Wire Rope Replacement

Lug-All come along ratchet winch hoists are built to last for many years, which means some parts may have to be replaced over time. Virtually every part of a Lug-All hoist can be replaced, including the wire rope assembly. A worn, frayed, or damaged wire rope can be a serious safety risk, so it should be replaced as soon as possible. Fortunately, that’s easy to do by following these steps.

Step 1:

Pull the full length of the wire rope off the drum and remove the cable shield.

Step 2:

Keep tension on the wire rope and use an angle grinder to cut off the hook and the copper sleeve from the end of the wire rope assembly.

Step 3:

Remove the old wire rope from the drum and from the pulley block assembly.

Step 4:

Insert the fused end of the new wire rope assembly through the drum anchor hole and through the wire guide on the main frame. Pull the wire rope assembly completely through the drum anchor hole so that the ball-shank end of the wire rope assembly sits completely inside the drum anchor recess.

Step 5:

Return the cable shield to the drum, securing it with a new E-clip, and place the pulley block onto the new wire rope assembly.

Step 6:

Remove the old thimble from the eye hook and replace it with a new one. Close the new thimble with needle nose pliers.

The eye-hook can be attached to the new wire rope assembly using either fist-grip clamps or swaging. If you are using fist-grip clamps, you can order a clamp kit which includes two fist-grip clamps and installation instructions. If you are swaging the attachment, you will need a copper sleeve and a hand swaging tool for the specified diameter of the wire rope.

Fist-Grip Clamps

Step 1:

Insert the fused end of the wire rope assembly through the eye hook and thimble, then turn back four inches of wire rope.

Step 2:

Place one fist-grip clamp near the end of the turned back section of wire rope and hand tighten it, then adjust the position of the clamp so that the distance between the end of the wire rope and the clamp is about the width of the clamp.

Step 3:

Use a torque wrench to tighten the nuts on the fist-grip clamp to 30 foot-pounds.

Step 4:

Place the second fist-grip clamp on the wire rope between the eye hook and the first clamp and hand tighten it, then slide the clamp tightly against the thimble.

Step 5:

Ensure that the wire rope is seated completely in the thimble, then use a torque wrench to tighten the nuts on the fist-grip clamp to 30 foot-pounds.

Swaging

Step 1:

Slide one side of the copper sleeve over the fused end of the wire rope assembly.

Step 2:

Insert the end of the wire rope through the eye hook and thimble, then loop the wire rope around the thimble and insert the end into the other side of the copper sleeve.

Step 3:

Slide the copper sleeve tightly against the hook and thimble, leaving about a cable-width of distance between the end of the sleeve and the fused end of the wire rope assembly.

Step 4:

Use the hand swaging tool to crimp the sleeve at the left, right, and center with equal spacing between crimps. Avoid crimping too close to the edges of the copper sleeve.

Once the hook has been attached to the new wire rope assembly, simply wind the wire rope onto the drum and ensure it sits tightly and evenly on the drum.