Manual No.

103-0042
REV. 1/25/08

Installation and Maintenance Manual for the

SPANCO Lift Boss Wire Rope Hoist

ISO 9001 REGISTERED

 TABLE OF CONTENTS
Forward...................................................................................................................... 3
Installation................................................................................................................. 3
Operation....................................................................................................................3
Care and Inspection.....................................................................................................4
Changing Wire Rope Cable on the SPANCO Lift Boss......................................................5
Recommended Spare Parts.......................................................................................... 5
Spare Parts List...........................................................................................................6
Exploded Hoist View.................................................................................................... 7
Wiring Diagrams:
- For 5 Ton Hoist with 7 1/2 HP Hoist Motor and 1/3 HP Trolley Motor 460 Volts.............8
- For 3 Ton Hoist with 5 HP Hoist Motor and 1/3 HP Trolley Motor 460 Volts................... 9
- For 5 Ton Hoist with 7 1/2 HP Hoist Motor and 1/3 HP Trolley Motor 460 Volts
/ with Overload Sensor........................................................................................ 10
- For 3 Ton Hoist with 5 HP Hoist Motor and 1/3 HP Trolley Motor 460 Volts
/ with Overload Sensor........................................................................................ 11
- For 5 Ton Hoist with 7 1/2 HP Hoist Motor and 1/3 HP Trolley Motor 460 Volts
/ with Rotary Limit Switch.................................................................................. 12
- For 3 Ton Hoist with 5 HP Hoist Motor and 1/3 HP Torlley Motor 460 Volts
/ with Rotary Limit Switch.................................................................................. 13
Basic Safety Rules.................................................................................................... 14
Dos & Donts - Electric Powered Hoists.......................................................................15
Warranty and Service Policy........................................................................................16

WHEN ORDERING SPARE PARTS, HAVE THE SERIAL NUMBER READY.

IMPORTANT! THE SERIAL NUMBER IS ATTACHED TO THE HOIST FRAME.

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FORWARD:

The LIFT BOSS has been engineered to provide many years of service. Proper installation,
care, and operation within its rating will result in the lowest operating cost. Please read
and understand the following instructions thoroughly before using the hoist. All OSHA and
ANSI hoist standards must be followed to ensure the safe operation and longest life of your
LIFT BOSS wire rope hoist.

Before installing your LIFT BOSS wire rope hoist:

1. Read and understand the following instructions thoroughly.

2. Double check supply voltage with motor name plate voltage.

3. Double-check oil level in speed reducer. (All SPANCO reducers are shipped from the
factory with the correct amount of lubricant)

4. Make sure breather plug on gear reducer is in the vent orientation, if so equipped

INSTALLATION:

TROLLEY Removing the trolley side plate, lift into position, and reinstall side plate. Be
sure that the trolley wheel spacing is correct for your beam. Shims may have been provided
to allow adjustment to flange widths between sizes.

CONTROLS A wiring diagram is provided with every SPANCO hoist. Installation of

electric components should be done only by a certified industrial electrician. Check for
proper voltage. Make electrical connection and test run hoist.

OPERATION:

DIRECTION OF ROTATION After turning on the line current, the hoist operation should be
carefully checked by raising the hook a short distance to determine that the direction of
rotation is correct. Raise the hook until the load block raises the limit switch lever. This
should open the UP circuit and the hoist should stop. If it does not stop, the direction of
rotation must be corrected by reversing any one phase of the line circuit. This may be
done at the collectors or at the incoming lead.

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The upper limit switch must be functioning properly before placing hoist
! WARNING into service.

LIMIT SWITCH The switch operates when the hook block comes in contact with the lever,
opening the circuit and causing the hoist to stop in the upward direction. It resets itself
automatically as soon as the hook block has been lowered.

ELECTRIC MOTOR AND BRAKE - Separate instructions are furnished for the care of the
electric motor and brake.

CARE AND INSPECTION:

HOIST CABLE - Hoist cable should be treated with any good cable lubricant to keep it in
good condition. This will prevent rust and abrasion and increase the life of the cable. Per
ANSI standards, all lift should be as near vertical as possible. Never side load or side pull
the hoist. Side pulling may pull the cables out of the drum grooves causing them to over-
wind and reduce cable life.

Wire rope should be thoroughly inspected each month by a person authorized to perform a
proper inspection.

Replace the wire rope if any wires or complete strands are broken.
Replace the rope if it shows unusual wear, bend, kinks, bird-caging, or heavy wear.


Use only factory approved wire rope.
! WARNING
Replace the wire rope if it skips-over drum grooves while raising the hook.


Using a hoist with an improperly functioning wire rope or improperly
! WARNING functioning upper limit switch can result in serious bodily injury or death.

LUBRICATION The gear cases are filled with oil at the factory. This lubricates the gears
and bearings within the gear case. This oil only needs renewal at very infrequent intervals.
Drum shaft outboard bearing is of the grease seal type and is filled before shipment, not
needing any further lubrication. Sheave bushings are of the self-lubrication type and do
not require lubrication. Trolley wheels, when used, are of the ball bearing type and should
be oiled occasionally with a good grade of heavy oil.

IMPORTANT: Remove plug at top of gear case and replace with Vent Plug attached to
hoist. When communicating about your SPANCO hoist, provide the serial number as
indicated on the hoist nametag.

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 CHANGING WIRE ROPE CABLE ON SPANCO, LIFT BOSS INSTRUCTIONS

FOR 4-ROPE HOOKS BLOCKS

Save time by noting path of cable through sheaves before removing old cable.

1. Remove cable where anchored to frame. Remove hook block.

2. Rotate drum until cable is completely removed from drum and cable clamp is visible.

3. Remove cable clamps to remove cable from drum.

4. Attach new cable to drum using all cable clamps.

5. Wind cable on drum, being sure to make first two wraps tight.

6. Thread cable through sheaves and anchor to frame. Relieve all twist from cable
before anchoring.

RECOMMENDED SPARE PARTS

Wire Rope....... 2-9072 (20ft. lift) or 2-9081 (30ft. lift)

Upper Limit Switch.......... 90-0015
Load Block.........2-9041 (5 Ton) or 2-9057 (3 Ton)
Reversing contactor, Hoist....... 75-0053 (5 Ton) or 75-0014 (3 Ton)
Reversing contactor, Trolley........ 75-0004
Transformer........ 75-0001

IMPORTANT!
WHEN ORDERING SPARE PARTS, HAVE
THE SERIAL NUMBER READY.
THE SERIAL NUMBER IS ATTACHED TO
THE HOIST FRAME.

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Electric hoists and trolleys of all types are designed with the safety of the operating
personnel first in mind. Your own safety and that of your fellow workers will be assured
when overhead materials handling equipment is used properly. Disregarding such
recommendations endangers life and property. Following are the basic safety rules worth of
your careful consideration and attention.
1. DO NOT LOAD BEYOND the RATED CAPACITY. The
immediate danger is the possible failure of some load
carrying parts. Overloading might also start a defect
which could lead to some future failure even at less
than rated capacity.
_____________________________________
2. DO NOT USE ANY OVERHEAD MATERIALS HANDLING
EQUIPMENT for HANDLING PERSONNEL.
_____________________________________
3. Conduct a periodic visual inspection for SIGNS
OF DAMAGE OR WEAR Particular attention should be
paid to the cable and hook. If the cable shows signs
of wear or damage or hook is distorted or opened, call
it to the attention of the safety engineers before
loading the hoist.
_____________________________________
4. DO NOT USE HOISTING CABLES as a SUBSTITUTE
FOR SLINGS Use slings only. Cable or chain slings
should be of proper size and type for load handling
never use slings showing physical damage of any
degree.
_____________________________________
5. WHENEVER THE HOIST IS LOWERED in such a
manner as to take the load off the wire rope, the
operator should determine, before again making a lift,
if the wire rope is properly reeved on the drum.
_____________________________________
6. STAND CLEAR of all loads If you must travel a
load over the heads of other personnel, give ample
warning of your intention before you move.
_____________________________________
7. ALWAYS INCH THE HOIST into the LOAD.
Running into the load at full hoist speed imposes
excessive overloads on the hoist and could result in
failure of parts and/or supporting structure. This is
particularly true with high hoisting speeds.
_____________________________________
8. LIMIT SWITCHES are FOR EMERGENCY USE ONLY
and should not be tripped during normal operation.
If it is necessary to travel to the limit, use extreme
caution and approach the limit in slow speed or by
inching. Do not leave hook block in contact with
limit switch at the end of the operation. A phase
reversal with the bloc in this position will probably
result in damage to the hoist if the down button or
control rope is operated.
____________________________________
9. Be sure the hoist RAISES AND LOWERS
PROPERLY WHEN THE CORRESPONDING PUSH
BUTTONS or control ropes ARE OPERATED A
reversal of direction indicates a phase reversal in
the current conductor, the reversal of the tope on the
drum or an interchange of writes on a push button
any of which would cause the limit switch to be
inoperative. Do not under any circumstances
operate the equipment until the trouble has been
found and corrected.
____________________________________
10. CENTER THE HOIST OVER THE LOAD before
lifting. Do not side pull or end pull.
____________________________________
11. KNOW THE HAND SIGNALS for hoisting, cross
travel and crane travel if working with cab operated
hoists or cranes. Operators should accept the
signals of only those persons authorized to give
them.
____________________________________
12. DO NOT LEAVE the LOAD SUSPENDED in the air
UNATTENDED.
____________________________________
13. DO NOT JOG CONTROLS unnecessarily. Hoist
motors are generally high torque, high slip types.
Each start causes an inrush of current greater than
the running current and leads to overheating and
heat failure, or burn-out, if continued in excess.
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DOS & DONTS - Electric Powered Hoists
The following warnings and operating practices have
been taken from American National (Safety) Standard
ANSI B30.l6 and are intended to avoid unsafe hoisting
practices which might lead to personal injury or property
damage.
These recommendations apply to all electric and air
powered hoists for vertical lifting service involving
material handling of freely suspended unguided loads.

! WARNING
TO AVOID INJURY
1. DO read ANSI B30.16 Safety Standard for Overhead
Hoists and Hoist Manufacturers Operating and
Maintenance Instructions.
2. DO be familiar with hoist operating controls,
procedures and warnings.
3. DO make sure hook travel is in the same direction as
shown on controls.
4. DO make sure hoist limit switches function properly.
5. DO maintain firm footing when operating hoist.
6. DO make sure that load slings or other approved
attachments are properly sized and seated in the hook
saddle.
7. DO make sure that the hook latch, if used, is closed
and not supporting any part of the load.
8. DO make sure that load is free to move and will clear
all obstructions.
9. DO take up slack carefully, check load balance, lift a
few inches and check load holding action before
continuing.
10. DO avoid swinging of load or load hook.
11. DO make sure that all persons stay clear of the
suspended load.
12. DO warn personnel of an approaching load.
13. DO protect wire rope and load chain from weld
spatter or other damaging contaminants.
14. DO promptly report any malfunction, unusual
performance, or damage of the hoist.
15. DO inspect hoist regularly, replace damaged or worn
parts, and keep appropriate records of maintenance.
16. DO use the hoist manufacturers recommended
parts when repairing a hoist.
17. DO use hook latches wherever possible.
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18. DO apply lubricant to the wire rope or load chain as
stated under care and inspection section of manual
19. DO NOT lift more than rated load.
20. DO NOT use the hoist load limiting device to measure
the load.
21. DO NOT use damaged hoist or hoist that is not
working correctly.
22. DO NOT use the hoist with twisted, kinked, damaged
or worn wire rope or chain.
23. DO NOT lift a load unless wire rope is properly seated
in its groove(s) or unless chain is properly seated in chain
wheel(s) or sprocket(s).
24. DO NOT use load rope or load chain as a sling or
wrap load rope or chain around the load.
25. DO NOT lift a load if any binding prevents equal
loading on all supporting ropes or chains.
26. DO NOT apply the load to the tip of the hook.
27. DO NOT operate unless load is centered under hoist.
28. DO NOT allow your attention to be diverted from
operating the hoist.
29. DO NOT operate the hoist beyond limits of load rope
or load chain travel.
30. DO NOT use limit switches as routine operating stops
unless recommended. They are emergency devices only.
31. DO NOT use hoist to lift, support or transport people.
32. DO NOT lift loads over people.
33. DO NOT leave a suspended load unattended unless
specific precautions have been taken.
34. DO NOT allow collision between two hoists or between
hoist and obstructions.
35. DO NOT allow the rope, chain or hook to be used as a
ground for welding.
36. DO NOT remove or obscure the warnings on the hoist.
37. DO NOT adjust or repair a hoist unless qualified to
perform hoist maintenance.
38. DO NOT attempt to lengthen the load rope or chain or
repair damaged load rope or chain.
 SPANCO, Inc. Toll Free: (800) 869-2080
604 Hemlock Road Local: (610) 286-7200
Morgantown, PA, 19543 Fax: (610) 286-0085

spanco.com

ONE-YEAR EQUIPMENT WARRANTY

SPANCO offers this Equipment Warranty (the Warranty) on the Lift Boss Electric Wire Rope Hoist (the Equipment). SPANCO warrants the
Equipment and wearable end truck and trolley wheels only, to be free from defects in material and workmanship for a period of one (1) year,
commencing on the date of shipment to the first retail purchaser (Purchaser). This Warranty does not extend to Equipment which has been
subject to misuse, use in excess of rated capacity, negligent operation, use beyond SPANCOs published service factors, improper installation
or maintenance, and does not apply to any Equipment which has been repaired or altered without SPANCOs written authorization. Written
notice of any claimed defect must be given to SPANCO within thirty (30) days after such defect is discovered. SPANCOs obligation, and
Purchasers sole remedy under this Warranty is limited to, at SPANCOs discretion, the replacement or repair of the Equipment at SPANCOs
factory or at a location approved by SPANCO. Purchaser is responsible for all freight and transportation costs relating to the repair or
replacement of the Equipment. THE FOREGOING WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER WHETHER EXPRESS,
IMPLIED, OR STATUTORY. SELLER MAKES NO WARRANTY AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OF THE EQUIPMENT
AND MAKES NO OTHER WARRANTY, EITHER EXPRESS OR IMPLIED. SPANCO shall not be liable, under any circumstances, for any indirect, special
or consequential damages including, but not limited to, lost profits, increased operating costs or loss of production. This Warranty shall not
extend to any components or accessories not manufactured by SPANCO, and Purchasers remedy for such components and accessories shall
be determined by the terms and conditions of any warranty provided by the manufacturer of such components and accessories.

SERVICE POLICY
1. Obtain as much information as possible concerning the problem through personal observation by yourself or other authorized personnel
familiar with the job and equipment: include model, serial and/or part numbers, voltages, speeds and any other special identifying
features. Be prepared to discuss the situation in detail.

2. All authorized labor charges will be based on straight time. Hourly rates, estimated man hours, and not to exceed total dollar amount
required for corrections are to be agreed upon before authorization is given. There will be no allowances for overtime except in dire
emergencies and then only with prior approval.

3. A verbal agreement may be reached immediately on both the method of correction and the approximate cost. A warranty authorization
number will be assigned for the specific incident. A confirming written authorization will be forwarded to the distributor.

4. The distributor must send an itemized invoice, showing our release number or invoice number and warranty authorization number after
authorized corrections have been made. A credit memo will be issued by accounting after the invoice has been received and approved.
Warranty charges ARE NOT to be deducted from outstanding open account invoices under any circumstances.

5. Any field corrections made prior to an authorization by SPANCO will not be accepted as a warranty charge or the responsibility of
SPANCO. Any modification to the equipment made without the prior approval of the seller will void all warranties. A verbal authorization
for modification may be obtained, in which event a warranty authorization number will be assigned for the specific modification.
A confirming written authorization will be forwarded to the distributor.

This warranty and service policy will be incorporated as a permanent section of the current price book as issued by SPANCO.

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