careful inspection of threads and saddle area Proper torque values must be attained whenever Crosby clips are reused The U bolt must fit into the base without requiring a forceful change in U bolt spread The clip assembly must be properly installed and capable of being torqued to its ful
66. CIE NO E 15T 1192408 1191643 Theta a 2np 1192408 1197423 1 03 1192881 101 103 1 08 1 76 osi DIE MAXIMUM AFTER SWAGE DIAMETER SIZE INSTRUCTIONS SKT 1 Set FITTING SIZE in window STO 2 Road MAXIMUM AFTER SWAGE DIAMETER l and DIE SIZE and TYPE WARNING DO NOT EXCEED DIE WLL CONTACT DIE MANUFACTURER FOR WLL ther OS Uysroun NATIONAL pe NATIONAL STANDARD El SWAGE DIE DIE NO 9266 1 8 4 1 2 3 505 DE BLOCK WLL 500 TONS ADJUST TONMAGE TO WEL When buying Crosby you re buying more than product you re buying Quality F a USING THE NATIONAL SWAGE DIE GUIDE An example of how to use the Die Guide would be if you needed to swage a 1 2 S 501 Swage Socket in National Standard Dies First find the 7 16 1 2 fitting size designation and follow that row across the different product types to the column heading 501 502 Die No You can see that the required Die No is 1192881 and the size and type is 5 x 7 Std When you have located and verified that you have the correct dies you are ready to begin the swaging process You can also find the maximum after swage dimension listed below the corresponding Die No i e 0 91 Remember side 1 refers to National Standard Dies and side 2 refers to Mark Series Dies 20 Copyright 2012 The Crosby Group LLC All Rights Reserved COLD TUFF Swage Fittings Introduction m it ae y 1 A number of years ago we
67. E B30 26 for full information 109 G 450 Forged Wire Rope Clips e Each base has a Product Identification Code PIC for material traceability the name CROSBY or CG and a size forged into it e Based on the catalog breaking strength of wire rope Crosby wire rope clips have an efficiency rating of 80 for 1 8 7 8 sizes and 90 for sizes 1 through 3 1 2 e Entire clip Galvanized to resist corrosive and rusting action e Sizes 1 8 through 2 1 2 and 3 have forged bases e All clips are individually bagged or tagged with proper application instructions and warning information e Clip sizes up through 1 1 2 have rolled threads e Meets or exceeds all requirements of ASME B30 26 including identification ductility design factor proof load and temperature requirements Importantly these wire rope clips meet other critical performance requirements including fatigue life impact properties and material traceability not addressed by ASME B30 26 e Look for the Red U Bolt your assurance of Genuine Crosby Clips Crosby Clips all sizes 1 4 and larger meet the performance requirements of Federal Specification FF C 450 TYPE 1 CLASS 1 except for those provisions required of the contractor For additional information see the Crosby General Catalog SS 450 AN fe fal i 14 yey rm i pia ji 110 G 450 Crosby Clips ie oe Ee Rope Size G 450 Package Per 100 i
68. ER TERMINATOR WEDGE SOCKET WARNING amp APPLICATION INSTRUCTIONS Patent Pending S 423T SUPER TERMINATOR The intended purpose of the SUPER TERMINATOR is to offer a Wedge Socket termination which when assembled properly with high performance high strength compacted strand rotation resistant wire rope will achieve an 80 termination efficiency Due to the unique construction of these ropes Crosby cannot make a broad general statement that all current and future designed ropes when properly assembled with a SUPER TERMINATOR will achieve a minimum 80 termination efficiency To determine the efficiency rating for a specific rope contact Crosby Engineering at 918 834 4611 The SUPER TERMINATOR may be purchased as a complete Wedge Socket assembly or the wedge assembly may be purchased for retrofit onto your Crosby S 421T wedge socket basket The Crosby S 423TW SUPER TERMINATOR Wedge is designed to be assembled only into the Crosby S 421T socket basket For the 1 1 4 S 423TW assemble only on to S 421T basket marked TERMINATOR Important Safety Information Read and Understand 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 e Inspe
69. IIMU Termination Program Al TENTION w RE ROPE FABRICATORS Another industry first from Crosby In addition to our long time philosophy of providing quality products Crosby is committed to offering our valued Business Partners support services that enhance their wire rope fabrication business As our partner you know that the reputation of the Crosby brand has been built on providing products with uncompromising quality As a further commitment to that promise we have put in place tools designed to support and enhance your fabrication operations of the swaging and socketing of wire rope assemblies We call it the Crosby Termination Program We see this new program as a way to expand Crosby s overall philosophy of providing Value Added features and services to the products that we supply The Termination e Program accomplishes this through a combination of inspection and maintenance services along with a newly developed on site training program for your employees As a further commitment to this program we now have a full time dedicated technician In association with the Crosby Termination Program our technician is available to provide your company with e Inspection Services e Maintenance Services e Employee Training The following services are available through the Crosby Termination program Inspection Maintenance Services At the standard day rates the follow
70. Installation Procedures 0008 114 Crosby Fist Grip Clips Warnings and Application Instructions cccccseccseeeeeeeeeeeeeees 115 107 Wire Rope Clip Information Application and General Information Pom z AN ON gt wwe UT 3 5 G429 Crosby G 450 Crosby SS 450 Crosby G 429 Crosby Red U Bolt Stainless Fist Grip Clip Fist Grip Clip Clip Steel Clip 3 16 5 8 3 4 1 1 2 Figure 1 Figure 2 Figure 3 Figure 4 There are three basic types of wire rope clips forged U Bolt forged fist grip and cast malleable Wire rope clips are sometimes referred to as Crosby s or clamps Wire rope clips are used to make a loop at the end of wire rope e Crosby U Bolt style clips consists of a U shaped bolt a forged saddle and two nuts see Figure 1 amp 2 e Crosby Fist Grip clips consists of two saddles and two nuts see Figures 3 amp 4 e Malleable clips consist of a U shaped bolt an inferior cast iron saddle and two nuts It is worth noting that Crosby does not manufacturer cast malleable clips IMPORTANT Only the forged clips can be used for the critical applications such as guying tie down and suspension WIRE ROPE CLIP TYPES CRITICAL APPLICATIONS FORGED U BOLT MALLEABLE ON a4 f f a a ae FIST GRIP We y J J oe WIRE ROPE CLIPS SHALL BE DROP FORGED STEEL OF SINGLE SADDLE U BOLT OR DOUBLE SADDLE CLIP MALLE
71. NI olo Jolo NIN MDIOINIO O1 01 oe N ol A N Ol N Ol O AJ O O NO ol a_i O O O N N ol N math oO rece O O A yN ol WINI 00 CO AA Ol O CO NO ol a Oo CO I O1 o1 ro O ioe h N A 0 0 00 O Ql O h Q O i QO O GO C0 o gt N O O1 O1 Oo Ni Po OJo h d My i olal 2 AJOJN oO O O O O O d l N NIN N N O1 ioe O N On Q O l oo Ol O NO Ol O Ql M o w w N No a0 O1 P GO Oo NOTE Available with bolt nut and cotter Contact Crosby for more information Copyright 2012 The Crosby Group LLC 61 All Rights Reserved Closed Spelter Sockets through 4 e Spelter socket terminations have an efficiency rating of 100 based on the catalog strength of wire rope Ratings are based on the recommended use with 6 x 7 6 x 19 or 6x 36 IPS or XIP EIP XXIP EEIP RRL FC or IWRC wire rope Strand constructed with minimal number of wires e g 1 x 7 requires special consideration that socket basket be five 5 times the strand diameter or fifty 50 times the wire diameter whichever is the greater G 417 S 417 e Forged steel sockets through 1 1 2 cast alloy steel 1 5 8 Closed grooved sockets meet the performance requirements of Federal Specification RR S 550D Type B except for those provisions required of t
72. OCK cccceecceeceseeeeeeeseeesaeeeeeeeeaeeenes 73 Certificate Of Testing ccccccccccsseseeeeeeeeeeeeeeeeeeseeeees 81 Preparation Of BrOOM cccccccccececseeeessseeeeeeesaeeesaeees 74 a Compression Test Results cccceccsseceseeeeeeeeeeees 82 Positioning of Broom and Alignment of Socket 75 Appendix A Materials wicewscca natin thunsuveiesientodiadeeiantatieinavndiahwnanactwaryes 15 Material Safety Data Sheets MSDS a 83 86 Use of FOAL ecetennccsecaxnaddcanavexwtcedacswsencasadsiersdaderiaehesaeases 76 Appendix B POUMMIAG aeee E E E E EE 76 Resin Socketing of Steel Wire Rope 87 92 Movement escrire aE 76 Appendix C Check on Penetration cccescccsesesseseessersessenseereerees 77 Technical Bulletin Reuse of Sockets 93 Re Lubrication eccececeeescerceeseerecersesseeeeereesevereesteess 77 WIRELOCK Warnings and Application Instructions ccccsseeeeseeeeeeeeees 94 95 LAdA eure ter eee ere ene eer tern een ante entre tr te 77 Copyright 2012 The Crosby Group LLC 69 All Rights Reserved WIRELOCK Socketing Compound WIRELOCK is a unique socketing compound for use with wire ropes The product eliminates the hazards of working with a molten metal and allows socketing to be done on site when required in virtually all weather conditions WIRELOCK is generally used in long term applications such as crane ropes boom pendants winches lifting straps
73. PROVIDES A QUIC CHECK LOOK TO DETERMINE IF THE TERMINATION HAS BEEN SWAGED AND PROVIDES A FLAT SURFACE THAT ALLOWS FOR EASE OF I D STAMPING ON THE FINISHED SLEEVE Copyright 2012 The Crosby Group LLC All Rights Reserved National Steel Swaging Sleeves i Te DIE GUIDE web art Polen be TT BUT E miin ee PINS HARGA Le a The National Die Guide will eGrosbgige opm assist you in selecting the i proper dies to meet your swaging needs When bining Crosky ymi re heyi more Han product yon re buying Chealnty e For Flemish Eye wire rope splicing e Can be stamped for identification after swaging without l concern for fractures when following these directions e Designed for low temperature toughness e Use round corner stamps to a maximum depth of 0 015 in 1 64 The area for stamping should be on the side of the sleeve in the plane of the sling eye and no less e Resists cracking when swaged equals or exceeds stainless steel sleeves e Special processed low carbon steel than 0 250 in 1 4 from either end of the sleeve e COLD TUFF for better swageability e Standard 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 in IWRC 4 1 1 1 8 2 2 1 8 and Larger NOTE S 505 Standard Sleeves are recommended for use with 6 x 19 or 6 x 36 IPS or XIP EIP XXIP EEIP
74. Properties of WIRELOCK Physical Viscosity 3 4 Poise Heat Distortion Point 212 Fahrenheit 100 C to 240 Fahrenheit 115 C Flexural Strength Flexural Modulus Tensile Strength 1500 lb sq in 5 8 x 10 Ib sq in 1 09T in 16 15N mm Flashpoint 89 F 31 C Electrical Dielectric Strength 230 volts mm Arc Resistance 191 S Volume Restivity Greater than Surface Resistance Insulation Resistance 14 5 log ohms cm Flashpoint Please note that this is not the auto ignition Spontaneous combustion temperature but the temperature above which the material will give off a significant amount of vapor 14 0 log ohms cm 8 2 x 10 log ohms cm Graph A Staining rate 0 062 in min 300 250 200 load Ib oO O 100 50 0 0 0 05 0 10 0 15 Withdrawl distance in The individual wires of the rope are retained by a combination of bonding and frictional forces The frictional forces are the result of e Shrinkage during the curing of the resin e Coefficient of friction between the resin and the individual wires Additional forces develop due to the wedge action of the socket as the rope is loaded As WIRELOCK cures it shrinks by between 1 5 and 2 5 High Volume WIRELOCK by less than 0 5 and with the introduction of a hard inert filler of specific grain size a high coefficient of friction is obtained 80 Graph B Projec
75. SS swaging system allows Flemish style wire rope terminations to be swaged in only two passes This is accomplished while maintaining currently published efficiency ratings and utilizing National Swage S 505 Standard COLD TUFF Steel Sleeves The special design of the QUIC PASS dies allows the swaging process to be completed in just two passes resulting in a 50 75 reduction in the number of passes required with conventional swaging systems Unlike standard round dies the QUIC PASS dies close completely with each pass resulting in an increase in overall swaging process efficiencies the job can be performed quicker a reduction in the complexity of swaging the concern for excess flashing between dies has been eliminated and a reduction in training time needed for operators more user friendly The finished sleeve has a Hex appearance that provides a QUIC CHECK look to determine if the termination has been swaged and provides a flat surface that allows for ease of I D stamping on the finished sleeve Refer to page 24 of the Wire Rope End Termination User s Manual for proper die selection 15 Dies for S 501 amp S 502 Swage Sockets Swaging all S 501 amp S 502 Swage Sockets requires the use of single cavity die This is a special die designed with a relief for swage sockets and extra length to swage the full length of the shank Refer to pages 36 and 37 of the Wire Rope End Termination User s Manual fo
76. TIVITY DATA Unusual Fire and Explosion Hazards atapility Conditions to Unstable X Dibenzoyl Peroxide may decompose explosively if exposed to high temperature pressure or shock Stable ONG Incompatibility Materials to Avoid Contact with Oxidizable materials such as Lithium Aluminum Hydride may cause fire and explosions Hazardous Decomposition or By products Carbon Monoxide Carbon Dioxide Hazardous Polymerization May occur X Conditions to Avoid Styrene or other vinyl Polymerizing agents Will not occur SECTION VI HEALTH HAZARD DATA Route s of Entry a Yes sats Yes n Yes Health Hazard Acute amp Chronic AMON A amp C a A amp C Ingestion Carcinogenicity NTP No Gi Nala ad OSHA Regulated No Signs and Symptoms of Exposure Irritation To Eyes Nose Throat Skin Rash with chronic Exp Medical Conditions Generally Aggravated by Exposure Persons with pre existing skin conditions should be screened prior to working with this material Copyright 2012 The Crosby Group LLC 85 All Rights Reserved SECTION VI HEALTH HAZARD DATA Continued from page 1 Emergency and First Aid Procedures Eyes Flush with water while raising upper and lower eyelids Seek medical attention Do not wear contact lenses Skin Wash all affected skin surfaces with mild soap amp water Remove clothing saturated with contaminant Seek medical attention if rash persists Ingestion
77. Throat amount is equal to 5 X width of eye to be formed Note All standard eyes have a width of the Standard Eyes 7 lay length Example 6 wide X 12 long eye Pull amount or tail is equal to 3 75 X diameter d of rope Throat amount is equal to 40 X diameter d of rope See example below Use assembly procedure for Flemish Eye on Page 28 Example Standard Eye 7 lay for 1 2 wire rope Step 1 To find the Pull Amount or tail Mark 1 See Figure 1 Mark 1 3 75 X d dis the diameter of the rope Example Mark 1 3 75 X 5 1 875 This is Mark 1 Diameter of Rope Step 2 To find the throat Mark 2 See Figure 2 Mark 2 40 00 Xd Example Mark 2 40 00 X 5 20 00 a Standard Throat Constant Diameter of Rope Measure from Mark 1 This is Mark 1 Total amount of rope to form Standard eye including tail from end of rope for Flemish style splice is 21 875 Figure 2 Copyright 2012 The Crosby Group LLC 27 All Rights Reserved Flemish Type Wire Rope Sling Eyes Fabrication Procedure for Mechanical Spliced Flemish Eyes We recognize that there are other ways to produce a Flemish Eye However this is one way that can be employed Step 1 Mark 1 and 2 See page 27 for instructions Slide proper sleeve on rope and unlay the rope dividing it into 2 sections consisting of 3 strands and 3 strands plus the core See page 23 for recommended rope to use Step 3 Relay or cros
78. 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 2 e To use 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 than 6 See Figure 2 e Properly match socket wedge and clip See Table 1 to wire rope size rev 3 Copyright 2012 The Crosby Group LLC All Rights Reserved e Align live end of rope with center line of pin See Figure 2 e Secure dead end section of rope See Figure 2 e Do not attach dead end to live end or install wedge backwards See Fig 3 e 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
79. achine Machine Machine Schedule e e msee y e e w Oe a em O a d o o o o 6 emesos a fy Torque in ft Ibs Copyright 2012 The Crosby Group LLC All Rights Reserved Die Holder Bolt Torque 1 4 20 UNC 13 5 16 18 UNC 15 5 8 11 UNC 211 7 8 9 UNC 583 13 14 NATIONAL HYDRAULIC SWAGING MACHINE TORQUE MAINTENANCE INFORMATION i A Table A 500 Ton Swaging Description Machine Tie Rod Nuts Piston Bolts Packing Gland Nuts over spacers only all others hand tighten Platen Guide Bolts Packing Gland Bolts Side Cylinder Bolts Guide Bushing Bolts Item No Req d Description 1 1 Cylinder 2 1 Housing Cap 3 1 Piston 4 4 Tie Rod 5 8 Nut 6 1 Platen 7 2 Guide 8 1 Gland 9 4 Bushing 10 1 Packing Set 11 12 Packing Gland Nut 12 4 Packing Gland Spacer 13 12 Stud SL i 14 4 Cap Screw e BY WINS ie xX 15 4 Cap Screw ay PASSE x 9 16 2 Lower Bracket ana m Ji JAE LX 17 1 Upper Bronze Rin NIS I WZ 18 2 Tee Bracket i E Y AY AS id o 19 8 yea Screw Ai Wan 9 20 2 Side Cylinder KN Ys ae 21 1 Lower Bronze Ring W al Vj A 1 Block LY ns B 4 Stud WY 5 W C 4 Nut hm paa Ls NE D 1 Copper O Ring TTF lhe E E 4 a X 1 Top of Cylinder Y 1 Bottom of Packing Cavity Torque in Ft Lbs 800 Ton 1000 Ton 1500 Ton Swaging Swaging Swaging Maintenance Machine Machine Machine Schedule Weekly Monthly Weekly W
80. al passes may be required to round out the shank and insure the correct after swage dimensions are met Failure to reduce Swaging Machine tonnage to Working Load Limit WLL of die can cause serious injury or death For instructions on adjusting tonnage see Die Working Load Limit Pressure Adjustment section of Swaging Machine Application Instructions See Page 12 Copyright 2012 The Crosby Group LLC 4 All Rights Reserved COLD TUFF Swage Fittings Buttons Swaging Methods for S 409 Buttons National S 409 Steel Buttons are designed for use with swaging in National dies These swage fittings are designed to be used on one 1 part of 6 X 19 or 6 X 37 FC IPS or IWRC EIPS Right Regular Lay wire rope In addition these products are designed to be used with inch size 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 Cold Swaging Process Cold swaging is a process which causes considerable movement and work hardening of the steel in the fitting Exerting extreme pressures the swaging machine forces the steel to flow into the crevices between the wires and strands of the wire rope At the same time the swaging machine forces the material to flow plastically along the length of the wire rope These are a few of the reason
81. at is that the lubricant in the rope remains intact and is not burned off It is an easy matter to replace the lubricant on the outside of the rope but very difficult to replace the lubricant in the centre of the rope It is as it does not require any heat acid etching or neutralising an inherently safe method for the rigger to use both in the shop and on site Finally the quality and reliability of this method is without question superior to other methods of socketing It also avoids the damage caused to ropes by other mechanical methods of attachment of end fittings which may affect both the tensile and fatigue potential Bibliography Dodd J M Resin As A Socketing Medium Wire Industry May 1981 Chaplin Dr C R Load Transfer Mechanics in Resin Wire Industry Oct 1984 Sharman P C Socketing Cordon Dr C R R The Use Of Resin For Man Riding In Mine Shafts IMEMME March 1987 92 Copyright 2012 The Crosby Group LLC All Rights Reserved poEMENT Fe 0 thes PO SUYqroun Ai GENERAL OFFICES a 2801 DAWSON ROAD 74110 5040 CERTIFIED COMPANY P O Box 3128 TULSA OKLAHOMA 74101 3128 TELEPHONE 918 834 4611 CROSBY FAX 918 832 0940 August 2 1993 TECHNICAL DATA SHEET REUSE OF CROSBY SPELTER SOCKETS The following are general guidelines for the reuse of Crosby 416 417 Spelter Sockets The use and inspection of used spelter sockets is the responsibility of the user I Procedure for Removing Spelter Core A Cut the r
82. ate a crack To avoid excess flashing do the following e Select proper die e Make sure that dies are in good condition and properly lubricated e Apply lubricant such as a light hydraulic oil to both die cavities and the lower die face e Follow swaging instructions on pages 54 55 CORRECT EXCESS FLASHING 50 S 319SWG 4 i f Identification Stamping For identification purposes National swage products can be impression stamped after swaging Properly done there should be no concern for fractures initiating from such impressions To stamp S 319SWG hooks e Use round corner or low stress stamps Stamp to maximum depth of 0 015 in 1 64 e Stamp in the area on the side of the socket head as shown in the illustration NOTE DO NOT STAMP ON SWAGING SHANK Copyright 2012 The Crosby Group LLC All Rights Reserved Shank Hooks for Swaging an F k S 319SWG e Wide range of sizes available e Working Load Limit 0 4 14 Ton e Wire Rope sizes 3 16 through 1 1 8 e Swage shank hook terminations have an efficiency rating of 95 based on the catalog strength of wire rope e Quenched and Tempered Heat treat process allows for ease of swaging e Forged Carbon Steel e Design Factor of 5 to 1 e Black Oxide finish on body Shank is uncoated e Utilizes standard Crosby 319N shank hooks with interlocking hook tip Each hook has a pre drilled cam which can be e
83. aterial Safety Data Sheet MSDS Complies with OSHA Hazard Communication Standard 29 CER 1910 1200 the Grosbyqroup SECTION 1 PRODUCT IDENTIFICATION Manufacturer s Name The Crosby Group LLC Identity Wirelock Booster Pack Emergency Telephone Number 918 834 4611 Address 2801 Dawson Road Tulsa Oklahoma 74110 TEIE PONE NUMPEr TON ermanon te ere Date Prepared August 8 2012 Signature of Preparer optional SECTION Il HAZARDOUS INGREDIENTS IDENTITY INFORMATION Hazardous Components OSHA ACGIH Other Limits of Specific Chemical Identity Common Names PEL TLV Recommended PEL and TLV Levels are in parts per million ppm SECTION Ill PHYSICAL CHEMICAL CHARACTERISTICS Specific Gravity 1 33 Boiling Point NA Melting Point 103 C approx H 0 1 Vapor Density NA Evaporation Rate NA Vapor Pressure much less than 1 Air 1 Butyl Acetate 1 mm Hg At 20 C Solubility in Water lt 1 0 g 100g of Water 20 C Appearance and Odor Colorless Odorless Solid SECTION IV FIRE AND EXPLOSION DATA LEL UEL Flash Point NA Flammable Limits Not Available Highly Flammable When Dry Autoignition Temperature 103 C 217 F Special Fire Fighting Procedures Wear self contained breathing apparatus Avoid contact with combustibles such as wood and paper Dibenzoyl Peroxide Dust may form explosive mixture in air Sensitivity to mechanical impact static discharge SECTION V REAC
84. aterials to Avoid Signs and Symptoms of Exposure Benzoyl Peroxide Irritation To Eyes Nose Throat Skin Skin rash with chronic exp 1 2 Propanediol Mild to non existent effects at high dosages to Eyes Nose Throat Skin Copyright 2012 The Crosby Group LLC 83 All Rights Reserved SECTION VI HEALTH HAZARD DATA Continued from page 1 Emergency and First Aid Procedures Eyes Flush with water while raising upper and lower eyelids Seek medical attention Do not wear contact lenses Skin Wash all affected skin surfaces with mild soap amp water Remove clothing saturated with contaminant Seek medical attention if rash persists Ingestion For Styrene DO NOT induce vomiting Seek medical attention SECTION VII PRECAUTIONS FOR SAFE HANDLING AND USE Steps to take in case material is released or spilled Evacuate personnel not equipped with proper protective clothing and devices Ventilate the area of the spill Keep spill from incompatible materials it may come in contact with Remove ignition sources Waste Disposal Method Styrene Absorb small quantities on paper towels Allow for adequate ventilation in appropriate well ventilated location Large quantity spills should be absorbed in minimal quantities of Vermiculite dry sand or earth Dispose of in sanitary landfill Precautions to take in handling and storing Do not attempt to capture styrene in containers made of
85. be reused Procedures For Speltering Sockets amp Buttons 1 The proper procedure for speltering sockets can be found in the Wire Rope User s Manual 3rd Edition Copyright 2012 The Crosby Group LLC All Rights Reserved Appendix C American Petroleum Institute API Recommended Practice 9B RP9B 11th Edition September 2002 or SO17558 2006 Steel Wire Ropes Socketing Procedures Molten Metal and Resin Socketing 2 Some standards API ISO BSI recommend preheating of the zinc spelter socket button before pouring This temperature shall not exceed 850 F 450 C 3 Resin spelter sockets buttons shall follow the procedure outlined by the resin manufacturer See WIRELOCK Pages 73 77 Proof Testing We recommend the socketed assembly be proof tested at two 2 times the Working Load Limit 2 x WLL assigned to the socketed assembly STANDARD CONSIDERATIONS ASME B30 9 All slings terminated with sockets shall be proof loaded The proof load shall be a minimum of 2 and a maximum of 2 5 times the single leg vertical hitch rated load The proof load should be that specified by the wire rope or fitting manufacturer s recommendation provided that it is within the above specified proof load range When sockets are used in sling assemblies the minimum recommended design factor is 5 ASME B30 5 Cranes require that boom pendants terminated with sockets be proof tested When sockets are used in boom pendant lines
86. ccccceseceeeeeees 105 Copyright 2012 The Crosby Group LLC 97 All Rights Reserved Wedge Socket Information Application and General Information if W j S 421T aD 422T S 432T Super Terminator Utility Terminator Figure 1 Figure 2 Figure 3 Wedge sockets are commonly used on the end of crane ropes as a means to attach the hoisting rope to the crane block or overhaul ball Primary advantages of wedge style sockets include e Simplicity of installing and detaching product from the end of wire rope e When a mechanical spliced eye or poured socket is not practical e Applications where on the job attachment and quick or frequent rope replacement is necessary Crosby offers two standard styles of wedge sockets e The TERMINATOR Wedge Socket for use with standard wire ropes e The Super TERMINATOR Wedge Socket designed for high performance high strength compacted strand rotation resistant wire rope Efficiency Efficiency ratings for wire rope terminations are based upon the minimum breaking force of wire rope S 421T and US 422T Sockets The efficiency of Crosby Wedge Sockets is 80 percent when installed properly S 423T Super Terminator Sockets Due to the unique construction of the various high performance high strength compacted strand rotation resistant wire ropes Crosby cannot make a broad general statement that all current and future designed ropes when properly asse
87. ce conditions down to temperatures of 40 F 40 C McKissick blocks can be used in general service conditions down to temperatures of 4 F 20 C At temperatures from 0 F to 40 F 18 C to 40 C good rigging practice requires special attention in the following areas Lifting should be performed at a steady rate Shock loading should be avoided Equipment containing bearings should have increased inspection and maintenance schedule and may require special lubrication All lifting equipment should be given a thorough visual inspection before each lift Remove nicks gouges or cracks by grinding 5 maximum material removal Do not use fittings that have been welded or modified after leaving the factory If determined to be necessary by the user lifting equipment should undergo periodic inspection by dye penetrant or magnetic particle oo oN surface inspection For operation at temperatures below 40 F 40 C consider Cold Tuff products or contact Crosby Engineering Elevated Temperature Service Crosby forged and cast steel products can be used in general service conditions up to temperatures of 400 F 204 C The following should be considered when operating up to temperatures of 400 F 204 C 1 Products that contain non ferrous materials and lubricants plastics etc may be adversely affected by high temperatures and typically should not exceed 200 F 93 C 2 Galvanized plated or pa
88. cement buttons and sockets are available Locking feature available to prevent rotation of rope Button contains cap with eye that can be attached to and used to pull rope during reeving process O 0O A O 65 Button Spelter Sockets SB 427 e Available in six 6 sizes from 1 2 to 1 1 2 13mm 38mm e Button Spelter terminations have a 100 efficiency rating based on the catalog strength of the wire rope e Designed for use with mobile cranes Can be used to terminate high performance rotation resistant ropes and standard six 6 strand ropes e Easy to install assembly utilizes Crosby WIRELOCK socketing compound e Sockets and buttons are reusable e Replacement buttons and sockets are available e Locking feature available to prevent rotation of rope e Button contains cap with eye that can be attached to and used to pull rope during reeving process SB 427 Button Spelter Sockets Size Stock Load Each Only Only in No t Ibs StockNo StockNo A B c D E F J K Lt M_ 5 8 3 4 16 19 1052014 45 10 3 1052116 1052318 9 44 3 88 153 138 144 66 175 428 38 3 43 7 8 1 22 26 1052032 82 29 2 1052134 1052336 12 88 5 48 2 03 2 00 2 00 89 244 5 62 62 4 52 SB 427TB Bolt Nut and Cotter Pin SB 427 Socket Button Dimensions Size Stock Load Each Only Only in No t Ibs Stock No StockNo A
89. ct is made between the sleeve and dies Open dies and rotate fitting 45 to 90 degrees Copyright 2012 The Crosby Group LLC All Rights Reserved 1st STAGE Step 2 Assemble Flemish Eye See page 28 for assembly instructions Step 4 Lubricate both die cavities and lower die face See page 24 for proper die selection Step 6 2nd pass allow dies to remain open approximately Y the distance from the time initial contact is made between the sleeve and dies Open dies and rotate fitting 45 to 90 degrees Step 8 4th and 5th pass If sharp flashing does not occur close die Open dies and rotate fitting 45 to 90 degrees between each pass Flemish Type Wire Rope Sling Eyes 1 13 4 Swaging Instruction for Flemish Eye Continued 2nd Stage Lubricate both die cavities and lower die face See page 24 for proper die selection Step 9 1st pass allow dies to remain open approximately Y the distance from time initial contact is made between sleeve and dies Open dies and rotate fitting 45 to 90 degrees Step 10 2nd pass allow dies to remain open approximately Y the distance from the time initial contact is made between the sleeve and dies Open dies and rotate fitting 45 to 90 degrees Step 11 3rd pass allow dies to remain open approximately Y the distance from the time initial contact is made between the sleeve and dies Open dies and
90. ct permanent assemblies annually or more often in severe operating conditions e Do not mix and match wedges or pins between models or sizes e Always select the proper wedge and socket for the wire rope size Assembly Safety e Properly match socket and wedge assembly to wire rope size e Ensure the dead end is properly seized before inserting the wire rope into the wedge socket basket High performance high strength compacted strand rotation resistant wire ropes are sensitive to seizing methods For specific seizing procedures contact the wire rope manufacturer e The tail length of the dead end should be a minimum of 20 rope diameters but not less than 10 See Fig 1 e Mount wedge socket basket in vice e Insert live end of wire rope into wedge basket aligning live end of rope with center line of pin Make a loop and return See Figure 2 e Pull on live line to remove excess out of loop leaving enough room to properly insert wedge into basket See Figure 3 e Secure rope to SUPER TERMINATOR Wedge with clamp See Figure 4 e Pull Wedge and rope into basket until tensioner bolt with washers properly applied can engage threads in nose of wedge See Figure 5 e Use torque wrench to tighten tensioner bolt to recommended torque value properly seating wedge and rope into basket Reference Table 1 for recommended Torque in Ft Lbs e Secure dead end section of rope with clip base Tighten bolts to recommended torque va
91. ct swage dimensions See pages 17 18 for proper way to check fittings after swage dimensions Copyright 2012 The Crosby Group LLC All Rights Reserved Flemish Type Wire Rope Sling Eyes 4 1 Flemish Eye Terminations for 1 4 thru 1 National S 505 Sleeves For larger sizes see pages 31 34 Dies for National S 505 Standard Steel Sleeve sizes 1 4 thru 17 are provided with two cavities National 1 4 through 1 S 505 sleeves are designed to be swaged only in the tapered cavity of a two cavity die in a National Hydraulic Swaging Machine Step 1 Slide sleeve over rope Step 3 Slide sleeve fully over ends of wire rope Step 5 1st pass allow dies to remain open approximately Y the distance from time initial contact is made between sleeve and dies Open dies and rotate fitting 45 to 90 degrees Step 7 3rd pass If sharp flashing does not occur close die Open dies and rotate fitting 45 to 90 degrees Additional swaging may be required to provide smooth finish and achieve proper after swage dimensions Step 2 Assemble Flemish Eye See page 28 Step 4 Lubricate both die cavities and lower die face See page 24 for proper die selection Step 6 2nd pass allow dies to remain open approximately Y the distance from time initial contact is made between sleeve and dies Open dies and rotate fitting 45 to 90 degrees Step 8 4th pass Close dies to round fi
92. d 24mm Swaging on 6mm through 26mm metric ropes for Flemish Eye slings requires the selection of the proper S 505 Standard Steel sleeve and the use of the tapered cavity only Refer to page 24 of the Wire Rope End Termination User s Manual for proper sleeve and die selection Dies for 12mm 20mm and 24mm Swaging on 12mm 20mm and 24mm metric ropes for Flemish Eye slings requires the selection of the proper S 505 Standard Steel sleeve and the use of both the open cavity and tapered cavity in special dies Refer to page 25 of the Wire Rope End Termination User s Manual for proper sleeve and die selection Dies for 28mm and larger Swaging on 28mm and larger metric ropes for Flemish Eye slings requires the selection of the proper S 505 Standard Steel sleeve and the use of 2 sets of open channel dies 1st stage and 2nd stage for each size Beginning with the 1st stage die and finishing with the 2nd stage die will achieve proper after swage dimensions Dies for S 505 sleeves 28mm and larger are single cavity with open channel Refer to page 24 of the Wire Rope End Termination User s Manual for proper sleeve and die selection Important If the specific size metric rope required is not listed on page 24 of the Wire Rope End Termination User s Manual refer to Intermediate Metric Die Chart on page 25 of the manual for proper sleeve and die selection Dies for QUIC PASS Swaging System 1 4 through 1 1 2 The QUIC PA
93. d poured see 6 3 within the temperature range of 27 F 95 F 3 C 35 C The kits are not adversely affected by storage at temperatures below 27 F 3 C It is recommended the WIRELOCK kit be stored ina cool place 7 The operating temperature of WIRELOCK is 240 F to 65 F 115 C to 54 C 8 When cured WIRELOCK has a hardness of approximately 55 Barcol When the resin has set fully Opaque green or mustard color only a slight scratch mark will be seen when a sharp object such as a screwdriver blade is scraped over the surface of the resin On a small socket it is quite normal to have a very thin tacky layer on the surface of the resin The scratch test can be carried out through this layer 9 Cracks which may appear on the top of the cured cone are surface crazing only and are the result of heat stresses and shrinkage upon a thin layer of unfilled resin covering the tops of the wires The crazing does not affect the strength of the termination within the socket 10 Shrinkage of the WIRELOCK cone may leave a gap between the cone and the socket wall This is normal particularly with large sockets and high ambient temperatures This in no way affects the efficiency of the assembly Upon loading the cone will be seated perfectly in the socket The shrinkage of WIRELOCK is between 1 5 2 0 In high volume WIRELOCK the shrinkage is about 0 5 11 Excessive numbers of horizontal rings in the socket
94. dications as outlined above shall not be reused 67 DU NUTI BE FOULED You could be putting lives and your business at risk for a few pennies There are suppliers who would like you to believe swaging sleeves are a commodity Don t be fooled IT S NOT SO Since 1973 Crosby s proprietary COLD TUFF heat treat process has made swaging sleeves more reliable during the demanding conditions of swaging COLD TUFF virtually eliminates the cracking of sleeve during the swaging process especially at extremely low temperatures The steel microstructure created from the COLD TUFF heat treatment process reveals a uniform structure in the Crosby sleeve that result in Charpy impact values averaging up to ten times greater than those of competitive sleeves See photo lower left The improved steel microstructure provides increased resistance to cracks that can occur during the sling building process Cracks are initiated at stress risers Crosby COLD TUFF sleeves dramatically reduce the effects of stress risers that can occur during swaging where the cold worked sleeve makes ie contact with the wire Stress risers are not detectable Qe through visual inspection See photo at right Swaged Sleeve Cross Section Because of the higher Charpy values found in Crosby COLD TUFF sleeves stress risers caused by stenciling are not detrimental COLD TUFF process results in superior ductility that reduces the
95. e 4 7 Lay Type Il Rope Large Eye Type II Rope _ Thimble Type Il Rope Large Eye Type I Rope Type Il Rope Type Il Rope S 409 S 505 y S 50 S 506 Sockets Buttons Sleeves Turnbacks Rope Types _Type II 6 x 19 and 6 x 36 FC IPS RRL Wire Rope _ Copyright 2012 The Crosby Group LLC 56 All Rights Reserved Crosby Spelter Terminations G 416 Crosby Open Spelter Socket SB 427 Crosby Button Socket G 417 G 517 Crosby Closed Crosby Spelter Socket Mooring Socket ae WIRELOCK Socketing Table of Contents Spelter Termination Application and Closed Spelter Socket cccsscccseeceeeeeseeseeeeeeeeees 62 General Information cccccccceceeeeeeeseeeeeees 58 59 Crosby Mooring Sockets 0 c cccscssssessseseeeeeeseees 63 64 Crosby Spelter SOCKETS wi sciicsaiacenonstivdstenantswanedesaannaaiwnns 60 Crosby Button Spelter SOCKS ccc ccc ccccnccccccccccence 65 67 Open Spelter SOCKEtS eect eee eee reer 61 WIRELOCK corina 69 95 Copyright 2012 The Crosby Group LLC All Rights Reserved 57 Spelter Terminations Application and General Information G S 417 G 517 G S 416 SB 427 W416 7 Crosby Crosby Crosby Button WIRELOCK Open Closed Mooring Socket Socket Spelter Spelter Socket Compound Socket Socket Figure 1 Figure 2 Figure 3 Figure 4 Figure5 There are four basic types of sockets available from Crosby that utilize a poured zinc
96. e Crosby Group LLC All Rights Reserved factors are intended to account for end connector efficiency and total reeving system efficiency of 80 or greater ASME B30 5 requires that Wire rope clips used in conjunction with wedge sockets shall be attached to the unloaded dead end of the rope only ASME B30 26 The wedge socket shall be assembled as recommended by the manufacturer or a qualified person Wedge socket materials shall be of sufficient strength such that failure of the wire rope will occur before failure of the wedge socket Before installing a wedge socket on plastic coated or plastic impregnated wire rope consult the manufacturer or a qualified person Each new wedge socket body and wedge shall have forged cast or die stamped marking by the manufacturer to show e Name or trademark of manufacturer e Size e Model if required to match wedge to body Crosby wedge sockets exceed ASME B30 26 identification requirements The live end of wire rope in the wedge socket cavity shall be in alignment with the socket s pin The assembler shall match the proper wedge with the socket for the wire rope to be installed Wedges shall not be interchanged between different manufacturers sockets or models The length of dead end tail of the wire rope shall be as required by the manufacturer or a qualified person The dead end of the wire rope shall not be secured to the live end of the wire rope such that it
97. e Crosby S 421W wedge see Fig 1 Do not assemble or use The design of the basket for each US 422T TERMINATOR Wedge Socket does not allow proper fit to the old style UWO 422 wedge See Fig 1 Do not assemble or use All S 421T and US 422T TERMINATOR baskets are marked with a capital T or TERMINATOR TERMINATOR Non TERMINATOR Wedge S 421TW UWO 422T S 421W UWO 422 Figure 1 QUIC CHECK Go and No Go features QUIC CHECK 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 e Inspect permanent assemblies annually or more often in severe operating conditions e Do not mix and match wedges or pins between models or sizes e Always select the proper wedge and socket for the wire rope size Assembly Safety e Use only with standard 6 to 8 strand wire rope of designated size For intermediate size rope use next larger size socket For example
98. e Sockets csccessseeeeseeeeens 37 Copyright 2012 The Crosby Group LLC 4 All Rights Reserved Introduction to Swaging There are many styles of terminations that can be made in the end of wire rope using swage fittings The choice of the style is dependent upon the application and the task The Working Load Limit rating of the termination wire rope combination is not entirely a function of the fitting being used Therefore the listing of the working load ratings is not within the scope of this literature Refer to the Wire Rope Technical Board s Wire Rope Sling Users Manual for these values It is important that the proper components be used to make a termination For a specific style wire rope termination you must choose the correct size and type of fitting and its corresponding swaging die The information displayed in this brochure is based upon using only a one 1 part 6 X 19 or 6 X 36 FC IPS or IWRC EIPS Right Regular Lay Wire Rope National Swage fittings are designed to be used with inch and metric size wire ropes as designated in this manual and the Crosby general catalog Before using any National Swage fitting with any other type lay construction or grade of wire a i rope it is recommended that the termination be AN destructive tested and documented to prove the j adequacy of the assembly to be manufactured 8 Copyright 2012 The Crosby Group LLC All Rights Reserved Swaging In
99. e a termination efficiency of 100 percent based on the minimum breaking force of the wire rope see table at top of page Ratings for Crosby Spelter Sockets are based on recommended use with 6 x 7 6 x 19 or 6 x 36 IPS or XIP EIP XXIP EEIP RRL FC or IWRC wire rope Strand constructed with minimal number of wires e g 1 x 7 requires special consideration that socket basket length be five 5 times the strand diameter or fifty 50 times the wire diameter whichever is greater 58 Figure from Left Efficiency INSTALLATION INFORMATION 1 The spelter process begins by inserting the end of the wire rope into the narrow end of the cone shaped socket or button 2 Before pouring the socket the wire must be broomed and properly cleaned Once the socket or button and wire rope are properly prepared the broomed wire rope is pulled inside the socket cavity 3 The socket or button cavity is then poured with molten zinc or more commonly an epoxy resin called WIRELOCK 4 The socket must then be allowed to cure based on zinc resin manufacturer s recommendations 5 Assembly length is measured from center line of pins for both open and closed sockets bearing point to bearing point LENGTH Key Facts About Spelter Terminations 1 Poured spelter sockets are occasionally used in sling applications However if used in a choker hitch slin
100. e ends of the unlaid wires from the strands will be at the top of the socket basket Next apply the seizing one 1 socket basket length from the end of the rope minus one 1 rope diameter The length of the seizing must be at least two 2 rope diameters long Additional information can be secured from your Wire Rope Users Manual or your Wire Rope Manufacturers Catalogs or National Standard Seizing wire should be a soft annealed iron wire Seizing of Wire Rope Plastic coated or plastic filled wire ropes must have all plastic material non metallic materials removed from within the broomed area The socket basket should be examined prior to use and loose scale dirt or grease removed Do not use oversized sockets for Wire Rope When socketing Strand the time honoured method of one size up when choosing the socket is generally still applicable in the vast majority of cases However caution should be exercised as tests have shown that the length of the socket basket should be five 5 times the strand diameter or fifty 50 times the maximum wire diameter whichever is the greater Inserting the broom into the socket There are two procedures that can be used to position the broom within the socket The rope 73 WIRELOCK can be inserted into the socket prior to brooming Subsequently the socket can be pulled up over the broom The second method requires that the broom is closed and compacted to enable it to
101. e rope clips to 100 percent for swaged and speltered sockets What does efficiency mean in the field An 80 percent efficient termination will result in only 80 percent of the wire rope s minimum breaking force being available to be utilized To determine the actual working load limit that can be assigned to a particular termination the required design factor must then be applied to this reduced breaking strength Example 1 Wire rope clips need to be applied to 5 8 IWRC EIPS wire rope construction A Crosby 5 8 Wire Rope Clip is considered an 80 efficient termination The wire rope has a nominal strength of 20 6 tons and the design factor is 5 to 1 To calculate the allowed Working Load Limit for the assembly you would do the following calculations _ Termination _ Rope s Minimum PH he Suen ont Efficiency Breaking Force Working Load Limit _ Ultimate Design WLL Strength Factor Or Ultimate Strength 80 x 20 6 16 5 tons WLL 16 5 5 3 3 tons In summary the Working Load Limit of the assembly is determined by the efficiency of the termination the nominal strength of the rope and the design factor Example 2 The WLL needs to be determined for a Flemish Eye mechanical spliced wire rope sling using 5 8 IWRC EIPS wire rope construction A properly made Flemish Eye sling has an approximate efficiency of 96 The wire rope has a nominal strength of 20 6 tons and the design factor is 5 to 1 To calculat
102. e spelter socket is attached by inserting the end of the wire rope into the narrow end of the cone shaped socket 2 Before pouring the socket the wire must be broomed and properly cleaned Once the socket and wire rope are properly prepared the broomed wire rope is pulled into the socket cavity 3 The socket cavity is then poured with molten zinc or more commonly an epoxy resin called WIRELOCK 4 The socket must then be allowed to cure based on zinc resin manufacturer s recommendations 5 Assembly length is measured from center line of pins for both open and closed sockets Specific Instructions Socketing Using WIRELOCK Resin Material Seizing cleaning brooming and preparation of wire rope and pouring of WIRELOCK is to be carried out per instructions provided in the Wire Rope End Terminations User s Manual see pages 73 77 in this document and WIRELOCK Warnings and Application Instructions located on the WIRELOCK Product or in the Crosby General Catalog 60 Socketing using Zinc Spelter Material Seizing cleaning brooming and preparation of the wire rope and pouring of zinc is to be carried out in accordance with recommendations of the Wire Rope User s Manual 3rd Edition Appendix C American Petroleum Institute API Recommended Practice 9B RP9B 11th Edition September 2002 or IS017558 2006 Steel Wire Ropes Socketing Procedures Molten Metal and Resin Socketing Before operatio
103. e the allowed Working Load Limit for the assembly you would do the following calculations Ultimate Strength 96 x 20 6 19 8 tons WLL 19 8 5 3 9 tons Note The efficiencies above are valid only if the terminations are properly fabricated Copyright 2012 The Crosby Group LLC All Rights Reserved Swage Terminations S 501 502 Open Swage Closed Swage 319SWG Socket Socket Shank Hook 1500 Ton Hydraulic Swaging Machines S 505 Standard S 506 S 409 Steel Sleeves Duplex Sleeve Swage Button Table of Contents Introduction to Swaging ccccseeecseeeeseeeeeeeeeseeeeseeeees 8 National Closed Swage Sockets cccsssseesseeeeens 38 SWAGING Information cccseeeeeseeeeeceeeeeceeseesseeeeseaees 9 Swage Socket Terminations 14 1 cceeeeeeeeeeeees 39 National Hydraulic Swaging Machines 00 10 Swage Socket Terminations 1 1 8 amp Larger 40 Swaging Machine Warning cccsseseecsseeeeneeees 11 18 Swage Socket Terminations Progressive Swaging 41 Die IATORIMAN OM ssnin ensa N 19 20 Cold Tuffe Swage Fittings Buttons ccccccee 42 Cold Tuffe Swage Fittings Intro ce ceeeeeeeeeeeeeees 21 National Swage ButttONns ccccsssecesseseeeeeeeeeeeeeeens 43 Cold Tuff Swage Fittings S 505 eens 22 Button Terminations 1 8 7 8 ccccseseeeeseeeeeeeees 44 Nati
104. e time the WIRELOCK gels in the socket As the WIRELOCK cures a chemical exothermic reaction occurs causing a considerable rise in temperature Temperatures in excess of 212 F 100 C may be reached in large volume kits in the mixing container In the socket where the wires of the rope and the socket itself act as a heat sink the maximum temperature likely to be achieved will be of the order of 160 F 175 F 70 C 80 C 9 Movement kit Always mix all of the resin with all of the powder Never mix less than the total contents of both cans 76 9 1 Movement of resin poured sockets may damage the soft resin and reduce the efficiency of the termination Resin poured sockets should not be moved for a minimum of ten 10 minutes after the material in the socket has gelled Copyright 2012 The Crosby Group LLC All Rights Reserved WIRELOCK 10 Check on Penetration 10 1 A visual check for penetration of the resin into the socket bottom can be made by removing the centralizing clamp and the plasticine or putty Seizing on the rope adjacent to the neck of the socket should be removed up to the point where it enters the socket 11 Re Lubrication 11 1 After removing the rope from the vice any degreased area of the rope below the socket should be re lubricated 12 Loading 12 1 The rope can be put into service or proof loaded one 1 hour after the material in the socket has gelled 12 2 Whenever po
105. eck termination for proper after swage dimensions See page 17 for proper use of No Go Gauges Additional swaging may be required to provide smooth finish and achieve proper after swage dimensions Dies must be fully closed before swaging is complete 44 Copyright 2012 The Crosby Group LLC All Rights Reserved Button Terminations 1 amp Larger S 409 Button Terminations 1 15 through 1 1 4 17 See page 44 for smaller sizes Buttons are swaged in open channel dies Refer to chart on page 43 for proper die selection To swage the button use the following procedure Step 1 Slide wire rope through button until the end of the wire rope protrudes a minimum of 1 8 from the end of the button After swaging the rope should be about flush with the button end Step 3 1st pass allow dies to remain open approximately Y the distance from the time initial contact is made between the button and dies Open dies and rotate fitting 45 to 90 degrees Step 5 5th pass if sharp flashing does not occur close dies Open dies and rotate fittings 45 to 90 degrees Step 2 Lubricate both cavities and lower die face See page 43 for proper die selection Step 4 2nd 3rd and 4th passes allow dies to remain open approximately 1 2 the distance from the time initial contact is made between the button and dies Open dies and rotate fitting 45 to 90 degrees Ste
106. ed 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 5 8 225 iN mh 9 16 9 16 16 225 37 C A 360 55 360 O1 O1 O Od GO Go Go O01 01 01 O O 114 The following example illustrates the correct use of Table 1 in determining the proper application of Crosby G 429 Fist Grip Clips Example An installation requires the use of 7 16 6 x 19 RRL IPS wire rope From Table 1 Clip Size 7 16 Number of Clips 2 Amount of Turnback 6 1 2 Torque in Ft Lbs 65 Table 1 Amount of Rope to Minimum Rope Size No of Turn Back in in Clips in Inches 516 516 2 514 3 I8 i i Torque Clip Size Copyright 2012 The Crosby Group LLC All Rights Reserved CROSBY FIST GRIP CLIPS WARNINGS AND APPLICATION INSTRUCTIONS G T iv an 7 ob _ _ a New Style Fist Grip Fist Grip Clips 3 16 5 8 3 4 1 1 2 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 Do not mismatch Crosby clips with other manufacturer s clips Prepare wire rope end termination only as instructed Do not use wi
107. ed torque see D TREAD DIAMETER will KA F 8 used in place of a thimble add one additional clip 4 F F G 450 SS 450 Clip spacing should be J Red U Bolt 316 Stainless Steel as shown age 5 WIRE ROPE SPLICING ii PROCEDURES z ii The preferred method of Failure to read understand and follow these splicing two wire ropes together is to use inter locking instructions may cause death or serious injury turnback eyes with thimbles using the recommended number Read and understand these instructions before of clips on each eye See Figure 5 P T sel using clips An alternate method Nh a is to use twice the SSS ap AS PSS oe Match the same size clip to the same size wire rope number of clips as oe used for a turnback Figure 5 termination The rope ene a ee Do not use with plastic coated wire rope ends are placed parallel to each other IES amp J SSN RSSSSq SF SSS FSS D Prepare wire rope end termination only as instructed Apply first load to test the assembly This load N Es should be of equal or greater weight than loads he A cha E expected in use Next check and retighten nuts to shown in the application DEAD END LIVE END recommended torque See Table 1 this page instructions The Figure 6 minimum number of Efficiency ratings for wire rope end terminations are based upon clips should be installed on each dead end See Figure 6 the cata
108. ed with minimal number of wires e g 1 x 7 requires special consideration that socket basket be five 5 times the strand diameter or fifty 50 times the wire diameter whichever is the greater Open grooved sockets meet the performance requirements of Federal Specification RR S 550D Type A except for those provisions required of the contractor For additional information see Crosby General Catalog NOTICE All cast steel sockets 1 5 8 and larger are magnetic particle inspected and ultrasonic inspected Proof testing available on special order Drawing illustrates one groove used on sockets 1 4 through 3 4 Sizes 7 8 through 1 1 2 use 2 grooves Sizes 1 5 8 and larger use 3 grooves G 416 S 416 Open Spelter Sockets ae ee Rope Dia Structural Ultimate i in Ce Je SE ral in mm in t Galv S C Ibs p 4 e7 CU 45 1039619 1039628 110 4 56 ses s40 12 1039637 1039646 130 48 716 12 113 _ 20 1039655 1039664 2 25 5 56 C ones 1416 12 27 1039673 1039682 3 60 67 34 e ones 4 1039691 1039708 583 794 FS 222 a 10 56 e _ 26 30 enea _ 92 f 1039753 1039762 2150 11 61 se ante 14 170 1039799 1039806 4725 1 12 taa 17 44 48 1776 158 268 1030838 1039842 82 00 18 25 F214 2 3 8 56 60 113716 t7 8 360 1039879 1039888 16700 23 50 4 50 2 1 2 2 5 8 64 67 1 15 16 2 1 8 4
109. eekly 6 Months Weekly Weekly 80 M Piston Pump Pistons 96 to 125 all Swaging Machines m i a 4 Torque in ft Ibs Die Holder 1 4 20UNC 13 Bolt Torque 5 16 18 UNC 15 5 8 11 UNC 211 7 8 9 UNC 583 Copyright 2012 The Crosby Group LLC All Rights Reserved Die Information e Improper die selection could result in significant loss of efficiency in the termination National dies and die holders are made solely for swaging properly designed fittings on wire rope and any other uses are prohibited The swaging operation results in a high degree of cold metal flow The movement that occurs between the fitting and the dies will cause wear of the dies Therefore to prolong the life of the dies it is important to always lubricate die faces and cavities between each pass with a light weight oil or high pressure grease When scores appear in the die cavities the dies should be removed from service NEVER EXCEED THE WORKING LOAD LIMIT OF DIES OR DIE HOLDERS All National Standard dies 1 4 through 1 include an open channel die cavity and a tapered die cavity in the same die block Dies for S 505 Standard Steel Sleeves Flemish Eyes Die sizes for 1 4 through 1 Swaging 1 4 through 1 Standard Steel S 505 sleeves on Flemish Eye terminations requires the use of the taper cavity only Refer to page 24 of the Wire Rope End Termination User s Manual for proper die selection Die sizes for 1
110. el hoist and scaffold applications refer to ANSI A17 1 and ANSI A10 4 These standards do not recommend U Bolt style wire rope clip terminations The style wire rope termination used for any application is the obligation pring wee For OSHA Construction applications see OSHA a E A E a E E 1926 251 Cae tie 6 34 225 1 Refer to Table 1 otia tia 78 in following these sN 43 8 t38 7 instructions Turn back WSS NOY pave t12 8 5 _ 30 specified amount of rope Figuet oo Case tse 8 58 430 from thimble or loop 34 rsa 8st 5o Apply first clip one base width from dead end of rope Apply ee n n f U Bolt over dead end of wire rope live end rests in saddle C244 214 8 73 750 Never saddle a dead horse Use torque wrench to tighten AR a E evenly alternate from one nut to the other until reaching the o 106 Si ie he ae e e as 200 required apply the SS SSS Say lfa 1E iene is used for turning back the wire rope add one additional second clip as near the Figure 2 clip See Figure 4 loop or thimble as possible J If a greater number of clips are used than shown in the table the amount of Use torque wrench to tighten evenly alternating until reaching the recommended torque The tightening torque values shown are based upon the threads being clean When more than two clips are required apply the second clip rev 1 112 Copyright 2012 The Crosby Group LLC All Rights Reserved Fist Grip
111. embly to be manufactured 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 Tons e 1000 Tons e 1500 Tons a m l The following features of National Hydraulic Swaging Machines offer ae a number of advantages for high production sling shops Y 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 Four column wide stance which provides the operator ample working clearance between columns and a large area for in process sling storage Vertical swage action which gives an equalized press on the fitting to produce uniform high quality Self locating spring locks snap the shoe type dies into place for quick set up and change 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 e 500 tons 4450 kN e 1000 tons 8900 kN e 1500 tons 13350 kN 1500 Ton Hydraulic Swaging Machines Approximate weight 34 500 Ibs Overall height 8 ft 6 in Fast advance and retract speed Automat
112. end of the rope extends out of small diameter of the button Broomed end of rope should be inserted to the MAX FILL line marked on the button to ensure correct length of engagement with socketing material Socketing Using WIRELOCK Resin Material Seizing cleaning brooming and preparation of wire rope and pouring of WIRELOCK is to be carried out per instructions provided in the WIRELOCK Technical Data Manual and WIRELOCK Warnings and Application Instructions located on the WIRELOCK Product or in the Crosby General Catalog Socketing Using Zinc Spelter Material Seizing cleaning brooming and preparation of the wire rope and pouring of zinc is to be carried out in accordance with recommendations of the Wire Rope User s Manual 3rd Edition Appendix C or other approved procedures Before operation of the wire rope assembly it is recommended that all poured sockets whether with zinc or resin be proof loaded to seat the cone Copyright 2012 The Crosby Group LLC All Rights Reserved Reuse of Crosby Spelter Buttons The following are general guidelines for the reuse of a Crosby SB 427B Button The use and inspection of used buttons are the responsibility of the user Procedure For Removing Spelter Cone e Cut the rope close 12 to the nose end of the button and press the cone out of the button e For metallurgical medical and environmental reasons we do not recommend the use of heat to re
113. ening 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 nick or gouge shall be repaired by grinding lengthwise following the contour of the hook provided that the reduced dimension is within the limits shown in Figure 1 Contact Crosby Engineering to evaluate any crack rev 2 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 Latch attached when secured with bolt nut and pin may be used for lifting personnel A Crosby S 319N hook with an S 4320 Latch attached when secured with cotter pin or bolt nut and pin may be used for lifting personnel Hook must always support the load The load must never be supported by the latch Never exceed the Working Load Limit WLL of the wire rope and hook system Read and understand Wire Rope End Terminations User s Manual before swaging the hook ZONE A REPAIR NOT REQUIRED ZONE B 10 OF ORIGINAL DIMENSION ZONE C 5 OF ORIGINAL DIMENSION ZONE D SEE MINIMUM THREAD SIZE CHART Figure 1 Copyright 20
114. ents of EN13411 6 2003 e Meets or exceeds all requirements of ASME B30 26 including identification ductility design factor proof load and temperature requirements Importantly these sockets meet other critical performance requirements including fatigue life impact properties and material traceability not addressed by ASME B30 26 e Basket is cast steel and Individually Magnetic Particle Inspected e Pin diameter and jaw opening allows wedge and socket to be used in conjunction with closed swage and spelter sockets e 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 e The TERMINATOR Wedge eliminates the potential breaking off of the tail due to fatigue e The tail which is secured by the base of the clip and the tension device is left undeformed and available for reuse e Available with Bolt Nut and Cotter Pin NOTICE Due to the unique construction of various ropes Crosby cannot make a broad general statement that all current and future design of ropes when properly assembled with the Super TERMINATOR will achieve a minimum 80 termination efficiency Contact wire rope manufacturer or Crosby Engineering 918 834 4611 to determine efficiency rating for a specific rope S 423T Wedge Sockets Assembly includes Socket Wedge Pin Wire Rope Clip Tensioner Bolts and Secondary
115. formation The purpose of the swaging process is to produce an efficient termination in the end of wire rope that is permanent Done properly the swaging process will produce one of the most reliable and efficient terminations available Swaging is a cold forming fabrication method used to permanently attach a specially heat treated forged steel fitting to wire rope in order to form slings boom pendants or other useful devices for lifting A hydraulic swager required to provide the slow speed and high pressure necessary for ideal swaging control causes considerable movement of the steel fitting The extreme pressure forces the fitting s steel to flow into the crevices between the wires and strands of the wire rope and at the same time forces the flow along the length of the wire rope There are many types of swaged fittings including Sleeves Sockets Shank hooks Threaded studs Efficiency Efficiency ratings for wire rope end terminations are based upon the minimum breaking force of wire rope Termination efficiencies for swaged fittings typically range from 90 to 100 percent The efficiency of the termination depends on 1 The type of fitting 2 Utilizing proper swaging techniques 3 Type and construction of wire rope These will be covered in greater detail in this section of the manual This publication contains the recommendations of The Crosby Group LLC for the use of its products to produce such
116. formation please refer to the Wire Rope End Terminations User s Manual Copyright 2012 The Crosby Group LLC 25 All Rights Reserved National Steel Swaging Sleeves S 505 COLD TUFF Standard Steel Sleeves S 505 Standard Steel Sleeve Specifications Maximum After Swage Before gait eal a aa he Rope Size Standard Round Dies QUIC PASS Dies i Standard QUIC PASS S 505 Standard QUIC PASS Die Die Die Stock No in mm Ibs Qty r Die lt a Description Stock No Stock No t I 104106 6 7 5 250 100 66 31 26 47 565 1041090 _ 5 16 E E A E eee ee Ee a eee 1041107 pve eno 4 fiofiso si arf s fes zs 769 ave taper to3s4 1923551 oats yne Ti 00 104114 13 50 1041161 9 16 14 25 Par so es soa ize 1247 sie Taper 1ozaaa 1923598 104118 16 25 s4 428 146 1475 3 ATaper 1192462 1923614 o0 iss 168 1738 TBTaper 192480 1923635 413 172 1 1 8 Open 1041269 1 1 8 28 29 260 Bulk 2 170 1st Stage 1192523 1923677 2nd Stage 1192541 1 1 4 Open 1041287 1 1 4 31 32 355 Bulk i f 2 405 1st Stage 1192621 1923698 2nd Stage 1192587 1 3 8 Open 1041303 1 3 8 34 35 423 Bulk i 2 610 1st Stage 1192667 1923717 2nd Stage 1192621 1 1 2 Open 1041321 1 1 2 37 38 499 Bulk 2 835 1st Stage 1192649 1923736 2nd Stage 1192667 For metric rope sizes not shown see Intermediate Metric Die Chart on page 25 S 505 Standard Steel Sleeve Specifications Swager
117. g application the rated capacity must be reduced based on angle of choke See wire rope capacity chart for complete information 2 Assemblies with poured sockets can have tight tolerances Tolerances as small as plus or minus 1 8 inch is not uncommon 3 Specifications such as fitting type orientation of pin whether zinc or epoxy resin is to be used and type of application should be communicated to the fabricator of the socket assembly 4 Proper training is required before attempting to pour sockets See proper socketing procedures in following pages for complete information Copyright 2012 The Crosby Group LLC All Rights Reserved Spelter Terminations Reuse of Crosby Spelter Sockets and Buttons Crosby allows the reuse of sockets and buttons so long as recommended procedures are followed The following are general guidelines for the reuse of Crosby 416 417 Spelter Sockets and Crosby 427 Spelter Buttons The use and inspection of used spelter sockets and buttons is the responsibility of the user Procedure for Removing Spelter Cone 1 Cut the rope close 1 2 to the nose end of the socket button and press the cone out of the basket of the socket 2 We do not recommend the use of heat to remove the spelter cone for metallurgical medical and environmental reasons A However if this is the only means available for removing the zinc cone care should be taken not to exceed 850 F 450 C surface temperature
118. g p j ral l a E m t A ts oe k F 2A Ly ra A i Tl i P T Tt n I AA N Side Load Special dies and adapters available upon request Proper die selection and after swage dimensional information can also be found in the following Crosby sources NationaL SwaceE DiE GuibE SUPPLYING ALL Your SWAGING NEEDS tags S 3 a em 2 e HATIONAL SWAGE DIE GUIDE bl Sa tpi O ct Ooo F hie Iperi National T Swage Twe HEAVY WPT SPECIALIST Die Guide miaa ee Prier ped Mpges erent os gee Crechy Hetiened Die Blok Gopodty Chori theGrosbyorour Crosby Customer Service 800 772 1 500 Vine care Wed See mh ie arae teddy rby a Meeks rawh ep ene Tha on National Swage Die Guide Chart Crosby General Catalog Copyright 2012 The Crosby Group LLC 19 All Rights Reserved Die Information The National Swage Die Guide was developed to aid in determining which dies are required for swaging the various sizes and types of products manufactured by National Swage Side 1 of the Die Guide is to be referenced when working with National Standard Dies Side 2 of the Die Guide is to be referenced when using Mark Series Dies IMPORTANT Be sure to reference the correct information side 1 or side 2 for your particular swaging application SIDE 1 NATIONAL SWAGE DIE GUIDE faan 2 mm STAGE 505 ag 510 09 501 502 SIZE DIE NO DIE NO DIE HO DIE HO
119. ge sockets shall be proof loaded S 501 Open Swage Sockets S 501 and S 501B Open Swage Socket Specifications Swager Die Data mOpe MSE Before Swage Dimensions _StockNo sie Gece 5 S 501 Wt 1500 3000 Stock Each Die Ton Ton i in mm Ibs C L in Description 6x12 6x12 No 1039021 1054001 1 4 6 52 4 78 50 1 38 69 27 2 19 69 4 00 38 1 47 46 1 4Socket_ 1192845 1039049 1054010 5 16 8 1 12 6 30 78 1 62 81 34 3 25 80 5 34 48 1 67 71 5 16 3 8Socket 1192863 1039067 1054029 3 8 9 10 1 30 6 30 78 1 62 81 41 3 25 80 5 34 48 1 67 71 5 16 3 8Socket 1192863 l 1039085 1054038 7 16 11 12 2 08 7 82 1 01 2 00 1 00 49 4 31 1 00 6 69 56 196 91 7 16 1 2Socket 1192881 l 1039101 1054047 1 2 13 2 08 7 82 1 01 2 00 1 00 55 4 31 1 00 6 69 56 196 91 7 16 1 2Socket 1192881 l 1039129 1054056 9 16 14 4 67 9 54 1 27 2 38 1 19 61 5 38 1 25 8 13 68 2 21 1 16 9 16 5 8 Socket 1192907 16_ 4 51 9 54 1 27 2 38 1 19 68 5 38 1 25 8 13 68 2 21 1 16 9 16 5 8 Socket 1192907 20 7 97 11 61 1 56 2 75 1 38 80 6 44 1 50 10 00 78 2 69 142 3 4Socket_ 1192925 11 52 13 37 1 72 3 13 1 63 94 750 1 75 11 63 94 3 20 155 7 8 Socket_ 1
120. ging Machine For reducing tonnage use selector switch on front of control panel to select lower tonnage approximately 1500 Tons or 3000 Ton ALWAYS USE 5 X 7 OR 6 X 12 DIES AT 1500 TON SETTING USE ONLY 6 X 12 DIES ON TONNAGE THAT EXCEEDS 1500 TONS Swaging Machine Capacity Chart for S 501 and S 502 Swage Socket Largest Fitting Swaging Allowed to be Machine Swaging Swaged Size Method in Hydraulic Mark Series 2 1 2 x5 1000 Tons 5x7 A 5x7 Full Shank 6x12 1 1 4 5x7 3000 Tons 212 Largest size fitting available 1500 Tons Copyright 2012 The Crosby Group LLC All Rights Reserved NEW STYLE NATIONAL HYDRAULIC SWAGING MACHINE TORQUE MAINTENANCE INFORMATION Check Valve Seal Tie Rod Eyebolt Z AZN Z is GR OTe OlO Cre MA Item No Req d Description o A 1 Cylinder D B 1 Housing Cap 8 C 1 Piston D 4 Tie Rod E 8 Tie Rod Nut F 1 Platen 8 G 2 Guide SAT H 1 Gland J 4 Bushing K 1 Mono Seal DOORS 5 L 1 Seal Spacer J i M 2 Side Cylinder A N 2 Side Cylinder Mount TINS HAKAN P 2 Lower Bracket i Wd Q 2 Knuckle NSEJ R 2 Upper Bracket AT S 1 Check Valve T 1 U 4 YY F V 1 Cap Eyebolt YY Yr X 2 Bumper YY VLD Y 2 Bumper Strip oes Z 2 Rubber Skirt 1 BVOUeVO2D0ee Oo e gt gt Bottom of Seal Cavity Table B Torque in Ft Lbs 500 Ton 1000 Ton 1500 Ton Swaging Swaging Swaging Maintenance i Description M
121. hank that encloses the rope Thimble Grooved metal fitting to protect the eye or fastening loop of a wire rope U Bolt Wire Rope Clips Fittings for clamping parts of wire rope to each other to form an eye or splice Crosby G 450 Red U Bolt Clips Ultimate Load The average load or force at which the product fails or no longer supports the load Wedge Socket A Wire Rope Fitting wherein the rope end is secured by a wedge Crosby S 421T Crosby S 423T or McKissick US 422T Wedge Style Sockets Wire Rope Clips Fitting for clamping parts of wire rope to each other See Crosby G 450 Red U Bolt Clips or Crosby G 429 Fist Grip Clips WIRELOCK A resin based mixture used for forming a 100 efficient termination for wire rope in sockets Working Load The maximum mass or force which the product is authorized to support in a particular service Working Load Limit The maximum mass or force which the product is authorized to support in general service when the pull is applied in line unless noted otherwise with respect to the centerline of the product This term is used interchangeably with the following terms 1 WLL 2 Rated Load Value 3 Resultant Working Load Copyright 2012 The Crosby Group LLC 5 All Rights Reserved Introduction to Crosby End Terminations Wire rope is a very useful tool However for the wire rope to be utilized some approved type of termination must be attached The Crosby Grou
122. has grooves or rings internally It is obvious that these rings must shear before the locking mechanism can operate and as such are a hindrance to that process Incidentally in the case of zinc and white metal this rupturing of the rings is also required before the rope will break The only justification for these rings is to stop the cone backing out of the socket In fact once seating of the cone within the socket has occurred it is not reversible and the cone is then locked into position This irreversibility offers the bonus that the stresses created within the socket are fixed and because there is no fluctuation it follows that the opportunities for fatigue within the socket are reduced Let us return to the question of clean and uncleaned wire A series of tests were carried out by A I F in France in which two samples of each of a series of rope sizes and constructions were broomed One sample was degreased with trichlorethane and the other sample was left uncleaned Both samples went on to achieve the full breaking strength of the rope and almost identical breaking loads were achieved This highlights the fact that the frictional grip on the wires is highly efficient If we take an overview of the whole situation it becomes apparent that the key operation in the resin socketing process is the brooming of the rope Indeed this operation is vital for zinc and white metal as well Surface area of wire is vital especiall
123. he contractor For additional information see Crosby General Catalog NOTICE All cast steel sockets 1 5 8 and larger are magnetic particle inspected and ultrasonic inspected Proof testing available on special order Drawing illustrates one groove used on sockets 1 4 through 3 4 Sizes 7 8 through 1 1 2 use 2 grooves Sizes 1 5 8 and larger use 3 grooves G 417 S 417 Closed Spelter Sockets Rope Dia Structural Ultimate in in mm in t Galv S C 4 6 amp 7 450 1039897 1039904 5 16 3 8 810 120 1039913 1039922 ee O 2 50 94 5 1 50 88 6 1 69 97 2 00 1 16 2 63 1 4 00 1 66 63 1 94 2 30 5 50 4 ASD 4 1 50 1 2 2 50 3 4 4 25 7 8 7 25 1 10 50 9 88 14 25 19 75 29 20 36 00 57 25 17 79 00 j oo o oles NIO olna NIQ w alN o o Q io CO lt a ua OJIN O w AINO N O0 0 O01 G oO s 2 75 5 25 6 00 2 50 5 50 6 50 2 75 3 13 6 38 750 Koad Ksal Find ead Cae NI Go O O1 01 00 O O w w n N O01 O I Ol N Ze D N o o N o h O CO N N P iN z O oo oO CO N ol i N o 0 U orj D N or O 105 00 21 50 140 00 9 75 4 88 1 11 75 NIN CPNL Pajos Alola NI on NINII Olan o Oo oe k N D D O O a_i oO O O NJ N Ol
124. he broom 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 2 Safety and Health Precautions for Using WIRELOCK It is very important that certain precautions be taken when using WIRELOCK for a wire rope socket termination When using the product be sure to read information on product containers and note the following WIRELOCK resin in liquid state is flammable Chemicals used in this product can give off toxic fumes and can burn eyes and skin 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 2012 The Crosby Group LLC All Rights Reserved 3 Selection of Socket 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 WIRELOCK is recommended for use with sockets that comply with Federal or International CEN ISO Standards 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 Measure the rope ends to be socketed The rope end should be of sufficient length so that th
125. he dies by pressing the foot pedal marked up A lf the tonnage is lower than desired Working Load Limit turn the valve clockwise while continuing to press the foot pedal marked up until desired Working Load Limit is reached 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 Swage Sleeves Ferrules and Buttons Largest Fitting Allowed to Hydraulic be Swaged Swaging in Machine Swaging Die Size S 505 S 506 S 409 Size Sleeve Sleeve Buttons 500 Ton Full Die 1 1 2 1 1 4 1000Ton FullDie 457 24 0 114 4 44 4 5x7 1500 Ton FullDie SX 34 0 11 4 141 4 6x12 Largest size fitting available iZ Full Shank 4x7 500 Tons 5x7 4x7 i i 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 machines 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 months Die Working Load Limit Pressure Adjustment on 3000 Ton Swa
126. here only a portion usually 1 3 to 1 2 of the length of the fitting is inserted into the die and swaged following specific swaging procedures for that product Proof Load The average force applied in the performance of a proof test the average force to which a product may be subjected before deformation occurs Proof Test A test applied to a product solely to determine injurious material or manufacturing defects Pull Amount or Tail The standard amount of wire used in a mechanical splice to complete the splice and give ample gripping area for the sleeve to secure the termination QUIC CHECK Swage Sockets incorporate a reduced machined area of the shank end of the swage socket Before swaging provides for an obvious visual difference in the shank diameter After swaging uniform shank diameter is created allowing for a QUIC CHECK and permanent visual inspection opportunity Designed to quickly determine whether the socket has been through the swaging operation It does not eliminate the need to perform standard production inspections which include gauging for the proper after swage dimensions or proof loading QUIC PASS Crosby swaging process that is completed in just two passes Regular Lay The type of rope where the lay of the wires in the strand is in the opposite direction to the lay of the strand in the rope The crowns of the wires appear to be parallel to the axis of the rope RLL Right Lang Lay
127. ic slow precision swaging speed Swaging Machine Capacity Chart for Swage Sleeves Ferrules and Buttons Largest Fitting Allowed to be Swaged in Hydraulic Swaging Machine Size Swaging Method NOTE For special applications or conditions contact Crosby National at 501 982 3112 10 S 505 S 506 S 409 Sleeve Sleeve Buttons 2 1 2 x en Series 500 Ton Full Die 1 1 2 1 1 4 7 8 xX 1000 100070 Full Die 4x7 2 1 2 1 1 4 1 1 4 5x7 5x7 1500 Ton Full Die 6x12 3 1 2 1 1 4 1 1 4 Largest size fitting available Swaging Machine Capacity Chart for S 501 and S 502 Swage Sockets Largest Fitting Allowed to be Swaged in Hydraulic Swaging Machine Size Die Size in Swaging Method 2 1 2 x p wee Series 500 Ton X 4 5x7 1000 Ton Progressive 4x7 1 1 2 g 5x7 Full Shank oe 1 1 4 1500 Ton Progressive aed 2 g 6x12 Largest size fitting available Copyright 2012 The Crosby Group LLC All Rights Reserved NATIONAL SWAGING MACHINE AND DIE WARNING USE MAINTENANCE AND APPLICATION INFORMATION National Four Post Swaging Machine 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 Wire Rope End Terminations User s Manual before operating the swaging machine Swaging machine operators must be trained in accordance with the information supp
128. ie lands touch each other effective swaging U S Patent 5 152 630 and foreign equivalents stops Additional swaging adds needless wear and strain on the dies and swaging machine We recommend Identification Stamping placing oil on the die faces and cavities When swaging ae the oozing of the oil from the die faces will indicate when For Identification purposes National Swage products the dies are closed At this point stop swaging can be impression stamped after swaging Properly done there should be no concern for fractures initiating Avoid Excess Flashing from such impressions Flashing occurs when socket material flows out into the To stamp S 501 and area between the die faces Once formed additional S 502 sockets passes will not eliminate flashing They will only fold back the flash and develop a permanent mark in the material and possibly create a crack low stress stamps Stamp to maximum To avoid excess flashing depth of 0 015 in e Select proper die e Stamp in the area on e Make sure that dies are the side of the socket in good condition and 2 E gt head as shown in the e Use round corner or properly lubricated illustration e Apply lubricant such as a CORRECT EXCESS light hydraulic oil to both FLASHING NOTE DO NOT STAMP ON SWAGING SHANK die cavities and the lower die face e Follow swaging instructions on pages 39 41 36 Copyright 2012 The Crosby Group LLC All Rights Reserved National O
129. ies 200 Ton National 500 Ton Mark Series 1 200 Ton Mark Series 1 500 Ton National 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 11 Inspection Maintenance Safety e Make sure all bolts and nuts are in place and tightened to recommended torque as shown in Table A on page 13 for new style swaging machines and Table B on page 14 for current swaging machines e Load block or die base plate surfaces must be to manufacturers specifications for thickness and flatness to provide complete support of the die during swaging e Make sure die holder side rails are not bent loose or damaged e Clean dies and die holder surfaces Keep free of metal shavings slag grit sand floor dry etc e 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 Follow this procedure to adjust swaging tonnage pressure on your swaging machine 1 Install the die holder s or die adapter with the dies to be used 2 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 t
130. ies to remain open approximately v2 the distance from time initial contact is made between sleeve and dies Open dies and rotate fitting 45 to 90 degrees Step 8 7th pass Close dies to round fitting Open dies and rotate fitting 45 to 90 degrees between passes Open dies and check for proper after swage dimensions See page 17 for proper use of No Go Gauges Additional swaging may be required to provide smooth finish and achieve proper after swage dimensions Dies must be fully closed in tapered die cavity before swaging is complete 30 Copyright 2012 The Crosby Group LLC All Rights Reserved Flemish Type Wire Rope Sling Eyes 1 13 4 Flemish Eye Termination for 1 1 8 through 1 3 4 S 505 Sleeves For other sizes see pages 29 30 and 32 33 National S 505 Standard Steel Sleeve dies are provided with a 1st stage and 2nd stage die National S 505 Standard Steel Sleeves 1 1 8 and larger require swaging in the 1st stage die and completing the swaging in 2nd stage dies in a National Hydraulic Swaging Machine Step 1 Slide sleeve over rope Step 3 Slide sleeve fully over ends of wire rope Step 5 1st pass allow dies to remain open approximately Y the distance from time initial contact is made between sleeve and dies Open dies and rotate fitting 45 to 90 degrees Step 7 3rd pass allow dies to remain open approximately Y the distance from the time initial conta
131. iginal packaging Fig 6 Upon mixing the compound should be poured immediately Fig 7 6 5 Only the 100cc 250cc amp 500cc can be mixed in the original packaging by pouring the resin into the granular materials container In the case of other kits a proper mixing vessel should be used Fig 6 Mixing vessels should be clean They can be of metal polythene or polypropylene Polymerization products of styrene i e styrofoam cups and similar products should not be used A flat wooden or metal paddle not a spike or screwdriver should be used as a Stirrer 6 6 Immediately upon pouring the resin into the granular compound or vice versa mix vigorously for two 2 minutes or until a homogenous mixture has been obtained Make sure that no unmixed granular compound remains on the bottom of the mixing container For larger sizes a mechanical mixer is ideal Upon mixing the WIRELOCK will turn to a greenish turquoise colour If the mix remains a pale straw yellow colour do not use the Immediate pouring will ensure that the gelling stage occurs in the socket and not in the mixing container Sufficient WIRELOCK should be mixed so that the socket can be completely filled at one pouring WIRELOCK is designed to gel in approximately 15 minutes and to cure within 60 minutes after gel To provide an adequate safety margin no load should be applied to the wire rope assembly until a minimum of one 1 hour has elapsed from th
132. inadequate number of presses are used it could be quickly identified by checking the after swage dimension of the part 10 Swaging Machine not producing sufficient tonnage will affect after swage dimensions Copyright 2012 The Crosby Group LLC All Rights Reserved No Go Gauge Information To assist in checking the after swage dimensions of the fitting the Crosby Group provides the National No Go Gauges When used correctly the National No Go Gauges can determine if the fittings were swaged to the proper diameter We would recommend that all Crosby products or product swaged in Crosby dies be checked with the proper gauge to determine the acceptability of the swaging process e Gauges are made of hardened alloy steel and machined to strict tolerances e Gauge can be used to verify that all fittings have been swaged properly e After swage dimensions not within the maximum limits may result from worn dies or improper swaging techniques e Other type gauges are available upon request e National No Go Gauges are available for a variety of products See Table 1 e No Go Gauges and QUIC PASS No Go Gauges are not interchangeable Table 1 Fitting and Size PartNo O 505 Sleeve 1 4 7 8 1095512 Using No Go Gauges When swaged properly the gauge will go up and down see Figure 1 and around the full length of the fitting see Figure 2 For the proper after swage dimensions see the section in this publication
133. inding until surfaces are smooth provided they do not reduce the dimensions by more than 10 of the nominal catalog dimension E Select sockets that are not distorted bent or deformed Note Sockets having any of the indications as outlined above A E shall not be reused III Procedures for Speltering Sockets A The proper procedure for speltering sockets can be found on pages 112 116 of the Wire Rope Users Manual 2nd Edition and in American Petroleum Institute API Recommended Practice 9B RP9B 9th Edition May 30 1986 B Some standards API ISO BSI recommend preheating of the zinc spelter socket before pouring This temperature shall not exceed 850 F 450 C IV Proof Testing A We recommend the socket assembly be proof tested at two 2 times the Working Load Limit 2 x WLL assigned to the socketed assembly Copyright 2012 The Crosby Group LLC 93 All Rights Reserved The following simplified step by step instructions should 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 Remove any non metallic coating from
134. ing inspection and maintenance services can be provided to your business by our factory trained technician e Thorough inspection of National swaging machines e Thorough inspection of National Swage dies with installation of RFID record keeping and documentation technology e Maintenance services for National swaging machines Training While at your facility we can also provide training to your employees in the following areas at no additional cost e Swaging training with certificates e Socketing and Wirelock training with certificates thes SUYqroun United States Canada Europe P O Box 3128 145 Heart Lake Rd Industriepark Zone b N 26 Tulsa OK 74101 3128 Brampton Ontario 2220 Heist op den Berg P 918 834 4611 Canada L6W 3kK3 Belgium F 918 832 0940 P 905 451 9261 P 32 0 15 75 71 25 crosbygroup thecrosbygroup com F 877 260 5106 F 32 0 15 75 37 64 sales crosby ca sales crosbyeurope com the POSUU group Greasy canada Crosby CROSBY PRODUCTS DISTRIBUTED BY 9992320 PPG2 5M 03 12
135. inted fittings may suffer some or total degradation of the surface finish 3 Extended exposure to elevated temperatures can cause severe surface scaling and significant permanent reduction of properties 4 Repeated heating and cooling to room temperatures can result in temper embrittlement For other operating temperatures or products contact Crosby Engineering 2 Copyright 2012 The Crosby Group LLC All Rights Reserved ANSI American National Standards Institute ASME American Society of Mechanical Engineers ASTM American Society for Testing and Materials Boom Pendant A non operating rope or strand with end terminations used to support the boom Closed Socket A wire rope end termination consisting of basket and bail made integral Core The axial member of a wire rope around which the strands are laid Commercial Surface Quality The surface condition of the products shown in this catalog The surface condition associated with the normal methods of production of raw materials and machined surfaces More refined surface qualities are considered as special Design Factor An industry term denoting a product s theoretical reserve capability usually computed by dividing the catalog Ultimate Load by the Working Load Limit and generally expressed as a ratio e g 5 to 1 Duplex Non Tapered Sleeves Oblong cylindrical sleeves used for fabricating wire rope turnback sling eyes Also used on grommet slings
136. l recommended value The roddles in the clip base must be undamaged and the clip assembly must be re torqued after the initial load is applied 9 Whenever possible use thimbles when forming eyes with wire rope clips Wire rope thimbles were designed to provide the wire rope with protection against wear They are not considered a primary load carrying member and are not rated by a load carrying capacity Efficiency Efficiency ratings for wire rope end terminations are based upon the minimum breaking force of wire rope Eyes formed in wire rope using properly installed clips have the following efficiency rating 1 through 3 1 2 Copyright 2012 The Crosby Group LLC All Rights Reserved Wire Rope Clip Information The efficiency of the termination depends on 1 Selection of the proper size clips 2 Utilizing the proper number of clips 3 Utilizing the proper amount of rope turned back 4 Correct placement of the clips 5 Applying the proper torque to the nuts It is important to recognize that efficiency cannot be increased by adding extra clips but it can be reduced by over tightening Standard Considerations When Utilizing Clips OSHA 1025 251 c 4 iii Eyes in wire rope bridles slings or bull wires shall not be formed by wire rope clips or knots ASME B30 9 The use of wire rope clips to fabricate wire rope slings is generally prohibited See ASME B30 9 for full details ANSI A17 1 AND ANSI A10 4
137. lied by The Crosby Group LLC THE SWAGING MACHINE OWNER IS RESPONSIBLE FOR THE TRAINING AND THE SAFE OPERATION OF THE SWAGING MACHINE 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 Do not shim between dies Do not shim die or die holder unless swaging aluminum sleeves Do not use die holders that are damaged or have loose side rails or side plates Keep head hands 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 Copyright 2012 The Crosby Group LLC All Rights Reserved Operation Safety e NEVER use dies that are cracked worn or abraded galled e NEVER use dies that have an oversized cavity e ALWAYS use a matched set of dies e When swaging steel fittings DO NOT SHIM DIES Dies for steel fittings must be free to float and align one to the other e When swaging aluminum fittings THE STEEL DIES MUST BE SHIMMED Shim
138. log breaking strength of wire rope The efficiency rating Spacing installation torque and other instructions still apply of a properly prepared loop or thimble eye termination for clip 6 IMPORTANT sizes 1 8 through 7 8 is 80 and for sizes 1 through 3 1 2 is 90 Apply first load to test the assembly This load should be of l l equal or greater weight than loads expected in use Next The number of clips shown see Table 1 is based upon using check and use torque wrench to retighten to recommended RRL or RLL wire rope 6 x 19 or 6 x 36 Class FC or IWRC torque In accordance with good rigging and maintenance IPS or XIP XXIP If Seale construction or similar large outer practices the wire rope end termination should be inspected wire type construction in the 6 x 19 Class is to be used for periodically for wear abuse and general adequacy sizes 1 inch and larger add one additional clip If a pulley l sheave is used for turning back the wire rope add one additional clip ar ies ip Size Ta Size Minimum Amount of Rope to ee The number of clips shown also applies to rotation resistant RRL wire rope 8 x 19 Class IPS XIP XXIP sizes 1 1 2 inch and smaller and to rotation resistant RRL wire rope 19 x 7 Class IPS XIP XXIP sizes 1 3 4 inch and smaller For other classes of wire rope not mentioned above we recommend contacting Crosby Engineering to ensure the desired efficiency rating me me 2 Te For elevator personn
139. lues See Table 1 e Properly install wire to securely lock tensioner bolt to tensioner See Figure 6 e Do not attach dead end to live end or install wedge backwards See Figure 7 Operating Safety e Proper application of the Super TERMINATOR eliminates the first load requirement of conventional wedge socket terminations Copyright 2012 The Crosby Group LLC All Rights Reserved e Efficiency rating of the Wedge Socket termination is based upon the catalog breaking strength of Wire Rope The efficiency of a properly assembled Super Terminator on most high performance high strength compacted strand rotation resistant ropes will achieve 80 of catalog breaking strength of rope depending on the unique construction of these ropes To determine the efficiency rating for a specific rope contact Crosby Engineering at 918 834 4611 e During use do not strike the dead end section with any other elements of the rigging Called two blocking e The SUPER TERMINATOR wedge socket may also be used with standard 6 to 8 strand and rotation resistant wire rope special wire rope constructions with 8 or more strands 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 recommended torque to tensioner and clip bolts and properly install wi
140. machines are available upon request Refer to page 19 Single Cavity Die 16 Two Cavity Die Never use dies that are cracked worn or abraded galled Copyright 2012 The Crosby Group LLC All Rights Reserved After Swage Inspection Procedures Read understand and follow these instructions before using the National QUIC PASS Swaging System Improper after swage dimensions can result in sling failure resulting in property damage serious injury or death Always gauge or measure the after swage dimensions to ensure proper sling performance Using National Swaging System with ropes and termination styles other than shown in these procedures may reduce the performance of the termination and lead to premature failure When using rope constructions other than shown in this procedure the termination must be destructive tested and documented to prove adequacy of the assembly to be manufactured The QUIC PASS Swaging System is designed only for Flemish Eye terminations using National S 505 Standard Steel Sleeves The QUIC PASS Swaging System is not designed for Cable Laid wire rope slings or fiber core wire rope Checking Swaging Dimensions One of the important considerations in producing a quality termination is the overall diameter of the fitting after the swaging process is complete Since all dies wear and the swaged fitting used in terminations have spring back the results
141. make a broad general statement that all current and future designed ropes when properly assembled with a SUPER TERMINATOR will achieve a minimum 80 termination efficiency To determine the efficiency rating for a specific rope contact Crosby Engineering at 918 834 4611 Type Approval and certification in accordance with ABS 2006 Steel Vessel Rules 1 1 17 7 and ABS Guide for Certification of Cranes Basket is cast steel and Individually Magnetic Particle Inspected Copyright 2012 The Crosby Group LLC All Rights Reserved Wedge Socket Information 6 Pin diameter and jaw opening allows wedge and socket to be used in conjunction with closed swage and spelter sockets 7 Crosby TERMINATOR Wedge Sockets secure the tail or dead end of the wire rope to the wedge thus eliminating loss or punch out of the wedge 8 The TERMINATOR Wedge eliminates the need for an extra piece of rope and is easily installed 9 The TERMINATOR Wedge eliminates the potential breaking off of the tail due to fatigue 10 The tail which is secured by the base of the clip and the wedge is left undeformed and available for reuse 11 Utilizes standard Crosby Red U Bolt wire rope clip 12 The 3 8 thru 1 1 8 standard S 421 wedge socket can be retrofitted with the new style TERMINATOR Wedge 13 Available with bolt nut and cotter pin 14 U S patent 5 553 360 Canada patent 2 217 004 and foreign equivalent
142. mbled with a Super TERMINATOR will achieve a minimum of 80 percent efficiency rating To determine the efficiency rating for a specific rope contact Crosby Engineering at 918 834 4611 The rated load for wire rope assemblies such as wedge sockets is based on the following factors 1 Wire rope minimum breaking force 2 80 percent minimum connection efficiency 3 Design factor of the wire rope application 98 The schematic below depicts the parts of a typical Crosby S 421T and US 422T TERMINATOR Wedge Socket Nz Bee 2 Se Q O The schematic below depicts the parts of a typical Crosby S 423T Super TERMINATOR Wedge Socket Key Facts About Wedge Sockets 1 S 421T and US 422T Wedge Socket terminations have an efficiency rating of 80 based on the minimum breaking force of XXIP wire rope Meets or exceeds all requirements of ASME B30 26 including identification ductility design factor proof load and temperature requirements Importantly these sockets meet other critical performance requirements including fatigue life impact properties and material traceability not addressed by ASME B30 26 The intended purpose of the SUPER TERMINATOR is to offer a wedge socket termination which when assembled properly with high performance high strength compacted strand rotation resistant wire rope will achieve an 80 termination efficiency Due to the unique construction of these ropes Crosby cannot
143. mmend a Texas Tuck style termination with Crosby National S 505 COLD TUFF Standard Steel Sleeves e Only Crosby National S 505 COLD TUFF Standard Steel Sleeves are recommended when using the QUIC PASS Swaging System e National S 505 Standard Steel Sleeves when used with the QUIC PASS Swaging System are only recommended for use with one 1 part 6 X 19 or 6 X 37 IPS or XIP EIP XXIP EEIP RRL IWRC rope e The condition of the swaging machine can cause sleeve After Swage size not to be within the proper dimensions Example worn bushings loose tie rods loose die holders misaligned platens worn pins worn linkage etc 18 e Swaging dies being worn damaged misused or undersized can cause sleeve After Swage size not to be within the proper dimension e Swaging die holders excessively worn damaged misused or loose can cause sleeve After Swage size not to be within the proper dimension Only use QUIC PASS dies and die holders inspected and properly secured in National swaging machines e Always refer to Warning and Application information found in the Crosby General Catalog and Wire Rope End Terminations User s Manual Copyright 2012 The Crosby Group LLC All Rights Reserved Die Information Optional Adapters N E i TNE 6 wE wN s MZ pen 6x12 wo eee Front Load Front Load F ais Sah ig a l i WN q z en i al ol eB S
144. move the spelter cone e However if this is the only means available for removing the zinc cone care should be taken not to exceed 850 F 450 C surface temperature The preferred method would be a slow heat ina temperature controlled oven If a torch rosebud is used the heat spot shall be monitored with a tempil stick or a temperature indicator to prevent localized heating from exceeding the 850 F 450 C limit e To remove a WIRELOCK cone heat the surface of the button to 350 F 177 C Do not exceed the 850 F 450 C limit for any localized hot spot Leave for 5 10 minutes then drive the cone out with a hammer and drift Selection of Buttons For Reuse e Use only buttons that e Do not show discoloration from excessive heating e Do not show any signs of welding e Select only buttons that have been cleaned and have passed a Magnetic Particle Inspection by a qualified technician Level Il ASNT SNT TC 1A 88 per ASTM E709 Acceptance criteria shall be per ASTM E125 Types II VIII Degree 1 No cracks are acceptable e Select only buttons that do not show any signs of overloading or wear e Select buttons that are free from nicks gouges and abrasions Indications may be repaired by lightly grinding until surfaces are smooth provided they do not reduce the dimensions by more then 10 of the nominal catalog dimension e Select buttons that are not distorted bent or deformed NOTE Buttons having any of the in
145. mum depth of 0 015 in 1 64 e Stamp in area on the side of the sleeve in the plane of the sling eye and no less than 0 250 in 1 4 from either end of the sleeve Copyright 2012 The Crosby Group LLC All Rights Reserved National Swage Duplex Sleeves S 506 NOTE 5 506 Duplex sleeves are recommended for use with 6 x 19 or 6 x 36 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 For turnback wire rope splicing Special processed low carbon steel Turnback terminations have efficiency ratings of 94 based on the catalog strength of wire rope Designed for lower temperature toughness Resists cracking when swaged equals or exceeds stainless steel sleeves COLD TUFF for better swageability Stamp for identification after swaging without concern for fractures See page 46 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 S 506 Stock No in mm 1039334 5 16 8 5 3 7 1039478 1039496 1039539 1 1 4 30 32 1 1 1 1 2 5 8 8 4 8 r 5 8 1039450 3 4 78B O1 Before Swage Dimensions Ibs i 50 1 06 n 1 02 1 02 25 25 10 263 216 152 10 2
146. n Stock No Qty Ibs A B c D E F G H ie 34 100015 100 6 22 72 44 47 37 38 81 99 1 4 31 103 50 75 66 56 119 143 5 16 8 1010079 100 38 138 75 88 73 69 131 166 3 A4 7 16 50 vat 2 1 2 50 56 56 9 16 r 16 1010177 2 62 75 2 5 3 47 8 7 5 8 3 4 7 8 1 2 5 52 i 283 75 3 59 1 1 4 88 4 13 1 3 88 4 19 a 1 50 50 50 6 50 25 22 1010211 25 E20 10 10 6 10 8 io 50 50 50 16 50 25 25 10 1 1 8 10 10 10 10 _ S N 88 4 44 1 5 8 1 00 4 75 1 3 4 1 13 5 24 1 25 5 88 2 1 4 1 25 6 38 2 1 2 1 25 2300 1 25 3 1 2 85 90 1010426 Bulk 4000 150 10 75 4 50 5 50 6 00 2 38 619 8 38 Electro plated U Bolt and Nuts 2 3 4 and 3 1 2 base is made of cast steel e Each base has a Product Identification Code PIC for material traceability the name CROSBY or CG and a size forged into it e Entire clip is made from 316 Stainless Steel to resist corrosive and rusting action e All components are Electro Polished e All clips are individually bagged or tagged with proper application instructions and warning information SS 450 Stainless Steel Wire Rope Clips Rope Size SS 450 Package Per 100 in Stock No __Qty Ibs Bo C DJ E F GJ H 97 56 59 50 44 9 4 11
147. n dry and free of lubrication Rope Size Da L O1 BR BC ONINININININ be Copyright 2012 The Crosby Group LLC All Rights Reserved NEVER SADDLE A DEAD HORSE NEVER PLACE U BOLT OVER THE LIVE LINE ALL THREE U BOLTS ARE ON THE LIVE LINE U BOLTS ARE STAGGERED ONE CLIP IS ON THE LIVE LINE INCORRECT SPLICING OF TWO WIRE ROPES NOT ENOUGH CLIPS U BOLTS NOT ALIGNED PROPERLY POH704 The following example illustrates the correct use of Table 1 in determining the proper application of Crosby G 450 Red U BOLT Clips Example An installation requires the use of 3 8 6 x 19 RRL IPS wire rope From Table 1 Clip Size 3 8 Number of Clips 2 Amount of Turnback 6 1 2 Torque in Ft Lbs 45 Amount of Rope to Turn Back Minimum Clip Size Rope Size No of in in Clips in Inches 3 1 4 Torque 3 16 3 16 3 3 4 o 4 4 2 434 E 546 2 St 30 lt 3 8 6 1 2 n6 mammaa aaee p65 111 CROSBY CLIPS as near the loop or thimble as possible turn nuts on second clip firmly but do not tighten Proceed to Step 3 WARNINGS AND APPLICATION When three or more ss a EN RE o E WN clips are required space TA Tn SL INSTRUCTIONS additional clips equally Figure 3 E between first two take IER up rope slack use torque wrench to tighten nuts on each K N U Bolt evenly alternating from one nut to the other until reaching recommend
148. n of the wire rope assembly it is recommended that all poured sockets whether with zinc or resin be proof loaded to seat the cone Reuse of Crosby Spelter Sockets and Buttons Crosby allows the reuse of sockets so long as recommended procedures are followed Refer to Page 59 for recommended procedures for reuse of Crosby Spelter Sockets STANDARD CONSIDERATIONS ASME B30 9 All slings terminated with sockets shall be proof loaded The proof load shall be a minimum of 2 and a maximum of 2 1 2 times the single leg vertical hitch rated load The proof load should be that specified by the wire rope or fitting manufacturer s recommendation provided that it is within the above specified proof load range When sockets are used in sling assemblies the minimum recommended design factor is 5 ASME B30 5 Cranes require that boom pendants terminated with sockets be proof tested When sockets are used in boom pendant lines the minimum recommended design factor is 3 See OSHA and ASME for full information Copyright 2012 The Crosby Group LLC All Rights Reserved Open Spelter Sockets G 416 S 416 e Forged steel sockets through 1 1 2 cast alloy steel 1 5 8 through 4 e Spelter socket terminations have an efficiency rating of 100 based on the catalog strength of wire rope Ratings are based on recommended use with 6 x 7 6 x 19 or 6 x 36 IPS or XIP EIP XXIP EEIP RRL FC or IWRC wire rope Strand construct
149. n place by forming a streamlined compact solid and permanent splice The Flemish wire rope sling eyes have all the advantages of a hand spliced eye with the added safety of a swaged steel sleeve to complete the termination while leaving no rope distortion wire ends or chance of rope slippage due to rotation The Flemish Eye ensures equal distribution of the load in both parts of the eye because pull is directly along the center line of the rope and eye Cold swaging the National S 505 Standard Steel Sleeve forms a solid bond around the splice which will achieve a breaking strength near the rated breaking strength of the wire rope thus giving maximum efficiency of the termination see page 23 for rated efficiencies The National S 505 COLD TUFF Steel Sleeves are engineered to be cold swaged without failure when proper swaging techniques as described on pages 27 35 are used in both extreme hot or cold environments One end of the sleeve is tapered to allow the splice to pass under obstructions without snagging The other end has a radius which helps to eliminate rope abrading Forming the Eye In accordance with the Wire Rope Technical Board s Sling committee s recommendation we endorse that a seven 7 lay rope eye will give maximum efficiency with no advantage in using more Separating Rope Strands Flemish Eyes are formed by separating the strand into two groups with the core and 3 strands in one group and 3 strands in
150. nd S 502 swage sockets are swaged in specially designed National Swage socket dies with a relief and extra length Sockets 1 1 8 and larger should be swaged full shank To swage the socket use the following procedure Step 1 For proper insertion mark rope using Column F Dimension on page 37 or 38 Step 3 Lubricate both die cavities and lower die face See pages 37 and 38 for proper die selection Step 5 2nd pass allow dies to remain open approximately 1 2 the distance from time initial contact is made between socket and dies Rotate fitting 45 to 90 degrees Step 2 Slide rope into socket until it is fully inserted in the shank Inspect mark for full insertion Step 4 1st pass allow dies to remain open approximately 1 2 the distance from time initial contact is made between socket and dies Rotate fitting 45 to 90 degrees Step 6 3rd pass If sharp flashing does not occur close dies Open dies and rotate fitting 45 to 90 degrees QUIC CHECK Step 7 4th pass Close dies to round Y fiting Open dies and check for proper after swage dimensions See page 17 for proper use of No Go Gauges Note Limited swaging capacity may require the use of progressive swaging See page 41 Additional swaging may be required to provide smooth finish and achieve proper after swage dimensions 40 Copyright 2012 The Crosby Group LLC All Rights Reserved Swage Socket Te
151. ns of the Wire Rope User s Manual 3rd Edition Appendix C American Petroleum Institute API Recommended Practice 9B RP9B 11th Edition September 2002 or IS017558 2006 Steel Wire Ropes Socketing Procedures Molten Metal and Resin Socketing Before operation of the wire rope assembly it is recommended that all poured sockets whether with zinc or resin be proof loaded to seat the cone Reuse of Crosby Mooring Sockets Crosby allows the reuse of sockets so long as recommended procedures are followed Refer to Page 59 for recommended procedures for reuse of Crosby Spelter Sockets Key Facts About Wire Rope Spelter Sockets 1 Design of bail allows for easy connection to shackles and other connecting links 2 Socket design utilizes features to keep cone from rotating 63 Mooring Sockets G 517 e Wide range of sizes available e 1 1 4 thru 4 wireline i e M Line socket terminations have a 100 efficiency rating based on the catalog strength of the wire rope Ratings are based on recommended use with 6 x 7 6 x 19 or 6 x 36 IPS or XIP EIP XXIP EEIP RRL FC or IWRC wire rope Strand constructed with minimal number of wires e g 1 x 7 requires special consideration that socket basket be five 5 times the strand diameter or fifty 50 times the wire diameter whichever is the greater e Galvanized finish e Designed for today s higher strength classes of wire rope e Design of bail allow
152. o a wedge socket termination Proper application of the Super TERMINATOR eliminates the first load requirement of conventional wedge socket terminations Additional features Wire rope sizes available 5 8 1 1 4 14 mm 32 mm Available as a complete assembly or as a wedge kit that can be retrofitted onto existing Crosby S 421T TERMINATOR wedge sockets Wedge accessories provided with a zinc finish Meets or exceeds all ASME B30 26 requirements including identification ductility design factor proof load and temperature requirements Importantly they meet other critical performance criteria not addressed by ASME B30 26 including fatigue life impact properties and material traceability Available with bolt nut and cotter S 423TB The Super TERMINATOR by Crosby The first wedge socket termination designed specifically for high performance wire rope thelsP OSU group www thecrosbygroup com Wedge Socket Terminations Table of Contents Wedge Socket Application Wedge Socket Warnings and and General Information ccccseceeeeeeeees 98 99 Application Instructions cccssceseeeeeeees 102 103 S 421T Wedge Socket cccccceeccccseeeeseeeeeseeeeeees 100 S 423T SUPER TERMINATOR 0 cc eeceeeeeees 104 US 422T Utility Wedge Sockets cccccccseeeeeeees 101 S 423T SUPER TERMINATOR Warnings and Application Instructions c
153. oast Guard ABS NATO Numbers 100 cc 8030 21 902 1823 250 cc 8030 21 902 1824 500 cc 8030 21 902 1825 Wirelock is a hazardous material regulated by US DOT ICAO IATA and 1000 ce 8030 21 902 1826 IMO for transportation Witnessed and tested by American Bureau of Shipping ABS Approximate U S Measurements 250 cc s Kit 1 Cup 72 Copyright 2012 The Crosby Group LLC All Rights Reserved WIRELOCK DETAILED INSTRUCTIONS FOR THE USE OF WIRELOCK With Strand or General Purpose Wire Rope These instructions explain the proper use of WIRELOCK for socketing wire rope terminations When reading and following these instructions pay close attention to warnings and safety information presented in bold print For maximum salety and efficiency use WIRELOCK only as instructed 1 Warning on Correct Application of WIRELOCK It is very important when deciding upon the use of WIRELOCK to note the following 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 without reading and understanding the information given on page XX 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 Remove any non metallic coating from t
154. obligation of the user For OSHA Construction applications see OSHA 1926 251 1 Refer to Table 1 in 9 Figure 1 following these instructions Turn back specified amount of rope from thimble or loop Apply first clip one base width from dead end of rope Use torque wrench to tighten 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 Use torque wrench to tighten 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 Figure 2 Copyright 2012 The Crosby Group LLC All Rights Reserved 3 When three or more clips are required space SUS ESS ES additional clips equally between Figure 3 first two take up rope slack use torque wrench to tighten on each Clip evenly alternating from one nut to the other until reaching recommended torque 4 lf a pulley sheave is used in place of a thimble add one additional Fist Grip Fist Grip spacing should be as shown 5 WIRE ROPE SPLICING PROCEDURES The preferred method of a splicing two wire ropes together is to use inter locking turnback eyes with thimbles OTE D TREAD DIAMETER using the recommended 1 ur number
155. ockets WIRELOCK Formula to estimate CC s required to pour standard spelter sockets D d o XN x 3142 ce 4 Note D d and H are in inches GUIDE TO AMOUNT OF WIRELOCK REQUIRED 1 6 5MM eee 9cc 1 3 4 44 5MM 0 ccc cec ccc eecceceeeeeeeeeeeeceeeeeseeeeesaaeees 700cc By SIMI eri a a EE 17cc t8 A OTM ecenin ei 700cc E 9 SIMO A EE 17cc 2 ANON ee E E E E E 1265cc PIV A a E ute eee stare oes 35cc 2a ELLE EA E E A E 1265cc We V2 OMAN AEE E E E A E 35cc A CE NIN E E T A T 1410cc 9 16 14MM 00 cece ccc eeeececeeeeeeeeeeeeeeseeeeeeeeeeaeeeeees 52cc 2 3 8 OMM ccccceeeececeeseeeeeeeeeceeeaeeeeeeesaeeess 1410cc O TO eee a 52cc EE ETEL A E E N EE 1830cc 3A OOTI reaa 86cc 2 5 0 G6 SIMIM ecaro 1830cc TIO 22 eas a E 125cc 229 4 FOM reiner a aasa 2250cc TAOM s E EERE 160cc 3 OM eee ene E 3160cc L E ES E seweteseosnecesasceseeexes 210cc 3 1 4 82 SIMI ia ceccerccaneecssparassenassstexeweseotmeaedeesa 3795cc 1 1 4 B2MM 00 cece ceeecc cc eececceeceeceeeeeeseeeeesaeeeesaeeees 350cc 3 1 2 BOIMM cc eecccceecceceeeeeeeeeeeeseeeeeseeeeseaeeeeas 4920cc 1723 8 SSM seorsa tenaa ead 350cc 3 3 4 95MM naaaisneseiennsurnnnrurnrnnnrnrenunnrennannennnnnn 5980cc Td SOMA eeigen E 420cc AOE LI AE E A 7730cc FS F e E 495cc POSS aS N N E EE E A 1 Cup OG TU secrete E E T 1 Pint 100000 Risan a 1 Quart Copyright 2012 The Crosby Group LLC 79 All Rights Reserved
156. of clips on each eye WIDTH WOTH See Figure 5 ADD ONE ADDITIONAL CLIP CLIP SPACING SHOULD BE AS SHOWN An alternate method is to use Figure 4 twice the number of clips as used for a e 8 A a E turnback termination SS Sar NSS au The rope ends are Figure 5 placed parallel to each other overlapping by twice the turnback amount shown in the asset deseo ees sce application ee instructions The minimum number ae Figure 6 of clips should be installed g on each dead end See Figure 6 Spacing installation torque and other instructions still apply 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 use torque wrench to retighten 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 LIVE END in in No of Clips Turn Back in Inches 3 16 2 1 4 5 16 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 7 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 115 thelsPOSUYroup Real Life F
157. of swaging should be checked periodically to determine the wear condition of the die as well as to ensure the fitting is swaged to proper dimensions Key Facts About After Swage Dimensions 1 In addition to worn dies not achieving the proper after swage dimension can also be due to the die not being fully closed during swaging Dies showing excessive wear should be replaced 2 The effective swaging that dies can accomplish stops when the die lands touch each other Any continued swaging adds needless wear and strain on the dies and swaging machine 3 By placing a light oil on the die faces and in the cavity the dies will be lubricated as well as protected 4 The oozing of the oil from the faces of the dies as they touch will indicate when the dies have closed At this point stop the swaging cycle 5 Additional swaging adds needless wear and strain to the dies and swaging machine 6 Never use dies that are cracked worn or abraded galled 7 The Crosby Group does not recommend the checking of die dimensions as an acceptable method of determining the quality of a swage sleeve button ferrule or socket 8 It is our recommendation that the checking of the after swage dimension of the swaged fitting is the most accurate indicator of a properly swaged termination Measuring the die cavity only is not an acceptable process control check 9 If the die cavity wears the dies are not closed completely during swaging If an
158. onal Steel Swaging Sleeves c cccccceeeee 23 24 Button Terminations 1 amp Larger ccccceeeeseeeees 45 Metric Die Chart ccccccssecccsseeecseeeeeeeeseeeeeeeeeaeeeens 25 Cold Tuff Swage Fittings Duplex Sleeves 46 Flemish Type Wire Rope Sling Eyes Introduction 26 National Swage Duplex SI eveS c cccceceeeeeeeees 47 Flemish Type Wire Rope Sling Eyes Marking 27 Turnback Terminations 5 16 5 8 cccccsseeeeeeees 48 Flemish Type Wire Rope Sling Eyes ccccssseeeeseeees 28 Turnback Terminations 94 1 1 4 a a 49 Flemish Type Wire Rope Sling Eyes 1 4 1 0 29 Swage Fittings HOOKS ccccecceseeeeeeeeeseeeeseeeeeees 50 Flemish Type Wire Rope Sling Eyes 12mm 20mm amp 24mm 30 Shank Hooks for SWAIN cccecceceeeeeeeeeseeeeseeeeeees 51 Flemish Type Wire Rope Sling Eyes 1 1 8 1 3 4 31 32 Shank HOOKS Warning ccsccceseeeeeeeeeeeeeeeeeeeeees 52 53 Flemish Type Wire Rope Sling Eyes 2 amp Larger 33 34 Swage Hook Terminations 3 16 1 54 QUIC PASS Swaging Procedures ssceeeeeeeees 35 Swage Hook Terminations 1 1 8 amp Larger 55 Swag Fittings SOcKetS cccssesecesseeeeseeeeeeeeeeeens 36 Swage Terminal Assemblies Fatigue Life 56 National Open Swag
159. ope close 1 2 to the nose of the socket and press the cone out of the basket B We do not recommend the use of heat to remove the spelter cone for metallurgical medical and environmental reasons 1 However if this is the only means available for removing the zinc cone care should be taken not to exceed 850 F 450 C surface temperature The preferred method would be slow heat in a temperature controlled oven If a torch rosebud is used the heat spot shall be monitored with a tempil stick or a temperature indicator to prevent localized heating from exceeding the 850 F 450 C limit 2 To remove a WIRELOCK cone heat the surface of the socket to 350 F do not exceed the 850 F limit for any localized hot spot Leave for 5 10 minutes then drive the cone out with a hammer and drift II Selection of Sockets for Reuse A Use only sockets that e Do not show discoloration from excessive heating e Do not show any signs of welding B Select only sockets that have been cleaned and have passed a Magnetic Particle Inspection by a qualified technician Level II ASNT SNT TC 1A 88 per ASTM E709 Acceptance criteria shall be per ASTM E125 Types II VIII Degree 1 No cracks are acceptable C Select only sockets that do not show any signs of overloading or wear on the socket or pin i e elongated pin holes undersized pins etc D Select sockets that are free from nicks gouges and abrasions Indications may be repaired by lightly gr
160. ottom small end of the socket Fig 2 Most of the load capacity of the termination is concentrated in the bottom one third of the socket 74 4 6 Except in the case of wire ropes of coarse construction e g 6 x 7 it is not necessary or desirable to hook the wires in the broom When the rope contains large numbers of wires hooking the ends causes congestion within the socket and can create penetration problems for the socketing medium although this is less of a problem with resin than with zinc or white metal 4 7 The open broom shall be thoroughly cleaned degreased Be sure that the cleaning is confined to the broom and does not extend to the rope beyond Incorrectly Broomed Wire Rope 4 8 The method of cleaning will depend on the lubricant and or coating on the wire 4 9 The methods and materials used for cleaning should comply with the current EPA regulations 4 10 Consult the Wire Rope Technical Board your Wire Rope supplier or the Wire Rope Manufacturer for recommended materials and methods 4 11 The currently recommended Trichlorethane does not comply with the Clean Air Act of 1990 Section 611 Ozone Depletion Substances 4 12 Do not clean the wire rope broom with acid soda methol hydrate or acetone A flux should not be used Copyright 2012 The Crosby Group LLC All Rights Reserved WIRELOCK 4 13 The wire rope broom after cleaning and drying should be kept in an upright position to p
161. p 6 3rd pass If sharp flashing does not occur close dies Open dies and rotate fitting 45 to 90 degrees QUIC CHECK Y Step 7 4th and 5th pass Close dies to round fitting Open dies and rotate 45 to 90 degrees between passes Open dies and check termination for proper after swage dimensions See page 17 for proper use of No Go Gauges Additional swaging may be required to provide smooth finish and achieve proper after swage dimensions Dies must be fully closed before swaging is complete 54 Copyright 2012 The Crosby Group LLC All Rights Reserved Swage Hook Terminations 11 4 and Larger S 319SWG Swage Hooks 1 1 8 and larger See page 54 for smaller sizes S 319SWG Swage Hooks are swaged in specially designed National Swage dies with a relief and extra length All hooks should be swaged full shank To swage the hook use the following procedure Step 1 For proper insertion mark rope using Column F Dimension on page 51 Step 2 Slide rope into hook until it is fully inserted in the shank Inspect mark for full insertion Step 3 Lubricate both die cavities and lower die face See pages 51 for proper die selection Step 4 1st pass allow dies to remain open approximately 1 2 the distance from time initial contact is made between hook and dies Rotate fitting 45 to 90 degrees Step 5 2nd pass allow dies to remain open approximately Y the distance from
162. p 6 6th and 7th passes Close dies to round fitting Open dies and rotate fitting 45 to 90 degrees between passes Open dies and check termination for proper after swage dimensions See page 17 for proper use of No Go Gauge Additional swaging may be required to provide smooth finish and achieve proper after swage dimensions Dies must be fully closed before swaging is complete Copyright 2012 The Crosby Group LLC All Rights Reserved 45 COLD TUFF Swage Fittings Duplex Sleeves Swaging Methods for National S 506 Turnback Eyes National S 506 carbon steel sleeves are designed for use with turnback eye splices and for swaging in National dies These swage fittings are designed to be used on one 1 part of 6 X 19 or 6 X 36 FC IPS or IWRC EIPS Right Regular Lay wire rope In addition these products are designed to be used with inch size 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 Cold Swaging Process Cold swaging is a process which causes considerable movement and work hardening of the steel in the fitting Exerting extreme pressures the swaging machine forces the steel to flow into the crevices between the wires and strands of the wire rope At the same time the swaging machine forces the ma
163. p LLC manufactures a variety of fittings designed specifically to terminate wire rope see table below Guidelines and procedures for the application of terminations shown are covered in this manual The type of end termination selected is determined by the application and strength required of the final assembly Each wire rope termination attaches with a special method which may affect the strength of the wire rope The terminations and stated efficiency shown in this document are based on the specific wire rope constructions defined for each respective product It is understood that other constructions of wire rope and strand are available in a variety of different constructions 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 Termination Type Termination Efficiency Swage Sockets 100 Wedge Sockets Swage Buttons Ia Turnback Eyes Wire Rope Clips Termination Efficiency S ii TTA s i The strength of the wire rope is measured by the concept of efficiency The efficiency ratings for wire rope end terminations are based upon the minimum breaking force of the wire rope The table above depicts some of the more common termination types and their efficiencies Notice the efficiencies range from 80 percent for wedge sockets and wir
164. p rope and socket vertically ensuring alignment of their axes CAUTION DO NOT USE OVERSIZED SOCKETS FOR WIRE ROPE 30 D STRAIGHT BEFORE BEND 1 STEP 6 SEAL SOCKET Seal the base of the socket with putty or plasticine to prevent leakage of the WIRELOCK STEP 7 WIRELOCK KITS WIRELOCK kits are pre measured and consist of two 2 containers one 1 with resin and one 1 with granular compound Use the complete kit NEVER MIX LESS THAN THE TOTAL CONTENTS OF BOTH CONTAINERS Each kit has a shelf life clearly marked on each container 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 2012 The Crosby Group LLC All Rights Reserved STEP 8 MIXING AND POURING 1 Mix and pour WIRELOCK within the temperature range of 48 degrees to 95 degrees F 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 minutes with a flat paddle 3 Immediately after mi
165. pair minor nicks or gouges to socket or pin by lightly grinding until surface 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 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 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 1 Use a hammer to seat Wedge and Rope as deep into socket as possible before applying first load To use with Rotation Resistant wire rope special wire rope constructions with 8 or more outer strands ensure that the dead end is welded brazed or sized before inserting the wire rope into 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 Figure 1 Loads may slip or fall if the Wedge Socket is not properly installed
166. pen Swage Sockets QUIC CHECK S 501 e Forged from special bar quality carbon steel suitable for cold forming e Swage socket terminations have an efficiency rating of 100 based on 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 perform standard production inspections which include gauging for the proper After Swage dimensions or proof loading the catalog strength of wire rope e Hardness controlled by spheroidize annealing e Stamp for identification after swaging without concern for fractures See page 36 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 e U S Patent 5 152 630 and foreign equivalents NOTE 5 501 Swage Sockets are recommended for use with 6 x 19 or 6 x 36 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 In accordance with ASME B30 9 all slings terminated with swa
167. quipped with a latch e Utilizes standard National Swage swaging dies e All hooks incorporate Crosby s patented QUIC CHECK markings Angle Indicators and Throat Deformation Indicators See Crosby General Catalog for detailed information NOTE For use with 6 X 19 or 6 X 36 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 Wire Rope End Terminations User s Manual for proper swaging techniques S 319SWG Shank Hooks for Swaging Size Hook Working Swaging Die After Swage er ec ID Load Limit S 319SWG Die Diameter in mm Tons Stock No Ibs Description Stock No in 516 8 516 8 l 1 7 1 Es 0 6 8 y 1 1 r 7 gt 1 16 28 30 1 1 8 Socket Minimum Ultimate Load is 5 times the Working Load Limit ID Code O is original 319 style hook Wire Size S 319SWG in mm StockNo B D E F G H J K L M o P R AA 14 67 1053011 50 315 27 69 84 94 97 71 572 71 97 222 263 2 25 2 00 5 6 8 1053020 65 359 34 75 100 116 106 88 639 88 106 244 280 250 2 00 56 8 1053039 77 399 34 81 114
168. r proper die selection Swage Sockets for Spiral Strand Rope Our tests indicate that if the spiral strand is 1 x 19 or greater and the ultimate strength does not exceed Table 4 of ASTM A586 you can use dies for size swage sockets up to the 1 1 4 For sizes greater than 1 1 4 the following table will apply If the strand is of greater strength than Table 4 or has less metallic area we must recalculate the design and test for adequacy Dies for S 506 Turnback Sleeves Turnback eye terminations using 5 16 through 1 S 506 Sleeves utilize the S 505 Standard Steel Sleeve die 1st Stage open channel die only The 1 1 4 S 506 Sleeve utilizes the 1 3 8 socket S 501 and S 502 die Refer to page 46 of the Wire Rope End Termination User s Manual for proper die selection Dies for S 409 Buttons Buttons are swaged in open channel dies Refer to page 43 of the Wire Rope End Termination User s Manual for proper die selection Specific recommended swaging practices can be found in each product section of this brochure The proper die selection and the recommended maximum after swage dimensions are referenced in the section of this brochure that contains the product you are swaging This information can also be found in The Crosby General Catalog See Section Wire Rope End Terminations the National Swage Die Guide or by referring to the National Swage Die Chart Dies and die adapters to fit other type swaging
169. re of the cone to share in the loading process This participation in load bearing diminishes as we proceed up the cone See figures IV amp V Copyright 2012 The Crosby Group LLC 59 All Rights Reserved Resin Socketing of Steel Wire Rope Slip Pressure Load Load causes the cone to slip at the socket interface and the pressure generated locks the cone within the socket Fig IV N Pressure Distribution of pressure on the cone within the socket t Fig V lf we examine the forces present in Fig IV we can see that when load is applied the cone will seat progressively generating forces normal to the socket face These forces are transmitted through the resin to the wire surface We are in effect creating a wire reinforced composite wedge on the end of the rope which is capable of withstanding the ultimate strength of the rope 90 Copyright 2012 The Crosby Group LLC All Rights Reserved Resin Socketing of Steel Wire Rope We now have to consider two different scenarios to establish the key to this mechanism In the first case when the load is applied the wire slips at the resin wire interface before the cone slips at the cone socket interface In the second case upon application of the load the cone slips in the socket resin interface before the wire slips within the resin In the first case we have a disaster as the rope will pull out In the second case we have success as the rope will break What is it tha
170. re rope These products are designed to be used with inch size wire rope 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 uniform shank diameter is created allowing for a QUIC CHECK and permanent visual inspection opportunity Designed to quickly determine whether the socket has been 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 Cold Swaging Process through the swaging operation and assist in field inspections es it does not eliminate the need to perform standard production Cold swaging is a process which causes considerable inspections which include gauging for the proper after swage movement and work hardening of the steel in the fitting dimensions or proof loading Exerting extreme pressures the swaging machine forces the steel to flow into the crevices between the QUIC CHECK wires and strands of the wire rope At the same time the CY swaging machine forces the material to flow plastically along the length of the wire rope These are a few of the reasons swaging is done in multiple passes in a well lubricated die Protecting Dies and Swaging Machine When the d
171. re to securely lock tensioner bolt to tensioner Do not assemble the S 423 Wedge in any brand or model socket basket other than the Crosby S 421T TERMINATOR The size is marked on the socket basket and wedge do not interchange wedge between sizes Figure 1 Figure 2 Fa Length Figure 3 Tail Length 2 A minimum of 20 rope diameters but not less than 10 TABLE 1 S 423T Torque Value Table in Ft Ibs Ft Ibs 1 1 4 Ooo 0 The tightening torque values shown are based upon the threads being clean dry and free of lubrication Figure 5 O WRONG Tail Clipped to Live Line Rope Backward Wedge Backward 105 106 Copyright 2012 The Crosby Group LLC All Rights Reserved Wire Rope Clips SS 450 Stainless Steel Wire Rope Clips G 450 Wire Rope Clips New Style Fist Grip Clips 3 16 5 8 Fist Grip Clips 3 4 1 1 2 a _ W i Is Lms Table of Contents Wire Rope Clip Information cccccsceeseeeeees 108 109 Forged Wire Rope CIDS ccceeeeeeeeeeeeeeeeeeeeeaeeeees 110 U Bolt Clip Installation Procedures o nenneennannennnnan 111 Crosby Clips Warnings and Application Instructions cccccseceseeeseeeseeeeeees 112 Copyright 2012 The Crosby Group LLC All Rights Reserved Fist Grip Wire Rope CLIDS csecccceeseeeeseeeeeeeees 113 Fist Grip Clip
172. reline size for which the wedge TERMINATOR design and is to be used may vary in shape from above i product shown e Load pin is forged and headed on one end e US 422T Wedge Sockets contain a hammer pad lip to assist in proper securement of termination e Meets or exceeds all requirements of ASME B30 26 including identification ductility design factor proof load and temperature requirements Importantly these sockets meet other critical performance requirements including fatigue life impact properties and material traceability not addressed by ASME B30 26 e UWO 422T Wedges are to be used only with the US 422T Wedge Socket Assemblies ere i i in Model No in van o oao ae morso 6 681 3 55 100 100 165 281 843 156 106 194 50 255 laa tot 1a 11 1044309 46 1047301 6 6 81 3 55 1 00 1 00 1 63 2 81 8 73 1 08 1 06 1 94 50 2 53 53 1 76 1 88 13 1044318 4 6 1047329 6 __ 6 81 3 55 1 00 1 00 1 63 2 81 8 73 1 02 1 06 1 94 50 2 53 53 1 76 1 88 13 9 14 9 19 4 23 1 41 1 25 2 13 3 31 11 47 2 40 1 50 3 00 63 3 25 69 2 00 2 18 9 141 1 25 2 13 3 31 11 47 2 34 1 50 3 00 63 3 25 69 2 00 2 18 9 9 2 38 5 53 13 19 1 91 1 53 2 88 75 4 13 69 3 26 3 50 1 _2 69 2 56 163 3 26 66 3 25 1 06 2 12 2 56 25 1 2 56 163 3
173. revent any grease or mixture of grease and cleaner from running back down from the main body of the rope and contaminating the clean wires 5 Positioning of Broom and Alignment of Socket 5 1 The broom should be inserted into the socket using one of the methods described in 3 8 Place rope in a vertical position with the broom end up It is recommended that there be thirty 30 rope diameters below the socket before any bending occurs in the rope or twenty 20 rope diameters if securely clamped to a beam Make certain the broomed wires are uniformly spaced in the basket with wire ends at the top edge of the basket Fig 3 and that the axes of the rope and the fitting are aligned A centralizing clamp should be used to assist in the alignment of the axes of the socket and the rope Fig 4 and Fig 5 Correct alignment will avoid premature failure of the assembly due to unequal loading of the wires Properly positioned broom with wire rope ends protruding slightly Fig 3 5 2 Plasticine or clay based putty i e window or glazing putty is required to seal the base of the socket prior to pouring thus preventing resin leakage which may cause voids Fig 4 and 5 Chemicals used in this product can give off toxic fumes and can burn eyes and skin Always check expiration date on the cans Never use out of date material Use only in well ventilated work areas Never breathe fumes directly or for extended time Alway
174. rminations Progressive Swaging S 501 and S 502 swage sockets and other fittings must be swaged progressively if one of the following conditions exist 1 The die Working Load Limit WLL is lower than the required swaging tonnage Warning you must adjust tonnage so maximum die Working Load Limit is not exceeded Failure to do this can result in serious injury or death 2 The Swaging Machine Capacity is lower than the required tonnage to swage the socket full shank Before swaging make sure you follow all instructions in this manual NOTE For additional information see Swaging Machine Capacity Chart on page 12 Step 1 Lubricate both die cavities and lower die face See pages 37 and 38 for proper die selection Step 2 Insert tapered end or rope end of socket about one third 1 3 of the shank into the proper die Close the die until it comes in contact with the shank and continue closing dies to approximately one half 12 the distance between the dies Step 3 Open dies and lubricate the socket shank Rotate the socket shank 45 to 90 degrees and repeat closing the die to about one half 1 2 the distance from the previous pass Step 4 Open dies and lubricate the socket shank Rotate the socket shank 45 to 90 degrees and close the die Step 5 Open dies and insert the next one third 1 3 into the die and repeat the process This should be done until the full shank is swaged Addition
175. rosby group Scan this QR Code with your smart device to visit our website United States Canada Europe P O Box 3128 145 Heart Lake Rd Industriepark Zone b N 26 Tulsa OK 74101 3128 Brampton Ontario 2220 Heist op den Berg P 918 834 4611 Canada L6W 3K3 Belgium F 918 832 0940 P 905 451 9261 P 32 0 15 75 71 25 crosbygroup thecrosbygroup com F 877 260 5106 F 32 0 15 75 37 64 sales crosby ca sales crosbyeurope com www thecrosbygroup com The M arke L nade Y stenday Tedas end Tomorrow Copyright 2012 The Crosby Group LLC All Rights Reserved General Information The purpose of this manual is to provide a resource for preparing wire rope terminations when using Crosby products The publication contains the recommendations of The Crosby Group LLC OSHA ASME and the Wire Technical Board All recommendations in this manual assume the use of Crosby products Properly following the procedures will produce the most reliable and efficient terminations available Crosby provides valuable knowledge about swaging socketing and other termination processes This knowledge is the result of many years of extensive testing and on the job experience There are many types of wire rope end terminations that can be produced Your choice will be dependent upon the application and the task in which the termination is going to be used The Working Load Limit rating of the termination wire rope combination is not entirely a func
176. rts of a system being employed to accomplish a task Therefore we can only recommend within the Working Load Limits or other stated limitations the use of products for this purpose The Working Load Limit or Design Factor or Efficiency Rating of each Crosby product may be affected by wear misuse overloading corrosion deformation intentional alteration and other use conditions Regular inspection must be conducted to determine whether use can be continued at the catalog assigned WLL a reduced WLL or whether the product must be withdrawn from service Specific warning and application instructions are included in this catalog The instructions can be found at the end of each product section The symbol shown to the right can be found on the page for products that have application instructions included in this catalog The page numbers that the specific product information can be found are shown in the box for easy reference Low Temperature Service Crosby Group products generally are intended for tension or pull Side loading must be avoided as it exerts additional force or loading which the product is not designed to accommodate Welding Crosby load support parts or products can be hazardous Knowledge of materials heat treatment and welding procedures are necessary for proper welding Crosby Group should be consulted for information The assigned Ultimate Load Rating of Crosby Group products for the reeving of wire manila or
177. s 15 Meets the performance requirements of EN 13411 6 200 16 The SUPER TERMINATOR may be purchased as a complete wedge socket assembly or the wedge assembly may be purchased for retrofit onto your Crosby S 421T wedge socket basket 17 The Crosby S 423TW SUPER TERMINATOR Wedge is designed to be assembled only into the Crosby S 421T socket basket For the 1 1 4 S 423TW assemble only on to S 421T basket marked TERMINATOR 18 Do not mix and match wedges or pins between models or sizes 19 The SUPER TERMINATOR Wedge Socket may also be used with standard 6 to 8 strand and rotation resistant wire rope special wire rope constructions with 8 or more strands Standard Considerations When Utilizing Wedge Sockets ASME B30 5 Mobile and Locomotive Cranes Section 5 1 7 1 d states The design factor specified in paras 5 1 7 1 a through c shall be the total minimum breaking strength of all ropes in the system divided by the load imposed on the rope system when supporting the static weights of structure and crane load The absence of a derating of the wire rope breaking strength due to termination efficiency in paragraph 5 1 7 1 d indicates that the termination efficiency was considered in the establishment of the design factors The methodology used in ASME B30 5 is not without precedent API specification 2C for Offshore Pedestal Mounted Cranes 6th Edition states Wire rope design Copyright 2012 Th
178. s cooled to 18 C in a refrigerator The control specimen was also placed between two similarly cooled platens The specimens were loaded until failure at a rate of 72KN min Specimen Height Length Width Weight Bulk Cooling Temperature Max Density Temperature of failure Load mm mm mm g Mg m C C kN 1 39 7 39 6 40 0 110 9 1 76 44 30 203 2 39 3 39 3 39 7 108 7 1 77 55 30 215 3 39 6 39 5 39 7 107 2 1 73 60 30 207 4 39 6 39 6 39 6 108 1 1 74 1 28 204 5 5 39 8 39 6 39 7 109 1 1 74 73 36 200 6 39 7 39 9 39 7 109 2 1 74 74 38 207 Failure Stress N mm 128 138 132 130 127 131 Direct dial 0191 222 6888 K 2 Cf Switchboard 0191 222 6000 Fax 0191 222 6613 Telex 53654 UNINEW G Copyright 2012 The Crosby Group LLC B G Clarke All Rights Reserved a Material Safety Data Sheet MSDS Complies with OSHA Hazard Communication Standard 29 CER 1910 1200 the Grosbyqroup SECTION 1 PRODUCT IDENTIFICATION Manufacturer s Name The Crosby Group LLC Identity Wirelock Emergency Telephone Number 918 834 4611 Address 2801 Dawson Road Tulsa Oklahoma 74110 sep one MumBer tor NIOrmangN ee Date Prepared August 8 2012 Signature of Preparer optional SECTION Il HAZARDOUS INGREDIENTS IDENTITY INFORMATION Hazardous Components Other Limits of Specific Chemical Identity Common Names PEL TLV Recommended Benzoyl Peroxide a o o a eee 0 1 1 0 1 2 Propanediol O NAF 50
179. s for easy connection to shackles and other connecting links e Socket design utilizes features to keep cone from rotating NOTICE All Cast Mooring Sockets are Individually Magnetic Particle Inspected and Ultrasonic Inspected G 517 ee Mooring Sockets Size Load G 517 Each in i nana t Stock No _ lbs a a a E 3 1 2 3 5 8 88 92 735 1005123 279 415 800 906 1172 369 1396 2770 412 64 Copyright 2012 The Crosby Group LLC All Rights Reserved Crosby Button Sockets Speltering Methods for SB 427 Button Sockets Crosby Button Sockets are designed to terminate all types of running ropes used on mobile cranes to connect hoist line Efficiency When properly fabricated all Crosby Button Sockets have a termination efficiency of 100 percent based on the minimum breaking force of the wire rope see table on page 58 Ratings for Crosby Button Sockets are based on recommended use with 6 x 7 6 x 19 or 6 x 36 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 Installation Information Install button on the rope so that the live end of the rope extends out of small diameter of the button Broomed end of rope should be inserted to the MAX FILL
180. s over the core and strand group until eye is formed Step 5 Slide sleeve over tail and make sure the sleeve is all the way upon tail before swaging This can be easily achieved by using a flat bar or a hammer and driving the sleeve from the nose end until it is fully seated over the tail The rope at the end of the sleeve should then be marked This will allow you to determine if the sleeve has moved before and during swaging 28 Step 2 Cross Mark 1 of the 3 strand group over the core group at Mark 2 Then bring the core group over the 3 strand group until they lock together in their natural configuration Keep Marks 1 and 2 as close together as possible Step 4 Relay the rope completely including tails or pull amount of rope Our tests have proven that when the tail s ends or pull amount H of rope are on the outside of the rope you achieve the greatest efficiency Making Flemish Eyes by tucking the tail s ends or pull amount on the inside of the rope is not recommended Step 6 Swage product using proper swaging methods on pages 29 35 Swage with proper dies to ensure required after swage dimension see pages 24 25 in this brochure or look up proper die and maximum after swage dimensions in either The Crosby General Catalog the National Swage Die Guide or the National Swage Die Chart Check the fitting with proper measuring devices or No Go gauges to insure the corre
181. s swaging is done on steel fittings in multiple passes in a well lubricated die Protecting Dies and Swaging Machines When the die lands touch each other effective swaging stops Additional swaging adds needless wear and strain on the dies and swaging machine We recommend placing oil on the die faces and cavities When swaging the oozing of the oil from the die faces will indicate when the dies are closed At this point stop swaging Avoid Excess Flashing Flashing occurs when sleeve material flows out into the area between the die faces Once formed additional passes will not eliminate flashing They will only fold back the flash and develop a permanent mark in the material and possibly create a crack F ty EXCESS FLASHING To avoid excess flashing do the following e Select proper dies e Make sure that dies are in good condition and properly lubricated e Apply lubricant such as a light hydraulic oil to both die cavities and the lower die face e Follow swaging instructions on pages 44 45 CORRECT 42 Identification Stamping For identification purposes COLD TUFF swage products can be impression stamped after swaging Properly done there should be no concern for fractures initiating from such impressions To stamp National S 409 Buttons e Use round corner or low stress stamps Stamp to maximum depth of 0 015 in 1 64 e Stamp in the area on the side of the button in the
182. s wear safety glasses to protect eyes Always wear gloves to protect hands Avoid direct contact with skin anywhere Copyright 2012 The Crosby Group LLC All Rights Reserved Axes of socket and rope properly aligned and sealed with plasticine Fig 4 Clamp used to align rope and socket before sealling with plasticine Fig 5 6 Materials 6 1 Always check expiration date on the cans Never use out of date material WIRELOCK should be stored in a cool 50 F 75 F 10 C 24 C dry place 6 2 WIRELOCK is formulated for mixing and pouring in the ambient temperature range 27 F 95 F 3 C 35 C At lower temperatures the gel time will increase Below 48 F 9 C the gel time of approximately 20 minutes can be maintained by the use of booster packs 6 3 At ambient temperatures below 48 F 9 C and above 35 F 2 C one 1 booster pack should be used Below 35 F 2 C and above 27 F 3 C two 2 booster packs should be used The booster pack compensates chemically for the slower gel time experienced at lower temperatures In order to comply with all the approvals granted WIRELOCK should not be mixed and poured at temperatures below 27 F 3 C Knowing the ambient temperature is useful however it should be remembered WIRELOCK will for some time afterwards tend to cure according to the temperature at which it the socket and the wire rope were stored The temperature of the socket
183. so it was necessary to establish some basic knowledge before a resin socketing system could be designed In theory the requirements for a successful system are 1 High bond strength between resin and wire 2 High modulus of elasticity To ascertain the bond strength and the magnitude of the predicted frictional grip tests were done on a single straight wire cast into a cylindrical block of resin The embedded length being such that the wire when loaded would slip rather than break The cylindrical resin termination was chosen so that there would be no distortion of the figures due to the mechanical lock inherent in a conical termination The results are shown in Figure 1 Staining rate 0 062 in min 300 250 200 150 100 50 0 0 05 0 10 0 15 Fig 1 Pull out characteristic for single wire embedded in polyester resin silica Copyright 2012 The Crosby Group LLC 87 All Rights Reserved Resin Socketing of Steel Wire Rope The graph shows that high bond strengths are achievable between the resin and the wire and that shrinkage of the resin and the inclusion of hard silica in the resin gave a very high frictional grip on the wire The classic slip grip peaks and troughs on the right hand side of the loading curve show that the frictional grip is very nearly of the same magnitude as the bond strength In practice it has been found that the wires in the rope broom which is about to be socke
184. ssible the assembly should be Proof Loaded in accordance with ASME B30 9 2 6 13 Reuse of Socket 13 1 To remove the resin from the socket a Cut the rope close to the base of the socket 1 2 is about right b Press the rope and cone out of the socket or c Heat the surface of the socket to 350 F 177 C Leave for 5 10 minutes Force out the rope and cone with a drift pin and hammer 13 2 For additional information on reuse of sockets see Appendix C Technical Bulletin 1 by The Crosby Group LLC page 93 Copyright 2012 The Crosby Group LLC HA All Rights Reserved Approvals Approvals vZ Lloyds Register Of Shipping v Det Norske Veritas Y Y United States Coast Guard V United States Navy Y Y American Bureau of Shipping NATO Numbers 100cc 8030 21 902 1823 250cc 8030 21 902 1824 500cc 8030 21 902 1825 1000cc 8030 21 902 1826 Witnessed and tested by American Board of Shipping ABS Manufactured by MILLFIELD ENTERSRISES MANUFACTURING LIMITED Shelley Road Newburn Industrial Estate Newburn Newcastle upon Tyne NEI5 9RT United Kingdom Distributed by The Crosby Group LLC P O Box 3128 Tulsa Oklahoma 74101 Telephone 918 834 4611 Fax 918 832 0940 www thecrosbygroup com crosbygroup thecrosbygroup com 78 U S Department of Transportation United States Coast Guard Copyright 2012 The Crosby Group LLC All Rights Reserved WIRELOCK Formula for Spelter S
185. synthetic rope is based upon design the catalog ultimate strength for the rope parts when totaled may exceed the assigned Ultimate Load Rating The Working Load Limit of a sling must not exceed the lowest Working Load Limit of the components in the system The recommended Proof Load on all items in this catalog is 2 times the Working Load Limit unless otherwise shown Products that Crosby intends for swaging are identified in this catalog For proper swaging machine training operations and die selection refer to specific product section in this manual To develop other product for swaging requires knowledge of materials heat treatment product design die design and performance of the final product Use only new genuine Crosby parts as replacements when servicing or repairing Crosby products Crosby products are to be considered as sparking unless otherwise noted Product Label Replacement In accordance with ANSI535 4 1991 Product Safety Labels should be periodically inspected and cleaned Product Safety Labels should be replaced when they are no longer legible Current Crosby warning and application labels for applicable products are available from The Crosby Group LLC Two decimal and fractional dimensions shown in catalog are intended as nominal dimensions only If three decimal dimensions are shown contact Crosby for tolerance information Crosby forged and cast steel products can be used in general servi
186. t determines which will occur Assuming that the coefficent of friction between the wire and the resin and the resin and the socket are of the same order an over simplification but it does produce a simple model the factor that determines which of the above scenarios will occur is the relationship between the surface area of the wire S1 and the surface area of the inside of the cone S2 If S1 is greater than S2 then the cone will seat and the rope will break If S2 is greater than S1 the assembly will fail If for example we take a 13mm diameter 6 x 19 IWRC rope the relationship between S1 and S2 is of the order of 6 1 for a 36mm diameter 6 x 36 IWRC 9 1 and for a 52mm diameter 6 x 41 IWRC 10 1 These figures give an indication of the margins of safety involved when resin socketing is employed It also shows that the degreasing would have to be disastrously bad to reduce the coefficient of friction at the wire resin interface to a critical level One factor that has been ignored in this simple model is that the unstraightened wires in the broom produce deformation forces when any attempt is made to induce slip thus increasing the grip of the resin on the wire and giving a further factor of safety This wire in the cast cone also tends to prevent any significant degree of axial extension of the cone during loading and the cone remains almost a constant length It would be useful at this point to examine the Federal Specification socket which
187. ted are rarely clean enough to achieve anything approaching a good bond strength Indeed it will be shown later when dealing with uncleaned wires that the frictional grip alone is enough to seat the cone Either the bond strength of the resin to the wire or the frictional grip of the resin on the wire is sufficient on their own to seat the cone Between them they offer a comforting reassurance that the wire will hold and the cone will seat even if the wire has not been cleaned properly The modulus of elasticity was measured and found to be 6085 Mpa BS63 19 Part 6 1984 It very soon became apparent that the bonding action between the socketing medium and the wire was not in itself sufficient to break the rope Therefore the focus was moved to the shape of the socket the wedging action it would produce and the mechanism by which this occurred The usual total included angle in sockets is between 14 15 degrees and experiments were carried out over the range 9 25 degrees total included angle It was predicted that the narrower the angle the lower the load at which movement occurred and the greater that movement would be In general this prediction was confirmed although in the case of the lower angles the straight line relationship experienced on the wider angles was not found See Figure II In all cases the rope ultimately broke this confirms that the system will cope with a fairly wide deviation from standard socket dimensions 30
188. ted Socket Draw Test Curves at Temp 2650F 1300C X xe at oe Effective Draw mm WIRELOCK Present Te 0 40 80 120 160 Effective Test duration Days WIRELOCK has excellent penetrating qualities and can flow through the most dense wire rope broom which would impede the flow of zinc The WIRELOCK system is designed to have a minimal amount of creep which ceases once the wedging and frictional forces develop for any given load WIRELOCK excels in its ability to resist the action of fatigue fatigue in a wire rope assembly is normally prevalent in the rope close to the neck of the socket WIRELOCK will minimize such problems Copyright 2012 The Crosby Group LLC All Rights Reserved 11 Mar 99 Millfield Enterprises 16 Shelley Road Newcastle upon Tyne 15 Job No 99R007 Test Compressive Strength and Stiffness of Resin Sample 31436 R1792 T40 The specimens were prepared cured and sent to us by the client Date of test Ambient conditions during the test UNIVERSITY OF NEWCASTLE loa Department of Civil Engineering Cassie Building University of Newcastle Newcastle upon Tyne NE1 7RU United Kingdom Head of Department Professor B G Clarke 60 RH Testing machine Sample Compressive 31436 R1792 T40 1 31436 R1792 T40 3 31436 R1792 T40 5 31436 R1792 T40 2 31436 R1792 T40 4 31436 R1792 T40 6 average Sample 31436 R1792
189. tely 1 2 the distance from the time initial contact is made between the sleeve and dies Open dies and rotate fitting 45 to 90 degrees Step 6 4th and 5th pass Close dies to round fitting Open dies and rotate fitting 45 to 90 degrees between passes Open dies and check for proper after swage dimension See page 17 for proper use of No Go Gauge Additional swaging may be required to provide smooth finish and achieve proper after swage dimensions Dies must be fully closed before swaging is complete 48 Copyright 2012 The Crosby Group LLC All Rights Reserved Turnback Terminations 34 114 Turnback eye terminations using 3 4 through 1 National S 506 Sleeve utilize open cavity of the S 505 Standard Steel Sleeve die on the National Hydraulic Swaging Machine Each 3 4 through 1 S 505 Standard Steel Sleeve die contains 2 cavities open and tapered The 1 1 4 size S 506 sleeve utilizes the 1 3 8 socket S 501 and S 502 die See page 48 for smaller sizes To form the eye and swage the termination use the following procedure Step 1 Slide the end of the rope through the sleeve and turn back the wire rope end through the S 506 Duplex Steel Sleeve and adjust the rope to form proper eye size Allow approximately 1 one rope diameter to extend past the end of the sleeve This will provide for elongation of the fitting during swaging See page 47 for proper die selection
190. tential breaking off of the tail due to fatigue e The tail which is secured by the base of the clip and the wedge is left undeformed and available for reuse e 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 1 The wire rope should pass thru the Go hole in the wedge 2 The wire rope should NOT pass thru the No Go hole in the wedge e Utilizes standard Crosby Red U Bolt wire rope clip e The 3 8 thru 1 1 8 standard 5 421 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 Canada patent 2 217 004 and foreign equivalents e Meets the performance requirements of EN 13411 6 2003 S 421T Wedge Sockets Assembly includes Socket Wedge Pin and Wire Rope Clip i Optional G 4082 eE Wedge Only Bolt Nut amp Cotter S 421T Weight S 421TW Weight G 4082 Weight east Stock Each Stock No Each Stock Each in mm No Ibs Wedge Only Ibs No Ibs 9 10 1035000 318 1035555 50 1092227 50 11 13 1092236 69 8 14 16 1092254 4 8 3 18 19 1092281 20 22 1092307 1 24 26 1092325 28 1092343 30 32 1092372 Dimensions 3 1 00 1 00 2 56 1 25 119 3 25 69 2 00 2 19 2 00 2 00 2 94 6 96 16 29 3 04 2 00 3 75 88 4 70 D 81 in C HoT wt kT E re
191. terial to flow plastically along the length of the wire rope These are a few of the reasons swaging is done on steel fittings in multiple passes in a well lubricated die Protecting Dies and Swaging Machines When the die lands touch each other effective swaging stops Additional swaging will add needless wear and strain on the dies and swaging machine We recommend placing oil on the die faces and cavities When swaging the oozing of the oil from the die faces will indicate when the dies are closed At this point stop swaging Avoid Excess Flashing Flashing occurs when sleeve material flows out into the area between the die faces Once formed additional passes will not eliminate flashing They will only fold back the flash and develop a permanent mark in the material and possibly create a crack To avoid excess flashing do the following e Select proper dies A A e Make sure that dies are in good condition and properly lubricated EXCESS FLASHING e Apply lubricant such as a light hydraulic oil to both die cavities and the lower die face e Follow swaging instructions on pages 48 49 CORRECT 46 Identification Stamping For identification purposes National COLD TUFF swage products can be impression stamped after swaging Properly done there should be no concern for fractures initiating from such impressions To stamp S 506 sleeves e Use round corner or low stress stamps Stamp to maxi
192. th 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 1 8 through 7 8 is 80 and for sizes 1 through 3 1 2 is 90 The number of clips shown see Table 1 is based upon using RRL or RLL wire rope 6 x 19 or 6 x 36 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 1 inch 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 1 1 2 inch and smaller and to rotation resistant RRL wire rope 19 x 7 Class IPS XIP XXIP sizes 1 3 4 inch and smaller For other classes of wire rope not mentioned above we recommend 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 The style wire rope termination used for any application is the
193. the other group See page 28 Step 1 The stopping point for separating the strands determines the length of the strand ends at the throat of the splice If the strand ends or pull amount are too short relay the strands and insert one strand to the left If the strand ends or pull are too long move one strand to the right See pages 27 28 for detail steps in marking and making a Flemish Eye Important The Flemish Eye for the QUIC PASS system is formed in the same manner as the standard round sleeves See page 35 for detail steps in marking a QUIC PASS Flemish Eye 26 Swaged Flemish Eye Termination using a National S 505 COLD TUFF Standard Steel Sleeve Copyright 2012 The Crosby Group LLC All Rights Reserved Flemish Type Wire Rope Sling Eyes Marking Marking amp Calculations for Forming Mechanical Spliced Flemish Style Eyes Calculation for Forming Standard Thimble Eyes Different Size Eyes Pull amount is equal to 3 75 X diameter d of rope Throat amount is equal to 15 X diameter d of rope Many methods have been used to form the Flemish See example below change throat amount to 15 Style Eye i e from counting the number of lays to unlay to trial and error The method used here is based ona mathematical formula that will produce the required results on the rope recommended by Crosby National Swage Larger than Standard Eyes Pull amount or tail is equal to 3 75 X diameter d of rope
194. the side of the die to ensure the proper cavity alignment for flash removal e NEVER shim between the dies e 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 tonnage to the Working Load Limit shown on the die block being used See Table 1 for die block Working Load Limit e Always use the correct size and type of die for the size wire rope fitting used e Always lubricate die faces and cavities with light weight oil e Progressive swaging of fittings must be done in accordance with procedure shown in Wire Rope End Terminations User s Manual Only open channel dies are to be used e Stop swaging when the cavity side of both dies touch e Make sure part is swaged to the recommended after swage dimensions See Crosby General Catalog or Wire Rope End Terminations User s Manual Die Guide or Die Chart e Ifa swage fitting other than a Crosby National is used determine adequacy of the termination by a destructive pull test e All swage sockets must be swaged with socket head adjacent to the socket relief largest radius on the die e For special applications or conditions contact Crosby National TABLE 1 Die Size Working Load Limit Height x Width WLL 2 x 3 1 2 2 1 2 x 4 200 Ton Mark Ser
195. tion of the fitting being used Therefore the anticipated efficiency is shown as a function of the wire rope strength Refer to either the Wire Rope Technical Board s Wire Rope Sling User s Manual for the wire rope s rated capacity or the Wire Rope User s Manual for the minimum breaking force of the wire rope whichever applies to your application It is important that the proper components be used to make a termination For a specific style of wire rope termination you must choose the correct type and size of fitting the correct swaging dies if a swage product is required the correct WIRELOCK Kit if soeltered product is required and proper construction of wire rope as shown in the Crosby General Catalog These Crosby instructional materials provide basic application information for the Crosby products and their use with selected other lifting devices Refer to all manufacturer s warnings the current Crosby Seminar workbook the current Crosby General Catalog and current OSHA and ASME standards as they apply References to ASME OSHA and WRTB are for the revisions in effect at time this booklet was printed The Crosby Group LLC reserves the right to change product design materials and specifications without incurring obligations Copyright 2012 The Crosby Group LLC All Rights Reserved General Cautions and Warnings All products manufactured by The Crosby Group LLC are sold with the express understanding
196. tting Open dies and rotate fitting 45 to 90 degrees between passes Open dies and check for proper after swage dimensions See page 17 for proper use of No Go Gauges Dies must be fully closed in tapered die cavity before swaging is complete Copyright 2012 The Crosby Group LLC All Rights Reserved Flemish Type Wire Rope Sling Eyes 12mm 20mm amp 24mm Flemish Eye Terminations for 1 2 1 National S 505 sleeves on 12mm 20mm and 24mm metric ropes For larger sizes see page 31 34 Special dies are required to swage National S 505 sleeves on 12mm 20mm and 24mm wire ropes The dies are provided with two cavities National 1 2 through 1 S 505 sleeves require swaging in the open cavity and then completing the swaging in the tapered cavity in a National Hydraulic Swaging Machines Step 1 Slide sleeve over rope Step 3 Slide sleeve fully over ends of wire rope Step 5 1st pass In open cavity allow dies to remain open approximately 1 2 the distance from time initial contact is made between sleeve and dies Open dies and rotate fitting 45 to 90 degrees Step 7 3rd through 6th pass If sharp flashing does not occur close dies Open dies Move assembly to tapered cavity and repeat steps 5 6 and 7 Step 2 Assemble Flemish Eye See page 28 Step 4 Lubricate both die cavities and lower die face See page 24 for proper die selection Step 6 2nd pass allow d
197. used in sling assemblies the minimum recommended design factor is 5 ASME B30 5 Cranes require that boom pendants terminated with sockets be proof tested When sockets are used in boom pendant lines the minimum recommended design factor is 3 See OSHA and ASME for full information 71 WIRELOCK RESIN FOR SPELTER SOCKETS NOT AVAILABLE IN CANADA Note For use on 416 417 427 and 517 spelter sockets only e 100 termination efficiency e Temperature operating range is 65 F to 240 F 54 C to 116 C e Ideal for on site applications e No hazardous molten metal e Improved fatigue life e Pouring temperature without booster pack is 48 F to 110 F 6 67 C to 43 3 C e One booster pack if pouring temperature is 35 F to 48 F 1 67 C to 8 89 C e Two booster packs if pouring temperature is 27 F to 35 F 2 78 C to 1 67 C e Refer to WIRELOCK Technical Manual for more information Approvals WIRELOCK W416 7 Socket Compound Lloyds Register of Shipping Booster United States Coast Guard Per Case Ibs Stock No United States Navy a oo 2 f ossos aso 1039609 DNV OS E304 1000 12 1039608 4 59 1039609 2000 1039610 9 00 1039611 Guide to amount of WIRELOCK Required egunea fo a es ue an Required etoos S L 7 mm cc i a mm i T E tom J e o Oi 7 16 2 118 1265 2 114 Us Departmen 3 16 238 60 of Transportation 212 ea United States 34 20 s 25s C
198. ving no question as to the quality or the manufacturer COLD TUFF process results in superior ductility that reduces the effects of stress risers 21 COLD TUFF Swage Fittings S 505 Swaging Methods for S 505 Sleeves Carbon Steel Sleeve for Flemish Eyes National S 505 carbon steel sleeves are specially designed for use with Flemish Eyes and for swaging in National dies These swage fittings are designed to be used on one 1 part of 6 x 19 or 6 x 36 FC IPS or IWRC EIPS Right Regular Lay 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 Cold Swaging Process Cold swaging is a process which causes considerable movement and work hardening of the steel in the fitting Exerting extreme pressures the swaging machine forces the steel to flow into the crevices between the wires and strands of the wire rope At the same time the swaging machine forces the material to flow plastically along the length of the wire rope These are a few of the reasons swaging is done on steel fittings in multiple passes in a well lubricated die Protecting Dies and Swaging Machines When the die lands touch each other effective swaging stops Additional swaging adds needless wear and strain on the dies and swaging machine We recommend
199. xing slowly pour the mixture down one side of the socket until the socket basket is full 4 Check for leakage at nose of socket add putty if required STEP 9 CURING 1 WIRELOCK will gel in approximately twenty 20 minutes in a temperature range 65 degrees F to 75 degrees F 2 The socket must remain undisturbed in the vertical position for an additional ten 10 minutes after gel is complete 3 The socket will be ready for service sixty 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 in accordance with ASME B30 9 2 6 ALTERNATE SEIZING AND BROOMING METHOD Reference the WIRELOCK TECHNICAL DATA MANUAL from Crosby for an alternative socketing method 95 Crosby Real Life Ritts The Super TERMINATOR offers several advantages over traditional ay we methods of wedge socket terminations T EN S 423T The innovative design will significantly increase the termination efficiency wg l Super over existing wedge sockets available today he A i Te rm in a t O r Terminations on most ropes have a minimum efficiency rating of 80 of the rope s catalog breaking strength Patent pending design eliminates the difficulty of installing high performance high strength compacted strand rotation resistant wire rope int
200. y in the highly loaded section at the neck of the socket From a quality point of view the broom should be opened right down to the seizing Very often we see brooms which look very pretty and are nicely opened at the top but the strands remain substantially closed near the seizing This state of affairs does not produce a quality assembly even though it may break the rope One further point on the production of a quality assembly is that care should should be taken to ensure that the neck of the socket has been sealed with clay or putty Any leaks could cause voids in the neck area of the socket These voids are able to form because the resin starts to gel harden in the centre of the mass and if resin leaks out at the neck of the socket the resin above it during gel is no longer liquid and is therefore unable to flow down to fill the void Copyright 2012 The Crosby Group LLC 91 All Rights Reserved Resin Socketing of Steel Wire Rope It is not necessary to hook wires when resin socketing except in the case of coarse construction wire rope such as 6 x 7 In use the resin socketed assembly offers a higher achievable tensile strength and a better fatigue performance of the assembly In general this can be attributed to two factors the excellent penetration of resin ensuring a complete cone and secondly the fact that there is no annealing of the wires due to heat from molten metal A further benefit that is derived from the lack of he
201. y 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 Installation Information General Overview 1 The socket is attached by inserting the end of the wire rope into the narrow end of the cone shaped socket 2 Before pouring the socket the wire must be broomed and properly cleaned Once the socket and wire rope are properly prepared the broomed wire rope is pulled into the socket cavity 3 The socket cavity is then poured with molten zinc or more commonly WIRELOCK resin 4 The socket must then be allowed to cure based on zinc resin manufacturer s recommendations 5 Assembly length is measured from center line of pins for both open and closed sockets Specific Instructions Socketing Using WIRELOCK Resin Material Seizing cleaning brooming and preparation of wire rope and pouring of WIRELOCK is to be carried out per instructions provided in theWire Rope End Terminations Users Manual see pages 73 77 in this document and WIRELOCK Warnings and Application Instructions located on the WIRELOCK Product or in the Crosby General Catalog Copyright 2012 The Crosby Group LLC All Rights Reserved Socketing Using Zinc Spelter Material Seizing cleaning brooming and preparation of the wire rope and pouring of zinc is to be carried out in accordance with recommendatio

WIRE ROPE END TERMINATIONS

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