OPERATIONS MANUAL

750 TON ABCO

Traveling Block Assembly

ASSY MODEL NO.: B60G750 AMERICAN BLOCK PART NO: 3036000

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TABLE OF CONTENTS
1.0 GENERAL INFORMATION 1.1 Equipment Specifications 1.2 Certificate of Compliance 1.3 Warranty Information

2.0

OPERATION AND ROUTINE MAINTENANCE 2.1 Operation 2.2 Required Routine Maintenance 2.3 Spare Parts List

3.0

ASSEMBLY / DISASSEMBLY 3.1 Disassembly 3.2 Reassembly 3.3 Testing After Reassembly

4.0

ASSEMBLY DRAWING

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1.0

GENERAL INFORMATION 1.1 Equipment Specifications 1.2 Certificate of Compliance 1.3 Warranty Information

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1.1

Equipment Specifications
750T Traveling Block Assembly B60G750

Product Description: Model Number:

Maximum Load Rating Block Assy: Maximum Load Rating Lifting Beam: Ambient Temperature (for Max. Load Ratings):

750 Short Tons 80 Short Tons SEE CERTIFICATE OF COMPLIANCE 31,000 lbs

Weight of Block Assembly: Block: Number of Sheaves: Sheave Diameter (OD):

7 60.0 inches

The 750 Ton Traveling Block Assembly is hereafter called the block assembly for simplicity.

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Remove this page and replace with Certificate of Compliance

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1.3

Warranty Information

Product information and support is provided during normal business hours by contacting:

Manufacturer: Address:

American Block Manufacturing Company 6311 Breen Road Houston, Texas 77086 U.S.A (281) 820-5332 (281) 820-3861 ABCO@americanblock.com

Telephone Number: Facsimile Number: Internet Address:

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2.0

OPERATION AND ROUTINE MAINTENANCE 2.1 Operation 2.2 Required Routine Maintenance

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2.1 Operation
All operational instructions reference the block assembly components by item numbers listed in the Assembly drawing 30360000 in Section 5.0.

WARNING:

THE BLOCK IS NEITHER DESIGNED NOR INTENDED FOR USE IN MOVING OR LIFTING PEOPLE OR THINGS OVER PEOPLE. MAKE SURE THAT PERSONNEL AND FOREIGN OBJECTS ARE CLEAR OF THE BLOCK BEFORE START UP. DO NOT REMOVE GUARDS. KEEP HANDS FREE OF MOVING PARTS.

WARNING:

2.1.1

Installation
Remove Screws/Pivot Pins (Lower) and Washers (Items 9 and 24) from the Side Guards (Items 13), swing Side Guards upward and secure them from falling down. String up the 1-3/4 dia wire rope through the Sheaves (Items 15) and the slots in the guards. Fasten the side guards back in place.

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2.2

Required Routine Maintenance

Routine maintenance of the block assembly consists of visual inspections performed at the intervals specified below in Section 2.2.1, and periodic lubrication of components as specified in Section 2.2.2.

2.2.1

Inspection Schedule and Procedures

2.2.1.1 Daily Inspection

For daily inspection, block assembly should NOT be disassembled. Exterior of entire block assembly should be cleaned to allow thorough visual inspection of all exterior parts for undue wear on exposed parts, loose items, cracks, or corroded surfaces. Wear surfaces and load path components should show only gradual wear and elongation over short periods of time. Any significant changes in wear patterns or elongation seen during daily inspections should be investigated immediately and corrective action should be completed prior to placing the hook assembly back into service. Any deficiencies noted (loose items, corroded surfaces) should be corrected immediately. Written and dated records should be kept of all deficiencies noted and the corrective actions taken and filed with the equipment maintenance records. Lubrication of the block assembly components should be performed as required per Section 2.2.2. Written and dated lubrication records should be kept and filed with the equipment maintenance records.

2.2.1.2 Shop Inspection (Six Month Intervals)

The block assembly should be removed from service and taken to a suitable shop approved by American Block Company for disassembly per procedure in Section 3.1 and thorough cleaning to allow a comprehensive inspection of all internal and external parts.

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Once disassembled and cleaned, all external and internal parts should be visually examined for cracks, corrosion, wear, elongation, and any other signs of damage. Any worn or damaged parts should be noted and replacements ordered from American Block Company (ABCO). American Block Company must approve any repairs to damaged/worn parts in writing prior to starting repair work. Failure to use American Block approved replacement parts may void ABCOs warranty. Repair of any worn/damaged part without written approval of repair and reinspection procedures from American Block Company may void ABCOs warranty.

A trained and certified operator should inspect all critical load path components listed below using MPI. Critical Load Path Items for MPI Inspection: (Reference: Assembly Drawing 30360000 in Section 5.0) Assy Item No. 1 2 3 6 7 10 15 16 Part Description Frame Weldment Sheaves Shaft Lifting Beam Clevis Pin (Qty 2) Sleeve (Qty 4) Clevis Sheave ( Qty 7) Bearing Assembly ( Qty 7)

Equipment should be reassembled carefully per procedure in Section 3.2, replacing any worn or damaged parts noted during visual examination and taking special care to lubricate and/or tighten all parts appropriately during assembly. Required shop inspection records include written and dated MPI inspection results of the critical load path components listed above and written visual observations of all parts inspected. All parts repaired or replaced during shop inspection should have reason for repair/replacement and action taken. All inspection and repaired/replacement part records should be filed with the owners equipment maintenance/repair data.

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2.2.2

Lubrication Schedule and Procedure

2.2.2.1 The block assembly should be lubricated once for every 8 hours of active usage Apply grease-to-grease fittings at the following locations with a grease gun (Use a Moly-EP quality grease): Qty (7) grease zerks for Sheave Bearings (see Items 18)

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2.3 Spare Parts List

ITEM NO.
1 2

DESCRIPTION
SHEAVE BEARING SHEAVE SEAL

PART NUMBER QUANTITY

107-0027 125-0027 7 14

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3.0

ASSEMBLY / DISASSEMBLY 3.1 Disassembly 3.2 Reassembly 3.3 Testing After Reassembly

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3.1 Disassembly
The 750 Ton Traveling Block Assembly can be disassembled into (2) main sub-assemblies, as follows: 1. 2. Block Clevis

3.1.1

Disassembly of Block Sub - Assembly

1. Position and support hook so that block face containing Sheaves Shaft Nut (Item 4) is facing upward and Clevis SubAssembly is suitably supported to keep its components from moving and the bottom Housing Side Plate is supported high enough to allow space to remove Sheaves Shaft (Item 2). Remove Items 21 and 22 from retaining the position of the Shaft Nut (Item 4). Remove fasteners (Item 21,22) and Key (Item 14) from bottom of Sheaves Shaft (Item 2). Remove fasteners (Items 8) from Lifting Beam (Item 3), and remove lower Side Sheave Guard fasteners (Items 9 and 24). Remove both Side Sheave Guards (Items 13). Remove Lifting Beam. Remove fasteners (Items 19,20) from Bottom Sheave Guard (Item 12), and remove the Bottom Sheave Guard. Install 1-8 UNC threaded eyebolt into center of threaded end of Sheaves Shaft (Item 2). Attach hoisting sling to 1 eyebolt. Partially loosen shaft nut (Item 4). Take the load of the Sheaves Shaft (Item 2) with the hoist/sling of step (6) above. Fully loosen the Sheaves Shaft Nut (Item 4) and fully lower and withdraw the Sheaves Shaft (Item 2).

2.

3.

4.

5.

6.

7. 8.

9.

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10.

Pick off the spacer (Item 5), sheaves (Items 15), and bearings (Items 16) from the inside of the Frame.

3.1.2

Disassembly of Clevis
1. Remove fasteners (Items 23,24) from Clevis Pin Lock Plate (Item 11). Remove Clevis Pins (Item 6) from Frame (Item 1) and Clevis (Item 10). Remove Clevis (Item 10).

2.

3.

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3.2

Reassembly
Reassembly is the exact opposite of the previous disassembly instructions. However, the following items should be noted:

3.2.1

Block Reassembly
1. Purge and clean the sheave bearing greasing holes in the Sheaves Shaft (Item 2). Clean and thoroughly inspect the sheave bearings (Items 16). Replace the sheave bearing seals (Items 17). Remove any burrs from the threads of the Sheaves Shaft (Item 2). Fit the mating nut (Items 4) prior to final assembly to assure a free fit. Install all components prior to tightening any bolt or nut. Tighten the Sheaves Shaft Nut (Item 4) first, followed by all other fastener. Tighten item 4 so that locking fasteners (Items 21 and 22) may be reinstalled at factory supplied positions. THE SHEAVES SHAFT (ITEM 2), AND ASSOCIATED NUT (ITEM 4), MUST BE TIGHTENED SUFFICIENTLY TO SUFFICIENTLY CLAMP THE INNER RACES OF THE SHEAVE BEARINGS (ITEMS 16). USE NEVER-SEIZE OR PIPE DOPE ON ALL THREADS TO PREVENT GALLING.

2. 3. 4.

5. 6.

NOTE:

7.

Relubricate the sheave bearings.

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3.3 Testing After Reassembly

3.3.1 Block Sub-Assembly
1. Verify tightness of Lifting Beam (Item 3) retaining fasteners (4x Items 8). Verify tightness of all shaft nut secondary locking screws (Items 21 and 22). Verify adequate greasing of the sheave bearings (Items 16). Verify that sheaves will rotate freely.

2.

3. 4.

3.3.2

Clevis Sub-Assembly
1. Verify tightness of Clevis Pin Locking Plate fasteners (Items 23 and 24).

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4.0

FIGURES

FIGURE 1: DERATING OF CLEVIS

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FIGURE 1: DERATING OF CLEVIS

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