
nTrolley Installation Over the Open End of the Beam
Pre-adjust trolley for installation using Dwg. MHP1537 on page 13 and steps 1
through 7 from the instructions in the 'Adjustments' section on page 4.
1. Support the assembled hoist under the beam.
2. Remove capscrews (317), lockwashers (318) and caps (319) from suspension
shafts (329) on one side plate (301).
3. Carefully separate side plates until trolley wheels clear beam flange.
4. Lift hoist assembly into place on the beam and slide side plates back together.
5. Install removed caps (319), lockwashers (318) and capscrews (317) on suspension
shafts (329). Apply a small amount Loctite®243 to suspension shaft (329)
threads. Refer to “TORQUE CHART” in Product Maintenance Information manual
for torque requirements.
6. Verify trolley wheel to beam total clearance.
7. Install trolley motor and reduction assembly.
nAll Capacities
Upon completion of installation, ensure beam stops are installed and conduct initial
operating checks as described in “OPERATION” section on page 6. Check that side
plates are vertical and parallel to each other and that side plates are perpendicular
to beam.
WARNING
•At least one mounting spacer must be used between the head of each trolley
bracket bolt and the trolley bracket and between each trolley bolt nut and
the trolley bracket. Failure to do this could cause the hoist to fall when used
improperly.
Ensure trolley bolts or nuts are torqued in accordance with manufacturer’s
specifications. For installation of hoist on beam, make certain the side plates are
parallel and vertical.
After installation ensure beam stops are in place, operate hoist over entire length of
beam with a capacity load suspended 4 to 6 inches (10 to 15 cms) off the floor.
NOTICE
• Trolley wheels ride on the top of the lower flange of the beam.
nInitial Operating Checks
1. After installation, ensure the hook is centered below the beam.
2. Check for air leaks in supply hose and fittings to pendant and hoist motors.
3. Raise a load equal to the rated capacities of the hoist 3 to 4 inches (75 to 100
mm) off the floor.
4. Operate the hoist along the entire length of the beam.
5. Check hoist performance when moving test load(s). Hoist must operate smoothly
at rated specifications prior to being placed in service for general use.
6. Check that hoist movement complies with the pendant arrows.
nTrolley Rack Drive (optional)
Install the trolley rack drive onto the support beam. Installation should only be done
by authorized service personnel.
nPre-Installation Checks
Refer to Dwg. MHP2990 on page 12, A. Rack; B. Pinion; C. Maintain clearance
between rack and pinion teeth of 0.16 inch (minimum) to 0.20 inch (maximum) [4
to 5 mm] to prevent pinion binding during operation. Measure gap between the
outside diameter of drive pinion and root of rack segment.
Before welding the rack segments onto the trolley beam, install the rack segments
on the bottom of the beam lower flange and clamp in place. Mount the trolley on the
lower beam flange. Measure the gap between the outside diameter of the drive pinion
and root of rack segment teeth. As shown in Dwg. MHP2990, the trolley drive pinion
and rack teeth must have a 0.16 to 0.20 inch (4 to 5 mm) clearance.
nTo Adjust Clearance
Refer to Dwg. MHP2991 on page 12, A. Mounting Capscrew; B. Jam Nut; C.
Adjustment Screw.
There is an adjustment screw located below the reducer adapter.
1. Loosen capscrews attaching trolley drive to sideplate.
2. Loosen jam nut and rotate adjustment screw to achieve clearance as shown in
Dwg. MHP2990 on page 12.
3. Tighten jam nut and mounting screws.
If a larger adjustment is required:
1. Add shims between the rack segment and beam to decrease distance.
2. Remove material from rack segment to increase distance.
nInstalling Rack Segments Onto Beam
Refer to Dwg. MHP1178 on page 12, A. Hoist Trolley Drive Assembly mounted this
side; B. Lower Beam Flange; C. Rack Segment; D. Fillet Weld: Allow 1/4 inch (6.5 mm)
clearance between edge of lower flange and rack segment. Apply weld to both sides
of rack segment. Refer to Dwg. MHP3016 on page 12, A. Stagger welds along rack;
B. (Not to scale); C . Check clearance between racks; D. Use the rack guide for correct
track positioning.
Rack segments should be installed on the outside edge of the lower flange of the
trolley beam. Allow 1/4 inch (6.5 mm) clearance between the edge of the lower flange
and rack segment for fillet weld. The rack segments should be clamped tight against
the lower flange so that there is no sagging. Sagging of the rack could cause the drive
pinion to bind as it traverses along the runway beam.
Racks are provided in segments. These segments should be tack welded (refer to
Dwg. MHP3016 on page 12) in place and the trolley traversed the entire length.
During this movement observe for any high or low spots and correct. Also check each
segment connection for drive tooth contact and correct as necessary. When all
clearances are achieved, weld both sides of the rack to the beam flange to prevent
corrosion between the rack segment and beam.
nAir Supply
The air supply must be clean, free from moisture and lubricated to ensure optimum
motor performance. Foreign particles, moisture and lack of lubrication are the primary
causes of premature motor wear and breakdown. Using an air filter, lubricator and
moisture separator will improve overall hoist performance and reduce unscheduled
downtime.
Refer to Table 2 ‘Specifications’ on page 4. If air supply varies from what is
recommended, hoist performance will change. The compressed air temperature must
not exceed 149°F (65°C) at the motor air inlet. Contact the factory for higher
temperature use.
Refer to Dwg. MHP0191 on page 11, A. Air Out; B. Lubricator; C. Regulator; D. Air
In; E. Filter.
nAir Lines
Inside diameter of the hoist air supply lines must not be less than size specified in
Table 2 ‘Specifications’ on page 4. Before making final connections, all air supply
lines should be purged with clean, moisture free air or nitrogen before connecting to
hoist inlet. Supply lines should be as short and straight as installation conditions will
permit. Long transmission lines and excessive use of fittings, elbows, tees, globe
valves etc. cause a reduction in pressure due to restrictions and surface friction in
the lines.
nAir Line Lubricator
The air motor may be operated without lubrication. If an air line lubricator is used,
it should be replenished daily, refer to “LUBRICATION” section on page 8. The
lubricator must have an inlet and outlet at least as large as the inlet on the motor.
Install the lubricator as close to the air inlet on the motor as possible.
CAUTION
• Lubricator must be located no more than 10 ft (3 m) from the motor.
•Shut off air supply before filling air line lubricator.
nAir Line Filter
Place the strainer/filter as close as practical to the motor air inlet port, but upstream
from, the lubricator, to prevent dirt from entering the motor. The strainer/filter
should provide 20 micron filtration and include a moisture trap. Clean the strainer/
filter periodically to maintain its operating efficiency.
nMoisture in Air Lines
Moisture that reaches the air motor through air supply lines is a primary factor in
determining the length of time between service overhauls. Moisture traps can help
to eliminate moisture. Other methods, such as an air receiver which collects moisture
before it reaches the motor, or an aftercooler at the compressor that cools the air to
condense and collect moisture prior to distribution through the supply lines are also
helpful.
nMotor
For optimum performance and maximum durability of parts, operate the air motor
within the operating specifications provided. Refer to the “SPECIFICATIONS” section
on page 2. The air motor should be installed as near as possible to the compressor or
air receiver. Refer to Dwg. MHP3161 on page 10 for motor port connections.
nEmergency Stop and Overload Device (optional feature)
Overload protection is integrated into the motor body and is standard on -E versions.
The overload system is based on detection of the difference in air pressure between
the inlet and outlet ports. It consists of a valve which is normally closed. The valve
senses pressure at the motor inlet and outlet and compares the difference between
the two pressures to the index value established by spring adjustment. A difference
in pressure greater than the index value causes the emergency stop to be activated.
This then exhausts the air and hoist operation stops.
Air supply line is connected to air control valve. When emergency stop or overload
valve is activated, all hoist movement will stop.
Overload protection is adjusted at the factory to 120% of the safe working load (SWL).
It is also able to operate on both sides for mining versions with two bottom hooks.
Refer to the “MAINTENANCE” section in Product Maintenance Information Manual for
adjustment procedures.
Refer to Dwg. MHP1547 on page 11, A. Pendant Handle; B. Emergency Stop Button;
C. “ON” Button; D. Hoist Control Levers; E. Trolley Control Levers.
nStart-Up Procedures
For hoists that have been in storage the following start-up procedures are required.
Form MHD56469 Edition 1 5