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INSTRUCTION MANUAL
Conveyor Sheaves
4024, 4036, and 4048
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
Register this product at www.greenlee.com
52055552 © 2010 Greenlee Textron Inc. 3/10
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4024, 4036, and 4048 Conveyor Sheaves
Table of Contents
Description .................................................................... 2
Safety ............................................................................ 2
Purpose of this Manual ................................................. 2
Important Safety Information ........................................ 3
Hook Load ..................................................................4–7
Some Hook Loads Illustrated .................................... 5
Calculating the Hook Load .....................................6–7
Crosby Hoist Hook ...................................................8–10
Illustration and Parts Lists ........................................... 11
Description
Greenlee Conveyor Sheaves are used to change the
direction of a rope or cable while installing cable in
conduit or raceway.
They may also be used to change the direction of the
cable puller tailing rope to allow the operator to stand
away from the line of the high tension pulling rope
approaching the puller.
Safety
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This instruction manual
and any markings on the tool provide information for
avoiding hazards and unsafe practices related to the
use of this tool. Observe all of the safety information
provided.
Purpose of this Manual
This manual is intended to familiarize all personnel with
the safe operation and maintenance procedures for the
following Greenlee tools:
4024, 4036, and 4048 Conveyor Sheaves
Keep this manual available to all personnel.
Replacement manuals are available upon request at no
charge at www.greenlee.com.
All specications are nominal and may change as design
improvements occur. Greenlee Textron Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.
Tugger is a registered trademark of Greenlee Textron Inc.
KEEP THIS MANUAL
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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4024, 4036, and 4048 Conveyor Sheaves
IMPORTANT SAFETY INFORMATION
SAFETY
ALERT
SYMBOL
This symbol is used to call your attention to hazards
or unsafe practices which could result in an injury or
property damage. The signal word, dened below,
indicates the severity of the hazard. The message
after the signal word provides information for preventing or avoiding the hazard.
Inspect all anchorings, structural
supports and hook sheaves. Verify
that they will safely withstand up to
twice the cable puller’s maximum
pulling capacity.
Any component that cannot withstand this much force could break
and strike nearby personnel, causing
severe injury or death.
Immediate hazards which, if not avoided, WILL result
in severe injury or death.
Hazards which, if not avoided, COULD result in
severe injury or death.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Read and understand all of the
instructions and safety information
in this manual as well as the manual
supplied with the cable puller before
operating or servicing this tool.
Failure to observe this warning could
result in severe injury or death.
The maximum force the cable puller will exert is twice
its capacity. Assume that twice the cable puller’s
capacity will be exerted on every hook sheave and
structural support.
Failure to observe this warning could result in severe
injury or death.
Consult the cable manufacturer’s specications for
minimum bending radius and other information. Using
sheaves that are too small can damage the cable.
Failure to observe this precaution may result in
property damage.
Note: Keep all decals clean and legible, and replace
when necessary.
Wear eye protection when operating
this tool.
Failure to wear eye protection could
result in serious eye injury from ying
debris.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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Hook Load
R
T
T
T T
R = 0
T T
R = 1.41 x T
T T
R = 2 x T
4024, 4036, and 4048 Conveyor Sheaves
Two variables interact with the sheave to produce a
resultant (total) force, or hook load. This load, represented by R in the formulas and illustrations, is exerted
on the hook, anchoring, and structural support.
R = the resultant force, or hook load; this force is
exerted on the hook, anchoring, and structural
support
θ = the angle of change in rope direction
T = the tension exerted on the rope by the cable
puller
Reference Table
Illustration
θ
180° 0
150° 0.52 x T
135° 0.77 x T
120° 1 x T
90° 1.41 x T
60° 1.73 x T
45° 1.85 x T
30° 1.93 x T
R
Sheave Forces
0° 2 x T
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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Hook Load (cont’d)
0
1
2
180°
120°
0
1
2
150°
0
1
2
90°
0
1
2
135°
0
1
2
0°
0
1
2
Some Hook Loads Illustrated
Hook Load Hook Load = Total Pulling Force
4024, 4036, and 4048 Conveyor Sheaves
A straight rope exerts no load on the hook and
structure.
Hook Load = 1/2 of the Pulling Force Hook Load = 1-1/2 Times the Pulling Force
A rope that makes a 150° angle exerts 1/2 of the
pulling force on the hook and structure.
Hook Load = 3/4 of the Pulling Force Hook Load = 2 Times the Pulling Force
A rope that makes a 120° angle exerts the total
pulling force on the hook and structure.
A rope that makes a 90° angle exerts 1-1/2 times the
pulling force on the hook and structure.
A rope that makes a 135° angle exerts 3/4 of the
pulling force on the hook and structure.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
A rope that makes a 0° angle exerts 2 times the
pulling force on the hook and structure.
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4024, 4036, and 4048 Conveyor Sheaves
R
T
T
Hook Load (cont’d)
Calculating the Hook Load
One Attachment Point
To calculate the hook load exerted at one attachment
point, use the Reference Table and Formula 1.
Sheave with One Attachment Point
Formula 1:
R = 2 x T x SIN [(180 – θ) / 2]
R = the resultant force, or hook load; this force is exerted on the hook, anchoring and structural support
θ = the angle of change in rope direction
T = the tension exerted on the rope by the cable puller
Note: The total load on the support structure = R + the weight of the sheave.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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4024, 4036, and 4048 Conveyor Sheaves
T
R1
R2
T
R1
R2
T
T
Q
A
N
G
L
E
B
A
N
G
L
E
B
A
N
G
L
E
A
A
N
G
L
E
A
1
2
Q
1
2
Q
Q
C
L
C
L
Hook Load (cont’d)
Calculating the Hook Load (cont’d)
Two Attachment Points
To calculate the hook loads exerted at two attachment
points, use the Reference Table and Formulas 1, 2, and 3.
Sheave with Two Attachment Points
Formula 2: Formula 3:
= ________________________ R2 = ________________________
R
1
R R
COS A + SIN A / TAN B COS B + SIN B / TAN A
R1 = resultant force on left hook, anchoring and support structure
R2 = resultant force on right hook, anchoring and support structure
A = angle between the left mounting and the centerline of the two legs of the rope
B = angle between the right mounting and the centerline of the two legs of the rope
R = the resultant force, or hook load; this force is exerted on the hook, anchoring and structural support
θ = the angle of change in rope direction
T = the tension exerted on the rope by the cable puller
Notes: The total load on the left support structure = R1 + the weight of the sheave.
The total load on the right support structure = R2 + the weight of the sheave.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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Crosby Hoist Hook
S-319 S-320 S-320N S-322
ZONE B
ZONE A
ZONE C
60°
45° 45°
2/3
ZONE B
ZONE A
ZONE C
60°
45° 45°
2/3
ZONE D
ZONE A: Repair not required
ZONE B: 10% of original dimension
ZONE C: 5% of original dimension
ZONE D: See minimum thread size chart
Side Load Back Load
Wrong
Tip Load
45° 45°
Right Wrong
4024, 4036, and 4048 Conveyor Sheaves
REPRINTED WITH PERMISSION BY THE CROSBY GROUP
Warnings and Application Instructions
Loads may disengage from hook if proper pro cedures 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, 320, or 322 hook with
a PL Latch attached (when secured with the bolt, nut and
pin) may be used for lifting personnel. A Crosby S-320N
Hook with a S-4320 Latch attached (when secured with
cotter pin or bolt, nut and pin) may be used for lifting
Important Safety Information –
Read and Follow
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 and threads should be periodically inspected by
personnel.
Threads may corrode and/or strip and drop the load.•
Hook must always support the load. The load must never •
be supported by the latch.
Never apply more force than the hook’s assigned Working •
Load Limit (WLL) rating.
Read and understand these instructions before using •
hook.
Magnetic Particle or Dye Penetrant. (Note: Some disassem-
bly may be required.)
Never use a hook whose throat opening has been •
increased, or whose tip has been bent more than 10
degrees out of plane from the hook body, or is in any other
way distorted or bent. Note: A latch will not work properly
on a hook with a bent or worn tip.
Never use a hook that is worn beyond the limits shown in •
Figure 1.
Remove from service any hook with a crack, nick, or gouge. •
Hooks with a crack, nick, or gouge shall be repaired by
grinding lengthwise, following the contour of the hook, pro-
vided that the reduced dimension is within the limits shown
in Figure 1.
Figure 1
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).
Eye hooks, shank hooks and swivel hooks are designed to •
be used with wire rope or chain. Efciency of assembly may
be reduced when used with synthetic material.
Do not swivel the S-322 swivel hook while it is supporting a •
load.
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
Figure 2
in “Understanding: The Crosby Group Warnings” for further
information.)
Always make sure the hook supports the load. (See Figure •
3). The latch must never support the load (see Figure 4).
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).
See ANSI/ASME B30.10 “Hooks” for additional information.•
For angles greater than 90 degrees, or more than two (2) •
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
legs, a master link or bolt type anchor shackle should be
used to attach the legs of the sling to the hook.
Figure 3 Figure 4 Figure 5
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4024, 4036, and 4048 Conveyor Sheaves
Minimum Thread Size
Maximum Shank Diameter
REPRINTED WITH PERMISSION BY THE CROSBY GROUP
Read and Understand These Instructions Before Using Hooks
Important — Basic Machining and Thread Information –
Read and Follow
Wrong thread and/or shank size can cause stripping and •
loss of load.
The maximum diameter is the largest diameter, after •
cleanup, that could be expected after allowing for straightness, pits, etc.
All threads must be Class 2 or better.•
The minimum thread length engaged in the nut should not •
be less than one (1) thread diameter.
Hook shanks are not intended to be swaged on wire rope or •
rod.
Hook shanks are not intended to be drilled and internally •
threaded.
Crosby cannot assume responsibility for: (A) the quality of •
machining, (B) the type of application, or (C) the means of
attachment to the power source or load.
Consult the Crosby Hook Identication & Working Load •
Limit Chart (see below) for the minimum thread size for
assigned Working
Load Limits
(WLL).†
Remove from •
service any Hook
which has threads
corroded more
than 20% of the
nut engaged
length.
Crosby Hook Identification & Working Load Limit Chart†
Hook Identification Working Load Limit (tons)
319-C
319-CN
320-C
320-CN
322-C
DC DA DB 0.75 1 0.5 0.53 1/2-13 unc 1/2-13 unc
FC FA FB 1 1.5 0.6 0.62 5/8-11 unc 5/8-11 unc
GC GA GB 1.5 2 1 0.66 5/8-11 unc 5/8-11 unc
HC HA HB 2 3 1.4 0.81 3/4-10 unc 3/4-10 unc
IC IA IB 3 *4.5/5 2.0 1.03 7/8-9 unc 7/8-9 unc
JC JA JB 5 7 3.5 1.27 1-1/8-7 unc 1-1/8-7 unc
KC KA KB 7.5 11 5.0 1.52 1-1/4-7 unc 1-3/8-6 unc
LC LA LB 10 15 6.5 1.75 1-5/8-8 un 1-5/8-8 un
NC NA NB 15 22 10 2.00 2-8 un 2-8 un
OC OA — 20 30 — 2.50 2-1/4-8 un 2-1/4-8 un
PC PA — 25 37 — 3.50 2-3/4-8 un 2-3/4-8 un
SC SA — 30 45 — 3.50 3-8 un 3-8 un
TC TA — 40 60 — 4.00 3-1/4-8 un 3-1/2-8 un
UC UA — 50 75 — 4.50 3-3/4-8 un 4-4 un
— WA — — 100 — 6.12 — 4-1/2-8 un
— XA — — 150 — 6.38 — 5-1/2-8 un
— YA — — 200 — 7.00 — 6-1/4-8 un
— ZA — — 300 — 8.62 — 7-1/2-8 un
* 319AN and 320-AN are rated at 5 tons.
† 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 team is used interchangeably with the following terms:
1. WLL 2. Rated Load Value 3. SWL 4. Safe Working Load 5. Resultant Safe Working Load.
319-A
319-AN
320-A
320-AN
322-A
319BN
319-C
319-CN
320-C
320-CN
322-C
319-A
319-AN
320-A
320-AN
322-A
319BN
Maximum
Shank
Diameter
after
Machining
(in)
Minimum Thread Size
319-C
319-CN
(carbon)
319-A
319-AN
(alloy)
319-BN
(bronze)
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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Hook Latch Kit
CAUTION
SEE INSTRUCTIONS
HOOK MUST SUPPORT LOAD
SS-4055
Right Wrong Right Wrong
4024, 4036, and 4048 Conveyor Sheaves
REPRINTED WITH PERMISSION BY THE CROSBY GROUP
Warnings and Application Instructions
Important Safety Information –
Read and Follow
Always inspect hook and latch before using.•
Never use a latch that is distorted or bent.•
Always make sure spring will force the latch against the tip •
of the hook.
Always make sure hook supports the load. The latch must •
never support the load. (See Figures 1 and 2.)
When placing two (2) sling legs in hook, make sure the angle •
between legs is small enough and the legs are not tilted so
that nothing bears against the bottom of the latch.
(See Figures 3 and 4.)
Latches are intended to retain loose sling or devices under •
slack conditions.
Latches are not intended to be an anti-fouling device.•
Lo• ads may disengage from hook if proper pro cedures are
not followed.
A falling load may cause serious injury or death.•
See OSHA Rule 1926.550(g)(4)(iv)(B). A hook •
and this style latch must not be used for lifting personnel.
Hook must always support the load. The load must never •
be supported by the latch.
Read and understand these instructions before using •
hook.
Figure 1 Figure 2 Figure 3 Figure 4
IMPORTANT — Instructions for Assembling SS-4055 Latch on Crosby Hooks
Step 1 Step 2 Step 3 Steps 4, 5, and 6
Place hook at approximately
a 45-degree angle with the
cam up.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Position coils of spring over
cam with tines of spring
pointing toward point of hook
and loop of spring positioned
down and lying against the
hook.
Position latch over tines of
spring with ears partially over
hook cam. Swing latch to
one side of hook, point and
depress latch and spring until
latch clears point of hook.
10
4. Line up holes in latch with
hook cam.
5. Insert bolt through latch,
spring, and cam.
6. Tighten self-locking nut on
one end of bolt.
Page 11
Illustration and Parts List
5
6
12
11
3
8
4
10 9
1
7
Maximum Pulling Force:
17.8 kN (4000 lb)
4024, 4036, and 4048 Conveyor Sheaves
4024
Key Part No. Description Qty
1 52043005 Yoke frame ................ 2
2 90541847 Latch unit,
small hook ................. 1
3 50153625 Sheave (includes
qty. 2 of item 4) ......... 4
4 50167987 Bearing ...................... 8
5 52055248 Sheave pin ................ 2
6 90503023 Hitch pin clip, #8 ....... 8
7 52042996 Frame, 24" ................ 2
8 50315730 Shaft.......................... 6
9 90514343 Washer .................... 12
10 90530918 Hex screw, 3/8"....... 12
11 90515285 Retaining ring ............ 2
12 52045548 Support edge ............ 2
Specifications
Outside width 19.7 7.75 19.7 7.75 19.7 7.75
Total height (to hook) 64.7 25.48 61.8 24.33 75.1 29.56
Inside width 15.3 6.03 15.3 6.03 15.3 6.03
Cable clearance to sheave outside diameter 22.0 8.67 22.0 8.67 22.0 8.67
Cable clearance to bottom of groove 19.5 7.67 19.5 7.67 19.5 7.67
Sheave inside width 11.4 4.50 11.4 4.50 11.4 4.50
Sheave groove diameter 7.6 3.00 7.6 3.00 7.6 3.00
Sheave outside diameter 15.2 6.00 15.2 6.00 15.2 6.00
Sheave groove depth 3.8 1.50 3.8 1.50 3.8 1.50
Mass/weight 20 kg (50 lb) 30 kg (60 lb) 40 kg (90 lb)
4036
Key Part No. Description Qty
1 52043005 Yoke frame ................ 2
2 90541847 Latch unit,
small hook ................. 1
3 50153625 Sheave (includes
qty. 2 of item 4) ......... 6
4 50167987 Bearing .................... 12
5 52055248 Sheave pin ................ 6
6 90503023 Hitch pin clip, #8 ..... 12
7 52042997 Frame, 36" ................ 2
8 50315730 Shaft.......................... 8
9 90514343 Washer .................... 16
10 90530918 Hex screw, 3/8"....... 16
11 90515285 Retaining ring ............ 2
4024 4036 4048
cm in cm in cm in
4048
Key Part No. Description Qty
1 Yoke frame ................ 2
2 90541847 Latch unit,
small hook ................. 1
3 50153625 Sheave (includes
qty. 2 of item 4) ......... 8
4 50167987 Bearing .................... 16
5 Sheave pin (includes
qty. 2 of item 6) ......... 8
6 90503023 Hitch pin clip, #8 ..... 16
7 52042998 Frame, 48" ................ 2
8 50315730 Shaft........................ 10
9 90514343 Washer .................... 20
10 90530918 Hex screw, 3/8"....... 20
11 90515285 Retaining ring ............ 2
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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USA 800-435-0786 Fax: 800-451-2632
815-397-7070 Fax: 815-397-1865
Canada 800-435-0786 Fax: 800-524-2853
International +1-815-397-7070 Fax: +1-815-397-9247
4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070
An ISO 9001 Company • Greenlee Textron Inc. is a subsidiary of Textron Inc.
www.greenlee.com
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