Ingersoll-Rand 3 CP 1500 User manual

Form MHD56039
OPERATION AND MAINTENANCE MANUAL
for
PALAIR AIR CHAIN HOISTS
MODEL 3 CP 1500 MODEL 6 CP 3000
(1.5 metric tons) (3 metric tons)
MODEL 3 CP 3000 MODEL 6 CP 6000
(3 metric tons) (6 metric tons)
MODEL 12 CP 6000
(6 metric tons)
MODEL 12 CP 12000
(12 metric tons)
(1 metricton = 2200 Ibs)
READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual
contains important safety, installation, operation and maintenance informa-
tion. Make this manual available to all persons responsible for the opera-
tion, installation and maintenance of these products.
Do not use this hoist for lifting, supporting, or transporting people or lifting or supporting
loads over people.
Always operate, inspect and maintain this Hoist in accordance with American National
Standards Institute Safety Code (ASME B30.16) and any other applicable safety codes and
regulations.
Refer all communications to the nearest Ingersoll-Rand Material Handling Office or
Distributor.
Form MHD56039
Edition 2
January 1993
71067888
© 1993 Ingersoll-Rand Company MATERIAL HANDLING

DESCRIPTION PAGE
Safety Information
Danger, Caution, Warning and Notice ................................................................................................................... 3
Safe Operating Instructions ................................................................................................................................... 4
Warning Labels ..................................................................................................................................................... 5
Description
Specifications ........................................................................................................................................................ 5
Installation
Mounting .............................................................................................................................................................. 6
Air Supply ............................................................................................................................................................. 6
Motor .................................................................................................................................................................... 6
Initial Operating Checks.. ...................................................................................................................................... 7
Operation
Description of Operation .............................................................
.......................................................................... 7
Troubleshooting
Troubleshooting Chart ........................................................................................................................................... 8
Inspection
Records and Reports ............................................................................................................................................. 9
Frequent Inspection ............................................................................................................................................... 9
Periodic Inspection .............................................................................................................................................. 10
Hoists not in Regular Use.. .................................................................................................................................. 10
Lubrication
Load Chain ......................................................................................................................................................... 11
Motor .................................................................................................................................................................. 11
Gear Case.. .......................................................................................................................................................... 11
Hook and Hook Latch ......................................................................................................................................... 11
Maintenance
Maintenance Intervals ......................................................................................................................................... 12
Chain Replacement ............................................................................................................................................. 12
General Disassembly ........................................................................................................................................... 12
Brake Disassembly .............................................................................................................................................. 12
Cleaning, Inspection and Repair.. ........................................................................................................................ 13
Hoist Assembly ................................................................................................................................................... 13
Hoist Storage ...................................................................................................................................................... 13
Parts Information
Hoist Assembly Drawing.. ................................................................................................................................... 14
Hoist Assembly Parts List ................................................................................................................................... 15
Return Goods Policy ........................................................................................................................................... 17
Warranty ............................................................................................................................................................. 19
2

This manual provides important information for all
personnel involved with the safe installation, operation and
proper maintenance of this product. Even if you feel you
are familiar with this or similar equipment, you must read
and understand this manual before operating the product.
Danger, Warning, Caution and Notice
Throughout this manual there are steps and procedures
which, if not followed, may result in a hazard. The
following signal words are used to identify the level of
potential hazard.
Danger is used to indicate the
presence of a hazard which will
cause severe personal injury, death,
or substantial property damage if the
warning is ignored.
Warning is used to indicate the
presence of a hazard which can
cause severe personal injury, death,
or substantial property damage if the
warning is ignored.
Caution is used to indicate the
presence of a hazard which will or
can cause minor personal injury or
property damage if the warning is
ignored.
Notice is used to notify people of
installation, operation, or mainte-
nance information which is impor-
tant but not hazard-related.
Safety Summary
l Do not use this hoist or attached equipment for
lifting, supporting, or transporting people or lifting or
supporting loads over people.
l The supporting structures and load-attaching devices
used in conjunction with this hoist must provide an
adequate safety factor to handle the rated load, plus the
weight of the hoist and attached equipment. This is the
customer’s responsibility. If in doubt, consult a quali-
fied structural engineer.
The National Safety Council, Accident Prevention Manual
for Industrial Operations, Eighth Edition and other recog-
nized safety sources make a common point: Employees
who work near cranes or assist in hooking on or arranging
a load should be instructed to keep out from under the
load. From a safety standpoint, one factor is paramount:
conduct all lifting or pulling operations in such a manner
that if there were an equipment failure, no personnel would
be injured. This means keep out from under a raised load
and keep out of the line of force of any load.
To the best of our knowledge, INGERSOLL-RAND
Material Handling hoists are manufactured in accordance
with the latest standards in effect at time of manufacture.
However, contrary to common belief, the Occupational
Safety and Health Act of 1970, as we understand it,
generally places the burden of compliance with the user,
not the manufacturer. Many OSHA requirements are not
concerned or connected with the manufactured product but
are, rather, connected with the final installation: “It is the
owner’s responsibility and user’s responsibility to deter-
mine the suitability of a product for any particular use.
Check all applicable industry, trade association, federal,
state and local regulations. Read all operating instructions
and warnings before operation”.
Rigging: It is the responsibility of the operator to exercise
caution, use common sense and be familiar with proper
rigging techniques. See ANSI/ASME B30.9 for rigging
information, American National Standards Institute, 1430
Broadway, New York, NY 10018.
l Using other than genuine INGERSOLL-RAND
Material Handling parts will result in the void of
warranty.

The following warnings and operating instructions have
been adapted in part from American National (Safety)
Standard ANSI B30.16 and are intended to avoid unsafe
operating practices which might lead to personal injury or
property damage.
These recommendations apply to hoists used for material
handling of freely suspended unguided loads.
INGERSOLL-RAND recognizes that most companies who
use hoists have a safety program in force in their plants. In
the event that some conflict exists between a rule set forth
in this publication and a similar rule already set by an
individual company, the more stringent of the two should
take precedence.
Safe Operating Instructions are provided to make an
operator aware of dangerous practices to avoid and are not
necessarily limited to the following list. Refer to specific
sections in the manual for additional safety information.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Only allow qualified people (trained in safety and
operation) to operate the hoist.
Only operate a hoist if you are physically fit to do so.
Only allow qualified people (trained in safety, mainte-
nance and troubleshooting) to perform service on
hoists.
When a “DO NOT OPERATE” sign is placed on the
hoist controls, do not operate the hoist until the sign
has been removed by designated personnel.
Never use a hoist which inspection indicates is
defective.
Do not use hoist if hook latch on a hook has been
sprung or broken.
22. Never use the hoist for lifting or lowering people, and
never allow anyone to stand on a suspended load.
23. Ease the slack out of the chain and sling when starting
a lift. Do not jerk the load.
24. Do not swing a suspended load.
25. Never suspend a load for an extended period of time.
26. Never leave a suspended load unattended.
27. Never weld or cut a load suspended by the hoist.
28. Never use the hoist chain as a welding electrode.
29. Do not operate hoist if chain jumping, excessive noise,
jamming, overloading, or binding occurs.
30. Keep the load from hitting the load chain.
31. Do not use the up and down emergency stop limit
protection as a normal means of stopping the hoist.
32. Avoid unnecessary jogging of hoist and/or trolley
controls.
Check that the hook latches are engaged before using. 33. Always rig the hoist properly and carefully.
Never splice a hoist chain by inserting a bolt between 34. Shut off air supply before performing any mainte-
links. nance.
Only lift loads less than or equal to the rated capacity 35. Avoid collision or bumping of hoist.
of the hoist. See warning labels attached to the hoist. 36. After use, properly secure hoist and all loads.
11. Never place your hand inside the throat area of a hook.
12. Never use the hoist chain as a sling.
13. Only operate a hoist when the load chain is centered
over the hook. Do not “side pull” or “yard’.
14. Never operate a hoist with twisted, kinked, “capsized”
or damaged load chain.
15. Do not force a chain or hook into place by hammering.
16. Never insert the point of the hook into a chain link.
17. Be certain the load is properly seated in the saddle of
the hook.
18. Do not support the load on the tip of the hook.
19. Never run the load chain over a sharp edge. Use a
sheave.
20. Pay attention to the load at all times when operating
the hoist.
21. Make sure all people are clear of the load path. Do
not lift a load over people.
10. When using two hoists to suspend one load, select two
hoists each having a rated capacity equal to or more
than the load. This provides adequate safety in the
event of a sudden load shift or failure of one hoist.
4

Each hoist is supplied from the factory with the safety
label shown. If the label is not attached to your unit, order
a new label and install it. See the parts list for the part
number. Read and obey all warnings and other safety
information attached to this hoist. Label may not be shown
actual size.
General
The Palair hoist is an air powered hoist designed to lift and
lower loads. The Palair hoist hook mounts to the suspen-
sion shaft of a trolley or a permanent mounting structure.
The air supply line can be strung to the hoist using either
cable hangers or cable trolleys.
Specifications
Pressure: 90 psi (6.2 bar)
Model Air Flow
No. (cu ft/min) (cu m/min)
3 CP 1500 78 2.2
3 CP 3000 78 2.2
6 CP 3000 120 3.4
6 CP 6000 120 3.4
12 CP 6000 120 3.4
12 CP 12000 120 3.4
Model Capacity
No. (metric tons)
3 CP 1500 1.5
3 CP 3000 3
6CP3000 3
6CP6000 6
12CP6000 6
12 CP 12000 12
Max Lifting Speed
With Rated Load
(ft/min) (m/min)
13 4.0
6 1.8
10 3.0
5 1.5
5 1.5
2.5 0.8
Model
No.
Unit Net Wt. Wt. of Chain
without chain (per ft) (per meter)
(lb) (kg) (lb) (kg)
3 CP 1500 84 38 3.3 1.5
3 CP 3000 84 38 3.3 1.5
6 CP 3000 130 59 8.5 3.85
6 CP 6000 130 59 8.5 3.85
12 CP 6000 213 97 12.6 5.75
12 CP 12000 213 97 12.6 5.75
(1 metric ton = 2200 lbs)

Prior to installing the hoist, carefully inspect it for possible
shipping damage.
Hoists are supplied fully lubricated from the factory.
l Owners and users are advised to examine specific,
local or other regulations, including American
National Standards Institute and/or OSHA Regulations
which may apply to a particular type of use of this
product before installing or putting hoist to use.
l A falling load can cause injury or death. Before
installing, read “SAFETY INFORMATION”.
Hook Mounted Hoist Installation
Place hook over mounting structure. Make sure hook latch
is engaged.
Trolley Mounted Hoist Installation
Preadjust trolley width for the beam flange measurement.
Remove the rail stop and slide trolley onto the end of the
beam. If trolley cannot be installed onto the end of the
beam due to insufficient space or fixed limit stops, the
trolley may need to be partially disassembled and installed
from underneath the beam.
l To avoid an unbalanced load which may damage the
trolley, the hoist must be centered under the trolley.
l Trolley wheels ride on the top of the lower flange of
the beam.
When a trolley is used, check that the trolley side plates
are parallel and vertical. Raise a load equal to the rated
capacity of the hoist a few inches off the floor and operate
the trolley along the entire length of the beam.
Air Supply
The air supply must be clean and free from moisture.
Air Lines
The inside diameter of the hoist air supply lines must not
be smaller than l/2 in. (13 mm) and 3/8 in. (10 mm) for
fittings on hoist models 3 CP 1500 and 3 CP 3000 or
3/4 in. (19 mm) and 5/8 in. (16 mm) for fittings on all
other size hoists. Before making final connections, all air
supply lines should be purged before connecting to system
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.
Air Line Lubricator
The air lubricator is built into the air motor. The lubricator
has a capacity of 0.44 pints (0.21 Its). When correctly
adjusted no oil mist should be visible from the air exhaust.
The air line lubricator should be replenished daily with
SAE 30W oil (minimum viscosity 135 Cst at 104” F
(40°C)).
l Shut off air supply before filling air line lubricator.
Air Line Filter
When a hoist is to be used in corrosive or moist atmos-
pheres it is recommended that an air line strainer/filter be
installed within 3 feet (1 meter) of the motor to prevent dirt
from entering the motor. The strainer/filter should provide
20 micron filtration and include a moisture trap. Clean
strainer/filter periodically to maintain its operating effi-
ciency.
Moisture in Air Lines
Moisture that reaches the air motor through the supply
lines is the chief factor in determining the length of time
between service overhauls. Moisture traps can help to
eliminate moisture and other methods, such as an air
reciever which collects moisture before it reaches the
motor or an aftercooler at the compressor that cools the air
prior to distribution through the supply lines, are also
helpful.
Motor
For optimum performance and maximum durability of
parts, operate air motor within the operating specifications
provided in the “SPECIFICATIONS” section. The air
motor should be installed as near as possible to the com-
pressor or air receiver.
Chain Container
l Do not pile chain carelessly in the chain container.
Piling the chain carelessly into the container by hand
may lead to kinking or twisting that will jam the hoist.
To attach the chain container: run lower block to lowest
point, attach chain container to hoist and run hoist in up
direction to feed the chain back into the container.
1. Check the chain bucket label to make sure the length
6

of load chain is within the capacity of the chain
bucket. Replace with a larger chain bucket, if re-
quired.
2. Attach stopper to the third link from the end of the
chain.
3. Attach the chain bucket to the hoist.
l When putting chain into the chain container by hand
begin with the stopper end of the chain so that it piles
naturally.
Attaching Free End of Load Chain
If chain bucket is not used:
1. Install stopper on the end of the load chain.
2. Attach stopper to the ninth link from the end of the
load chain.
3. Attach the free end of the load chain to the hoist.
Hoist Pendant
Check all hose connections are tight and that hoses are not
twisted or crimped.
l Disconnect air supply before performing any mainte-
nance.
l To avoid damaging the pendant hose, make sure the
strain relief cable, not the pendant hose, is supporting
the weight of the pendant.
Initial Operating Checks
1. After installation, make sure the chain is not twisted or
kinked. Fix before using. On the Palair, for a capsized
bottom hook, pass the hook between the two chain
falls until the chain is untwisted.
2. If a trolley is used, check that the hoist is centered
below the trolley. Raise a load equal to the rated
capacity of the hoist a few inches off the floor and
operate the trolley along the entire length of the beam.
3. Run hoist slowly in both directions with no load with a
good supply of lubricating oil.
Storing the Hoist
1. Always store the hoist in a no load condition.
2. Wipe off all dirt and water.
3. Oil the chain, hook pins and hook latch.
4. Place in a dry location.
5. Plug hoist air inlet port.
6. Before returning hoist to service follow instructions
for Hoists not in Regular Service in the “INSPEC-
TION” section
The four most important aspects of hoist operation are:
1. Follow all safety instructions when operating hoist.
2. Allow only qualified people to operate a hoist.
3. Subject each hoist to a regular inspection and mainte-
nance.
4. Be aware of the hoist capacity and weight of load at
all times.
Hoist Movement
Lifting and lowering a load is controlled by the pendant
push buttons.

This section provides the information necessary for troubleshooting this winch. The troubleshooting guide provides a general
outline of problems which could be experienced with normal use of this winch. It lists the trouble, the possible cause, and the
possible solution for the trouble being experienced.
SYMPTOM TROUBLE REMEDY
Hoistwill not No air supply to hoist. Check power supply and connections, in power supply line.
operate. Hoist is overloaded. . Reduce load to within rated capacity.
Motor is damaged. Repair or replace. See “MAINTENANCE” section.
Brake is not releasing. Remove end cover and inspect brake. Check brake release
circuit.
Load continues to Brake is slipping. Check brake spring and brake disc lining. See “MAINTE-
nove when hoist is NANCE” section.
stopped. Hoist is overloaded. Reduce load to within rated capacity.
Hoist will not lift Hoist is overloaded. Reduce load to within rated capacity.
rated capacity. Motor is damaged. Check for worn motor bearings.
Brake is not releasing. Remove end cover and inspect brake. Check brake release
circuit.
Kook lowers, but Hoist is overloaded. Reduce load to within rated capacity.
will not raise. Low air pressure. Check at hoist power supply connection with hoist under
load. Raise pressure to rated capacity.
Load chain jumps Worn or rusted chain. See “INSPECTION” to determine wear limit. Replace if
on sheave or is necessary.
making a snapping
sound. Incorrect chain. Replace with correct chain.
Worn sheave or chain guide. Replace worn parts.
No oil on load chain. Lubricate load chain.
Trolley
Trolley won’t stop or Damaged beam. Repair or replace beam.
trolley wheels slip. Too much oil or grease on track of Clean off oil or grease.
beam.
8

There are two types of inspection, the frequent inspection
performed by the operator and periodic inspections
performed by qualified personnel.
Careful inspection on a regular basis will reveal potentially
dangerous conditions while still in the early stages,
allowing corrective action to be taken before the condition
becomes dangerous.
Any deficiency revealed through inspection must be
reported to an appointed person. A determination must be
made as to whether a deficiency constitutes a safety hazard
before resuming operation of the hoist.
Records and Reports
Some form of inspection record should be maintained for
each hoist, listing all points requiring periodic inspection.
A written report should be made monthly on the condition
of the critical parts of each hoist. These reports should be
dated, signed by the person who performed the inspection,
and kept on file where they are readily available to
authorized personnel.
Frequent Inspection
On hoists in continuous service, frequent inspection should
be made at the beginning of each shift. In addition, visual
inspections should be conducted during regular service for
any damage or evidence of malfunction.
1. OPERATION. Check for visual signs or abnormal
noises (grinding etc.) which could indicate a defect.
Make sure all controls function properly and return to
neutral when released. Check chain feed through the
hoist and bottom block. If chain binds, jumps, is
excessively noisy or “clicks”, clean and lubricate the
chain. If problem persists, replace the chain. Do not
operate the hoist until all defects have been corrected.
2. UPPER AND LOWER LIMIT DEVICE. Test
operation with no load. Upward travel must stop when
the bottom block or stopper on chain hits hoist
directly.
3. HOOKS. Check for wear or damage, increased throat
width, bent shank or twisting of hook. Replace hooks
with 15% increase in throat width (see Dwg.
MHTPAO040) or 10” twist (see Dwg. MHTPAOlll).
If the hook latch snaps past the tip of the hook, the
hook is sprung and must be replaced. Refer to the
(Dwg. MHTPA0040)
WIDTH
Model Throat Width Discard Width
in.
3 CP 1500 1.18
3CP3000 1.18
6CP3000 1.18
6CP6000 1.61
12CP6000 1.61
12CP12000 2.24
TWISTED NORMAL
DO NOT USE CAN BE USED
30 in.
1.36 34.5
30 1.36 34.5
30 1.36 34.5
40 1.81 46.0
40 1.81 46.0
57 2.28 65.5
(Dwg. MHTPAOlll)
latest edition of ASME/ANSI B30.10 “HOOKS” for
additional information.
4. HOOK LATCH. Make sure the hook latch is present
and operating. Replace if necessary.
5. CHAIN. Examine each of the links for bending, cracks
in weld areas or shoulders, traverse nicks and gouges,
weld splatter, corrosion pits, straition (minute parallel
lines) and chain wear, including bearing surfaces
between chain links. Replace a chain that fails any of
the inspections. Check chain lubrication and lubricate
if necessary. See “Load Chain” under “LUBRICA-
TION”.
WEAR IN
THESE AREAS
(Dwg. MHTPA0102)
9

l Excessive wear or stretching may not be apparent
from visual observation. Also, inspect chain by measur-
ing five links in accordance with instructions under
“Periodic Inspection”. A worn load chain may cause the
load sheave to wear rapidly. Inspect the load sheave
and replace if damaged or worn.
6. CHAIN REEVING. Ensure welds on standing links
are away from load sheave. Reinstall chain if neces-
sary. Make sure chain is not capsized, twisted or
kinked. Adjust as required.
Periodic Inspection
According to ANSI/ASME B30.16, frequency of periodic
inspection depends on the severity of usage: NORMAL,
yearly; HEAVY, semiannually; SEVERE, quarterly.
Disassembly may be required for HEAVY or SEVERE
usage. Keep accumulative written records of periodic
inspections to provide a basis for continuing evaluation.
Inspect all the items in “Frequent Inspection”. Also inspect
the following:
1.
2.
3.
4.
5.
FASTENERS. Check rivets, split pins, capscrews and
nuts on hook, chain bucket and hoist body. Replace if
missing or tighten if loose.
ALL COMFQNENTS. Inspect for wear, damage,
distortion, deformation and cleanliness. If external
evidence indicates the need, disassemble. Check
gears, shafts, bearings, sheaves, chain guides, springs
and covers. Replace worn or damaged parts. Clean,
lubricate and reassemble.
HOOKS. Inspect hooks carefully for cracks using
magnetic particle or other suitable non-destructive
method. Inspect hook retaining parts. Tighten or
repair, if necessary.
CHAIN SHEAVES. Check for damage or excessive
wear. Replace if necessary.
MOTOR. If performance is poor, disassemble the
motor and check for worn gearing, bearings and
shafts. The parts should be cleaned, lubricated and
reassembled. Replace worn or damaged parts.
l A falling load can cause injury or death. To keep the
brake from slipping, do not get lubricant on the brake
lining.
6. BRAKE. Raise a load equal to the rated capacity of
the hoist a few inches off the floor and check ability
of hoist to hold the load without excessive drift. If
excessive drift occurs, disassemble. Check brake disc
lining thickness per “Hoist Brake Lining Measure-
ment” under “MAINTENANCE”.
7. SUPPORTING STRUCTURE. Check for distortion,
wear and continued ability to support load.
8.
9.
10.
11.
TROLLEY. Check that the trolley wheels track the
beam properly and clearance between wheels and
beam is correct, 3/32 to 5/32 in. (2 to 4 mm). Check
side plates for spreading due to bending.
LABELS. Check for presence and legibility. Replace
if necessary.
LOAD CHAIN END ANCHORS. Ensure both ends of
load chain are securely attached. Secure if loose,
repair if damaged, replace if missing.
LOAD CHAIN. Measure the chain for stretching by
measuring across five link sections all along the chain
paying particular attention to the most frequently
reeved links. When any five links in the working
length reaches or exceeds the discard length, replace
the entire chain (see Dwg. MHTPAOO41). Always
use a genuine INGERSOLL-RAND Material Han-
dling replacement chain for regular and nickle-
diffused load chains.
Model Size Normal Length
No. (mm) in. (mm)
3 CP1500 and 3 CP 3000 8.0 4.72 120
6CP3000 and6CP6000 13.0 7.09 180
12CP6000 and 12 CP 12000 16.0 8.85 225
Model Size Discard Length
No. (mm) in. (mm)
3 CP 1500 and 3 CP 3000 8.0 4.80 122
6CP3000 and6CP6000 13.0 7.24 184
12 CP 6000 and 12 CP 12000 16.0 9.02 229
GAUGE LENGTH
(Dwg. MHTPA0041)
12. CHAIN CONTAINER. Check for excessive wear.
Replace if necessary.
Hoists Not in Regular Use
A hoist which has been idle for a period of one month or
more, but less than six months, shall be given an inspection
conforming with the requirements of “Frequent Inspection”
before being placed into service.
A hoist which has been idle for a period of over six months
shall be given a complete inspection conforming with the
requirements of “Periodic Inspection”. Standby hoists shall
be inspected at least semiannually in accordance with the
requirements of “Frequent Inspection”. If adnormal
operating conditions apply hoists may require a more
frequent inspection.
10

Lubrication Schedule
The time intervals listed below are for service in a normal
environment. Units operating in a harsh environment
(excessively hot or cold, marine, hazardous gases or
abrasive dust) may require more frequent lubrication.
Usage:
Heavy
Normal
Occasional
Continual daily usage.
Subject to daily use, but not continually.
Average use of once a week or less.
Lubrication Frequency by Usage Level
I I I I I
I Component: I Heavy I Normal Occasional I
I Geared Trolley Wheels I Monthly Quarterly Yearly I
I Load Chain I Daily Weekly At Usage I
I Hook and Hook Latch Daily Weekly At Usage I
Gear Case I Yearly I Every 3 Years Unnecessary
Load Chain Gear Case
The gear case is packed with grease on assembly.
l Failure to maintain clean and well lubricated load
chain will affect the life of the chain resulting in prema-
ture wear.
Air Line Lubricator
To adjust. Remove plug then rotate screw to limit oil flow.
The air line lubricator should be replenished daily with
1. Lubricate each link of the chain and apply new SAE 30W oil (minimum viscosity 135 Cst at 104” F
lubricant over existing layer. (4O°C)).
2. Coat entire link surfaces, including bearing surfaces
between links.
3. Clean chain to remove rust or abrasive dust build-up.
After cleaning, lubricate the chain using SAE 50 to
9OWEP oil.
Hook and Hook Latch
Lubricate the hook and hook latch pivot points. Hook
should swivel freely. Hook latch should pivot freely. Use
SAE 30 oil or SAE 50 to 9OWEP oil.
HOOK SWIVEL
POINT HOOK
PIVOT LATCH POINT
11

l Never perform maintenance on the hoist while it is
supporting a load.
l Before performing maintenance, tag controls: DAN-
GER - DO NOT OPERATE - EQUIPMENT BEING
REPAIRED.
l Only allow qualified service personnel to perform
maintenance.
l After performing any maintenance on the hoist, test
hoist to 125% of its rated capacity before returning to
service.
l Turn off air system and depressurize air lines before
performing any maintenence.
INTERVAL
I--
Start of each shift
3 Months
MAINTENANCE CHECKS
Make a thorough visual inspection
of the hoist for damage. Do not
operate the hoist if damage is
found.
Check the operation of the brake.
Inspect the drum brake friction
linings. Clean or replace parts as
required.
Inspect the gearing, shafts, and
bearings for damage or wear.
Check all of the supporting
members, including the trolley if
used.
Disc Brake
Adjustment
No brake adjustment is required.
l When any part of the brake lining measures .062 in.
(1.6 mm) or less, lining must be replaced.
To check or replace the brake disc use the following
procedure.
1. Loosen capscrews one turn at a time progressively
round the housing until brake spring load is relaxed.
Remove capscrews holding brake assembly to the
hoist frame.
2. Pull brake disc from keyed shaft.
Chain Replacement
1. The hoist must be hung and connected to the air
supply. Reduce air pressure to 30 psi (2 bar).
2. Remove chain bucket, if used.
3. Remove free end of chain from hoist body, if attached.
Remove chain stopper.
4. Run hoist slowly in the lifting direction until the chain
free end is approximately 2 ft (60 cm) from the hoist.
5. Using a ‘c’ link which is the same size as the chain
join the new chain to the old taking care that the
“standing” links on the new chain are facing away
from the hoist load sheave.
(Dwg. MHTPA0172)
6. Run the hoist slowly until the new chain has passed 24
to 36 in. (60 to 90 cm) through the hoist.
General Disassembly
The following instructions provide the necessary informa-
tion to disassemble, inspect, repair, and assemble the hoist.
A parts drawing of the hoist assembly is provided in the
Parts Section.
If a hoist is being completely disassembled for any reason,
follow the order of the topics as they are presented.
It is recommended that all maintenance work on the hoist
be performed on a bench.
In the process of disassembling the hoist, observe the
following:
1. Never disassemble the hoist any further than is
necessary to accomplish the needed repair. A good
part can be damaged during the course of disassembly.
2. Never use excessive force when removing parts.
Tapping gently around the perimeter of a cover or
housing with a soft hammer, for example, is sufficient
to break the seal.
3. Do not heat a part with a torch to free it for removal,
12

unless the part being heated is already worn or
damaged beyond repair.
In general, the hoist is designed to permit easy disassembly
and assembly. The use of heat or excessive force should
not be required.
4. Keep the work area as clean as practical, to prevent
dirt and other foreign matter from getting into bearings
or other moving parts.
5. All seals and ‘0’ rings should be discarded once they
have been removed. New seals and ‘0’ rings should be
used when assembling the hoist.
6. When grasping a part in a vise, always use leather-
covered or copper-covered vise jaws to protect the
surface of the part and help prevent distortion. This is
particularly true of threaded members and housings.
7. Do not remove any part which is press fit in or on a
subassembly unless the removal of that part is neces-
say for repairs or replacement.
Cleaning, Inspection and Repair
Use the following procedures to clean, inspect, and repair
the components of the hoist.
Cleaning
l Bushings that are loose, worn or rotate in the frame
must be replaced. Failure to observe this precaution
will result in additional component damage.
Clean all hoist component parts in solvent (except for the
brake disc). The use of a stiff bristle brush will facilitate
the removal of accumulated dirt and sediments on the gears
and frames. If bushings have been removed it maybe
necessary to carefully scrape old Loctite from the bushing
bores. Dry each part using low pressure, filtered com-
pressed air. If the brake disc is oil soaked, it must be
replaced.
Inspection
All disassembled parts should be inspected to determine
their fitness for continued use. Pay particular attention to
the following:
1. Inspect all gears for worn, cracked, or broken teeth.
2. Inspect all bushings for wear, scoring, or galling.
3. Inspect shafts for ridges caused by wear. If ridges
caused by wear are apparent on shafts, replace the
shaft.
4. Inspect all threaded items and replace those having
damaged threads.
5. Inspect the brake disc lining for oil. If the brake disc
lining is oil-soaked, replace the brake shoe. If the
brake shoe is glazed, sand it lightly using fine emery
cloth.
6. Measure the thickness of the brake disc lining. If the
brake disc lining is less than .062 in. (2 mm) replace
the brake disc (15).
Repair
Actual repairs are limited to the removal of small burrs and
other minor surface imperfections from gears and shafts.
Use a line stone or emery cloth for this work.
1. Worn or damaged parts must be replaced. Refer to the
applicable Parts Listing for specific replacement parts
information.
2. Inspect all remaining parts for evidence of damage.
Replace or repair any part which is in questionable
condition. The cost of the part is often minor in
comparison with the cost of redoing the job.
3. Smooth out all nicks, burrs, or galled spots on shafts,
bores, pins, or bushings.
4. Examine all gear teeth carefully, and remove nicks or
burrs.
5. Polish the edges of all shaft shoulders to remove small
nicks which may have been caused during handling.
6. Remove all nicks and burrs caused by lockwashers.
13

14

15

16

17

18

19

TOTAL PART NO.
ITEM DESCRIPTION
NO. OF PART QTY. 3CP I