Ingersoll-Rand CL125K User manual

Product Information
Compact Lift Air Chain Hoist
Models
CL125K, CL250K and CL500K
(Dwg. MHP2967)
Save These Instructions
Form MHD56406
Edition 2
March 2010
45550183
©2010 Ingersoll-Rand Company
Distributed by Tri-State Equipment Company Inc. | [email protected] | [phone] | www.tsoverheadcrane.com

Form MHD56406 Edition 2
Only allow Ingersoll Rand trained Technicians to perform maintenance on this product. For additional information contact Ingersoll Rand
factory or nearest Distributor.
For additional supporting documentation refer to Table 1 on page 2 for Product Information Manuals.
The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased performance and increased maintenance and will invalidate
all warranties.
The original language of this manual isEnglish.
Refer all communications to thenearest Ingersoll Rand Office or Distributor.
Table 1: Product Manuals
PRODUCT DESCRIPTION
Description
The Compact Lift Air Chain Hoists (CLK) are air powered and designed for
industrial, assembly and general utility applications. CLK air hoists can be hook-
mounted to the suspension shaft of a trolley, permanent mounting structure or any
mounting point capable of supporting both load and hoist.
The air supply line can be strung to the hoist using cable hangers, cable trolleys or
any festooning system that will ensure the air line remains free of kinks or sharp
bends and is protected from being pinched or crushed by other equipment.
The CLK air hoists are in conformity, when equipped with optional ‘e-stop’, with the
most recent European Standards. Only models with a CE marking on the data (name)
plate, located on the end of the hoist body, meet these requirements. CE models
carry a mechanism classification 1Am/M4, and an ATEX rating of II 3 GD c IIB 135°C
X. Refer to Product Safety and Maintenance Information Manuals for further
explanation.
SPECIFICATIONS
Table 2: General Specifications
Note: CLK air hoists are designed for lifting with a 5:1 minimum safety factor at rated load.
Publication Part/Document Number Publication Part/Document Number
Product Safety Information Manual MHD56295 Product Maintenance Information Manual MHD56408
Product Parts Information Manual MHD56407
Model Code Explanation
Example: CL250K-2C10-C6U-E CL250K 2 C 10 C 6 U E
Series (Capacity):
CL250K = 250 kg (551 lbs), single fall
CL125K = 125 kg (276 lbs), single fall
CL500K = 500 kg (1,102 lbs), double fall
Control:
0=NoPendant
2 = 2 Button Pendant
Top Suspension:
A = Lug Mount
C=SwivelTopHook
DA = Rigid Trolley
Load Chain Lift:
10 = foot (standard)
X = Specify length
Bottom Suspension:
C = Swivel Snap Hook
Pendant Control Drop:
6 = 6 ft (standard)
X = Specify Length (maximum 40 ft [12.2 m])
Options:
U = Fabric Chain Container
E = Emergency Stop
Hoist
Models
Rated Capacity Load
Chain
Falls
Pressure Air Flow Chain
Size
mm
Wt. of Chain Unit Net Wt. with Standard 10 ft
(3 m) Lift
Sound
Pressure
Level
kg lbs psi bar scfm m³/min per ft (lb) per metre (kg) lbs kg dB(A)
CL125K 125 276 1
90 6.2 32 0.91 4 x 12 DAT 0.24 0.35
34 15.4
75CL250K 250 551 1 38 17.2
CL500K 500 1,102 2
Sound measurements are in accordance with ISO 11204 and ISO 3746 test specifications for sound from pneumatic equipment.
Hoist Performance at 90 psi (6.2 bar) Air Pressure
Hoist
Models
Rated Capacity Max. Lifting Speed @ Rated Load Lifting Speed @ No Load Max. Lowering Speed @ Rated Load
kg lbs ft/min m/min ft/min m/min ft/min m/min
CL125K 125 276 43 13.1 56 17.1 37 11.3
CL250K 250 551 32 9.8 45 13.7
CL500K 500 1,102 15 4.6 26 7.9 23 6.7

Form MHD56406 Edition 2
INSTALLATION
Prior to installing product, carefully inspect it for possible shipping damage.
Hoists are supplied fully lubricated from the factory. Refer to “LUBRICATION” section
for recommended oils and lubrication intervals. Lubrication of the load chain is
recommended before initial hoist operation. Remove shipping lubrication plug and
replace with breather.
WARNING
• A falling load may result in death or serious injury. Before installing, read
the ‘Product Safety Information Manual’.
CAUTION
• 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.
Mounting
Ensure hoist is properly installed before use. Seek advice from qualified source
should questions arise before and during installation.
Ensure structure from which hoist is suspended is able to support the weight of the
hoist plus the weight of the maximum rated load with a generous factor of at least
500% of the combined weights.
Hook Mounted Hoist
Place hook over mounting structure. Make sure hook latch is engaged.
When hoist is suspended by a top hook, the supporting member should rest
completely within the saddle of the hook and be centered directly above hook shank.
CAUTION
• Do not use a supporting member that tilts hoist.
Trolley Mounted Hoist
When installing a trolley on a beam, measure the beam flange and temporarily install
the trolley on the hoist to determine the exact distribution and arrangement of the
spacers. Adjust the spacers in accordance with the trolley manufacturer’s literature
to provide the correct distance between the wheel flange and the beam. The number
of spacers between the trolley side plate and the mounting lug on the hoist must be
the same in all four locations in order to keep the hoist centered under the I-beam.
The remaining spacers must be equally distributed on the outside of the side plates.
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 torque trolley bolts or nuts are torqued in accordance with manufacturer’s
specifications. For installation of hoist and trolley on beam, make certain the side
plates are parallel and vertical.
After installation ensure beam stops are in place, operate trolley over entire length
of beam with a capacity load suspended 4 to 6 inches (10 to 15 cms) off the floor.
CAUTION
• To avoid an unbalanced load which may damage the trolley, the hoist must
be centered under the trolley.
NOTICE
• Trolley wheels ride on the top of the lower flange of the beam.
Air 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 ‘General Specifications’ on page 2. If air supply varies from what is
recommended, product performance will change. The compressed air temperature
must not exceed 120° F (55° C) at the motor air inlet.
Refer to Dwg. MHP0191 on page 6, A. Air Out; B. Lubricator; C. Regulator; D. Air In;
E. Filter.
Air Lines
The inside diameter of air supply lines must not be smaller than 1/2 in (13 mm) for
flexible lines and 1/2 in. (13 mm) for connectors. Before making final connections,
all air supply lines should be purged with clean, moisture free air or nitrogen before
connecting to 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. Note: The inlet strainer is a 3/8 NPT thread.
Air Line Lubricator (standard)
The use of an air line lubricator is required and it should be replenished daily and set
to provide 2 to 3 drops per minute of IR #10 (10W non-detergent) tool oil. The
lubricator must have an inlet and outlet at least as large as the inlet on the motor
and capable of passing at least 150 percent of the hoist SCFM requirement. Install
the lubricator as close to the air inlet of 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.
Air 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.
Start-Up Procedures
For hoists that have been in storage the following start-up procedures are required.
1. Give the hoist an inspection conforming to the requirements in the
“INSPECTION” section on page 4.
2. Inject a small amount of ISO VG 32 (SAE 10W) oil in the motor inlet port.
3. Operate the motor for 10 seconds in both directions to flush out any impurities.
a. With no load, operate hoist in “UP” direction and adjust air pressure to 90
psi (6.2 bar).
4. The hoist is now ready for normal use.
Main Air Shut-off Valve
All hoists should have a wall mounted shut-off valve.
Chain Container (optional feature)
The chain container is an optional accessory. Check the chain container size to make
sure the length of the load chain is within the capacity of the chain container.
Replace with a larger chain container if required. When a chain bucket is used,
always connect the free end of the chain to the hoist.
Install the chain container per the instructions provided with the chain container
kit. Run bottom block to the lowest point and run hoist in the “UP” direction to feed
the chain back into the container.
NOTICE
• Allow chain to pile naturally in the chain container. Piling the chain
carelessly into the container by hand may lead to kinking or twisting that will
jam the hoist.
Pendant
Check that all hose connections are tight and that hoses are not twisted or crimped.
Contact the factory for pendant lengths greater than 6 ft (2 m).
NOTICE
• To avoid damaging the pendant hose, make sure the strain relief cable, not
the pendant hose, is supporting the weight of the pendant.

Form MHD56406 Edition 2
OPERATION
It is recommended that the user and owner check all appropriate and applicable
regulations before placing this product into use. Refer to Product Safety Information
Manual.
The hoist operator must be carefully instructed in his or her duties and must
understand the operation of the hoist, including a study of the manufacturers
literature. The operator must thoroughly understand proper methods of hitching
loads and should have a good attitude regarding safety. It is the operators
responsibility to refuse to operate the hoist under unsafe conditions.
WARNING
• The hoist is not designed or suitable for lifting, lowering or moving people.
• Never lift loads over people.
• The hook latch is intended to retain loose slings or devices under slack
conditions. Use caution to prevent the latch from supporting any of the load.
Hoist Controls
Pendant Operation
Refer to Dwg. MHP3111 on page 6, A. Lower; B. Raise.
The pendant is a control that allows the operator to control the positioning of a
load. The two-lever pendant will control hoist movement in the “UP” and “DOWN”
direction. Always apply smooth even pressure to pendant levers, avoid quick starts
and abrupt stops. This will allow smoother control of suspended loads and reduce
undue stress on components.
Emergency Stop
Refer to Dwg. MHP3112 on page 6, A. Lower; B. Raise; C. Emergency Stop.
INSPECTION
Inspection information is based in part on American Society of Mechanical Engineers
Safety Codes (ASME B30.16).
WARNING
• All new, altered or modified equipment should be inspected and tested by
Ingersoll Rand Certified Service Technicians to ensure safe operation at rated
specifications before placing equipment in service.
• Never use a hoist that inspection indicates is damaged.
Frequent and periodic inspections should be performed on equipment in regular
service. Frequent inspections are visual examinations performed by operators or
personnel trained in safety and operation of this equipment and include observations
made during routine equipment operation. Refer to Product Maintenance Information
Manual for Periodic inspections which are thorough inspections conducted by
Ingersoll Rand Certified Service Technicians.
ASME B30.16 states inspection intervals depend upon the nature of the critical
components of the equipment and the severity of usage. The inspection intervals
recommended in this manual are based on intermittent operation of the hoist eight
hours each day, five days per week, in an environment relatively free of dust,
moisture, and corrosive fumes. If the hoist is operated almost continuously or more
than the eight hours each day, more frequent inspections will be required.
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.
Deficiencies revealed through inspection, or noted during operation, must be
reported to a Ingersoll Rand Certified Service Technician. A determination as to
whether a condition constitutes a safety hazard must be decided, and the correction
of noted safety hazards accomplished and documented by written report before
placing the equipment in service.
Frequent Inspection
On equipment in continuous service, frequent inspections should be made by
operators at the beginning of each shift. In addition, visual inspections should be
conducted during regular service for any damage or evidence of malfunction.
1. Hoist. Check for visual signs or abnormal noises (grinding, etc.) which could
indicate a potential problem. Make sure all controls function properly and return
to neutral when released. Check chain feed through hoist and bottom block. If
chain binds, jumps, is excessively noisy or “clicks,” clean and lubricate chain. If
problem persists, replace chain. Do not operate hoist until all problems have
been corrected.
2. Hooks. Check for wear or damage, increased throat width, bent shank or twisting
of hook. Replace hooks which exceed the throat opening discard width specified
in Table 3 on page 4 or which exceed a 10° twist. Refer to Dwg. MHP0040 on
page 6, A. Throat Width; and refer to Dwg. MHP0111 on page 6, A. Twisted DO
NOT USE; B. Normal Can Be Used. If hook latch snaps past tip of hook, the hook
is sprung and must be replaced. Refer to the latest edition of ASME B30.10
“HOOKS” for additional information. Check hook support bearings for lubrication
or damage. Ensure that they swivel easily and smoothly.
3. Hook Latch. Make sure hook latch is present and operating. Replace if necessary.
4. Air System. Visually inspect all connections, fittings, hoses and components for
indication of air leaks. Repair any air leaks found. Check and clean filter.
5. Emergency Stop. Check Emergency Stop for proper operation.
6. Limit Switch Devices. Without a load on the hook, the load block should be
inched into the limit switch (run at slow speed), and the function of the limit
switch, to stop the load, should be confirmed. Similarly, this should be
performed for full extension of the chain.
7. Brake System. Check braking system for proper operation.
8. Load Chain. Examine each of the links for bending, cracks in weld areas or
shoulders, traverse nicks and gouges, weld splatter, corrosion pits, striation
(minute parallel lines) and chain wear, including bearing surfaces between chain
links. Refer to Dwg. MHP0102 on page 6, A. Diameter; B. Welded Area; C. Wear in
these areas. Replace a chain that fails any of the inspections. Check chain
lubrication and lubricate if necessary. Refer to ‘Load Chain’ in “LUBRICATION”
section on page 5.
NOTICE
• The full extent of load chain wear cannot be determined by visual
inspection. At any indication of load chain wear, inspect the chain and chain
wheel in accordance with instructions in “Periodic Inspection.” Refer to Product
Maintenance Information Manual.
9. Load Chain Reeving. Ensure welds on standing links are away from load sheave.
Reinstall chain if necessary. Make sure chain is not capsized, twisted or kinked.
Adjust as required. Refer to Dwg. MHP0043 on page 6, A. Make certain bottom
block has NOT been flipped through the chain falls.
10. Labels and Tags. Check for presence and legibility. Replace if necessary.
Table 4: Frequent Inspection Interval:
Hoists Not in Regular Use
1. Equipment which has been idle for a period of one month or more, but less than
six months, shall be given an inspection conforming to the requirements of
‘Frequent Inspection’ before being placed in service.
2. Equipment which has been idle for a period of over six months shall be given a
complete inspection conforming with the requirements of ‘Periodic Inspection’
before being placed in service. Refer to Product Maintenance Information
Manual.
3. Standby equipment shall be inspected at least semiannually in accordance with
the requirements of ‘Frequent Inspection’.
Table 3: Hook Throat Normal and Discarded Width
Hoist
Model Capacity (tonne)
Throat Width * Discard Width *
in. mm in. mm
CL125K 1/8
0.945 24 1.042 27.6CL250K 1/4
CL500K 1/2
* Dimensions are with no latch installed.
Item Conditions
Normal Heavy Severe
All functional operating mechanisms
for maladjustment and unusual
sounds. Monthly Weekly Daily
Hoist Braking System for proper
operation. Monthly Weekly Daily
Hooks, per guidance given in manual. Monthly Weekly Daily
Hook Latch for proper function. Monthly Weekly Daily
Load Chain, per guidance given in
manual. Monthly Weekly Daily
Load Chain reeving for compliance to
manufacturers recommendations. Monthly Weekly Daily
Air System; lines, valves, and other
parts for leakage. Monthly Weekly Daily
Pendant and e-stop; confirm proper
operation. Monthly Weekly Daily
Limit Switches. Monthly Weekly Daily

Form MHD56406 Edition 2
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 in section ‘Hoists Not in
Regular Use’ on page 4.
LUBRICATION
To ensure continued satisfactory operation of the hoist, all points requiring
lubrication must be serviced with correct lubricant at the proper time interval as
indicated for each assembly.
Lubrication intervals recommended in the Maintenance manual are based on
intermittent service run time and if the hoist is operated more frequently a more
frequent lubrication schedule will be required. Also, lubricant types and change
intervals are based on operation in an environment relatively free of dust, moisture,
and corrosive fumes. Use only those lubricants recommended. Other lubricants may
affect performance of hoist. Failure to observe this precaution may result in damage
to the hoist and it's associated components.
General Lubrication
WARNING
• Pneumatic Hoist Motors use oil to prevent excessive heat build up and to
prevent wear. Oil levels must be properly maintained.
• Always collect lubricants in suitable container and dispose of in an
environmentally safe manner.
Reduction Gear Assembly
NOTICE
• Fluid level verification is recommended every 400 hours, or sooner
depending on severity of use, of actual runtime.
The reduction gear assembly is oil lubricated, and is intended to be changed only at
major overhaul intervals. It is recommended that the gear cover not be removed to
prevent contamination.
Motor
The recommended grade of oil for the air motor is IR #10 (10W non-detergent) tool
oil.
Load Chain
WARNING
• Failure to maintain a clean and well-lubricated load chain will result in rapid
load chain wear that can lead to chain failure which may result in death, severe
injury, or substantial property damage.
1. Lubricate each link of load chain weekly, or more frequently, depending on
severity of service.
2. In corrosive environments, lubricate more frequently than normal.
3. Lubricate each link of the load chain and apply new lubricant over existing layer.
4. Use Ingersoll Rand LUBRI-LINK-GREEN® or an ISO VG220 to 320 (SAE 50W to 90
EP) oil.
WARRANTY
Ingersoll Rand Limited Warranty
Ingersoll Rand Company (“IR”) warrants to the original user its material handling
products (“Products”) to be free of defects in material and workmanship for a period
of one year from the date of purchase. IR will, at its option either (1) repair, without
cost, any Product found to be defective, including parts and labor charges, or (2)
replace such Products or refund the purchase price, less a reasonable allowance for
depreciation, in exchange for the Product. Repairs or replacements are warranted for
the remainder of the original warranty.
If any Product proves defective within its original one-year warranty period, it should
be returned to any Authorized Product Service Distributor, transportation prepaid
with proof of purchase or warranty card. This warranty does not apply to Products
which IR has determined to have been misused or abused, improperly maintained by
the user, or where the malfunction or defect can be attributed to the use of non-
genuine IR repair parts.
IR MAKES NO OTHER WARRANTY, CONDITION OR REPRESENTATION OF ANY KIND
WHATSOEVER, EXPRESSED OR IMPLIED, STATUTORY OR OTHERWISE, AND ALL
IMPLIED WARRANTIES AND CONDITIONS RELATING TO MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.
IR's maximum liability is limited to the purchase price of the Product and in no event
shall IR be liable for any consequential, indirect incidental or special damages of any
nature arising from the sale or use of the Product, whether in contract, tort or
otherwise.
Note: Some states do not allow limitations on incidental or consequential damages,
so that the above limitations may not apply to you. This warranty gives you specific
legal rights and you may also have other rights which may vary from state to state.
Fulcrum series electric winch, product code 405-002: 2 year warranty.
Winch and Hoist Solutions Extended Warranty
This option provides a price for extending the Ingersoll Rand Winch and Hoist
Solutions Warranty from the standard one (1) year to two (2) years from the date of
purchase. All other provisions of the standard warranty to remain in effect.
For additional information or quotations for warranties falling outside of these
parameters, please contact your Client Services Representative with your
requirements.
INTERVAL LUBRICATION CHECKS
Start of each shift If used, check flow and level of air line lubricator
(approximately 2 to 3 drops per minute required at
maximum motor speed).
Monthly Lubricate components supplied by grease fittings.
Inspect and clean or replace air line filter.
Yearly Drain and refill hoist reduction gear oil.

Form MHD56406 Edition 2
PRODUCT INFORMATION GRAPHICS
(Dwg. MHP0191)
(Dwg. MHP0040)
(Dwg. MHP0111)
(Dwg. MHP0102)
(Dwg. MHP0043)
(Dwg. MHP3111)
(Dwg. MHP3112)
Throat
Width
A
Lower
Raise
A
B
Emergency
Stop
Lower
Raise
C
A
B

Form MHD56304 Edition 2
DECLARATION OF CONFORMITY
(BG)ДЕКЛАРАЦИЯ ЗА СЪОТВЕТСТВИЕ (CS)PROHLÁŠENÍ O SHODĚ(DA) FABRIKATIONSERKLÆRING (DE) KONFORMITÄTSERKLÄRUNG (EL)ΔΗΛΩΣΗ
ΑΝΑΓΝΩΡΙΣΗΣ (ES) DECLARACIÓN DE CONFORMIDAD (ET) VASTAVUSDEKLARATSIOON (FI) VAKUUTUS NORMIEN TÄYTTÄMISESTÄ (FR) CERTIFICAT DE
CONFORMITÉ (HU)MEGFELELŐSÉGI NYILATKOZAT (IT) DICHIARAZIONE DI CONFORMITÀ (LT) ATITIKTIES DEKLARACIJA (LV) AT BIL STÎBA S
DEKLARÂCIJA (NL) SCHRIFTELIJKE VERKLARING VAN CONFORMITEIT (NO) KONFORMITETSERKLÆRING (PL)DEKLARACJA ZGODNOŚCI (PT) DECLARAÇÃO DE
CONFORMIDADE (RO)DECLARAŢIE DE CONFORMITATE (RU)ДЕКЛАРАЦИЯ СООТВЕТСТВИЯ (SK)PREHLÁSENIE O ZHODE (SL)IZJAVA O
SKLADNOSTI (SV) FÖRSÄKRAN OM ÖVERENSSTÄMMELSE
Ingersoll-Rand 1725 US 1 North, Southern Pines, NC 28387
Declare under our sole responsibility that the product: Pneumatic Hoists
(BG)Декларира на своя отговорност, че продуктът: Пневматични телфери (CS)Prohlašujeme na svou zodpovědnost, že produkt: pneumatický kladkostroj
(DA) Erklærer som eneansvarlig, at nedenstående produkt: Pneumatisk lift (DE) Erklären hiermit, gemäß unserer alleinigen Verantwortung, dass die Geräte: Druckluft-
Kettenzug (EL)Δηλώνουμε ότι με δική μας ευθύνη το προϊόν: Πνευματικός ανυψωτήρας (ES) Declaramos que, bajo nuestra responsabilidad exclusiva, el producto: Polipasto
neumático (ET) Deklareerime oma ainuvastutusel, et toode: suruõhumootoriga vintsid (FI) Vakuutamme ja kannamme yksin täyden vastuun siitä, että tuote: Paineilmanostin
(FR) Déclarons sous notre seule responsabilité que le produit: Palans pneumatiques (HU) Kizárólagos felelősségünk tudatában kijelentjük, hogy a termék: Pneumatikus emelő
(IT) Dichiariamo sotto la nostra unica responsabilità che il prodotto: Paranco pneumatico (LT) Prisiimdami atsakomybæ pareiðkiame, kad gaminys: pneumatiniai keltuvai
(LV)Uzòemoties pilnîgu atbildîbu, apliecinâm, ka raþojums: Pneimatiskie pacçlâji (NL) Verklaren, onder onze uitsluitende aansprakelijkheid, dat het produkt: Pneumatische
takel (NO) Erklærer på ære og samvittighet at produktet: Pneumatisk talje (PL)Przyjmując pełnąodpowiedzialność, oświadczamy, że produkt: Wciągnik pneumatyczny
(PT) Declaramos sob a nossa exclusiva responsabilidade que o produto: Guincho Pneumático (RO)Declarăpe propria răspundere căprodusul: Palane pneumatice (RU)Под
нашу исключительную ответственность заявляем, что изделие: пневматические тали (SK)Záväzne prehlasujeme, že výrobok: pneumatický kladkostroj (SL)Pod polno
odgovornostjo izjavljamo, da je izdelek: Pnevmatsko dvigalo (SV) Intygar enligt vårt ansvar att produkten: Tryckluftsdrivna lyftdon
Model: CL125K-( )-E, CL250K-( )-E, CL500K-( )-E / Serial Number Range: SPHXXX-0101-10
(BG)Модел: / Диапазон на серийните номера: (CS)Model: / Rozsah výrobních čísel: (DA) Model: / Serienummerområde: (DE) Modell: / Seriennummernbereich:
(EL)Μοντέλο: / Κλίμακα σειριακών αριθμών: (ES) Modelo: / Números de serie: (ET) Mudel: / seerianumbrite vahemik: (FI) Malli: / Sarjanumeroalue: (FR) Modèle: / Gamme de
numéros de série: (HU)Modell: / Gyártási szám-tartomány: (IT) Modello: / Gamma delle matricole: (LT) Modeliai: / Serijos numeriai: (LV) Modelis: / Sçrijas numuru diapazons:
(NL) Model: / Serienummer: (NO) Modell: / Serienr: (PL)Model: / Zakres numerów serii: (PT) Modelo: / Gama de Nos de Série: (RO)Model: / Interval număr de serie:
(RU)Модель: / Диапазон серийных номеров: (SK)Model: / Rozsah výrobných čísiel: (SL)Model: / Območje serijskih številk: (SV) Modell:/ Serienummer, mellan:
To which this declaration relates, is in compliance with provisions of Directive(s): 2006/42/EC (machinery), 94/9/EC (ATEX)
(BG)За който се отнася тази декларация, евсъответствие сразпоредбите на Директива(и): (CS)Ke kterým se toto prohlášení vztahuje, odpovídají ustanovením
směrnic: (DA) som denne erklæring vedrører, overholder bestemmelserne i følgende direktiv(er): (DE) auf das sich diese Erklärung bezieht, der folgenden Richtlinie entspricht:
(EL)στο οποίο αναφέρεται αυτή ηδήλωση, πληροί τις διατάξεις της Οδηγίας: (ES) a los que se refiere la presente declaración, cumplen con todo lo establecido en las
directivas: (ET)mida käesolev deklaratsioon puudutab, on vastavuses järgmis(t)e direktiivi(de) sätetega: (FI) johon tämä vakuutus viittaa, täyttää direktiiveissä: (FR) Objet de
ce certificat, est conforme aux prescriptions des Directives: (HU)Amelyekre ezen nyilatkozat vonatkozik, megfelelnek a következőirányelvek előírásainak: (IT) a cui si riferisce
la presente dichiarazione è conforme alle normative delle direttive: (LT) Kuriems taikoma ði deklaracija, atitinka ðiø direktyvø nuostatas: (LV) Uz kuru ðî deklarâcija attiecas,
atbilst direktîvas(u) nosacîjumiem: (NL) waarop deze verklaring betrekking heeft overeenkomt met de bepalingen van directieven: (NO) som denne erklæringen gjelder for,
oppfyller bestemmelsene i direktivene: (PL)Którego dotyczy niniejsza deklaracja, jest zgodny z wymogami dyrektyw: (PT) Ao qual se refere a presente declaração, está
de acordo com as prescrições das Directiva: (RO)La care face referire aceastădeclaraţie, se aflăîn conformitate cu prevederile Directivei (Directivelor): (RU)Ккоторым
относится настоящее заявление, соответствуют положениям Директив: (SK)Na ktorý sa toto prehlásenie vzt’ahuje, je v súlade s ustanoveniami Smernice (Smerníc):
(SL)Na katerega se ta izjava o skladnosti nanaša, v skladu z določili smernic: (SV) Som detta intyg avser, överensstämmer med följande direktiv:
By using the following Principle Standards: F.E.M. 1.001; EN 983-2006; EN 12100-1; -2; EN 14492-2; EN 13463-1; EN 13850:2006
(BG)При използването на следните основни стандарти:(CS)Použitím následujících zákonných norem: (DA) ved at være i overensstemmelse med følgende
hovedstandard(er): (DE) Unter Anlehnung an die folgenden Grundnormen entsprechen: (EL)Χρησιμοποιώντας ια παρακάτω κύρια πρότυπα: (ES) conforme a los siguientes
estándares: (ET) Järgmiste põhistandardite kasutamise korral: (FI) esitetyt vaatimukset seuraavia perusnormeja käytettäessä: (FR) En observant les normes de principe
suivantes: (HU)A következőelvi szabványok alkalmazása mellett: (IT) Seguendo i principi standard indicati di seguito: (LT) Remiantis ðiais pagrindiniais standartais:
(LV)Izmantojot ðâdus galvenos standartus: (NL) overeenkomstig de volgende hoofdstandaards: (NO) Ved å bruke følgende prinsipielle standarder: (PL)Spełniając wymogi
nastźpujących głównych norm: (PT) observando as seguintes Normas Principais: (RO)Aplicând următoarele Standarde de principiu: (RU)Сприменением следующих
основных стандартов: (SK)Pri dodržaní nasledovných noriem: (SL)Uporabljeni osnovni standardi: (SV) Genom att använda följande principstandard:
Date:
(BG)Дата: Януари:(CS)Datum: Leden: (DA) Dato: Januar: (DE) Datum: Januar: (EL)Ημερομηνία: lανουάριος: (ES) Fecha: Enero: (ET) Kuupäev: Jaanuar:(FI) Päiväys:
Tammikuu: (FR) Date: Janvier: (HU)Dátum: január: (IT) Data: Gennaio: (LT)Data: Sausis: (LV)Datums: Janvâris: (NL) Datum: Januari: (NO) Dato: Januar: (PL)Data:
Styczen: (PT) Data: Janeiro: (RO)Data: Ian: (RU)Дата: Январь:(SK)Dátum: Január: (SL)Datum: januar: (SV) Datum: Januari:.
Approved By:
(BG)Одобрено от:(CS)Schválil: (DA) Godkendt af: (DE) Genehmigt von: (EL)Eγκρίθηκεαπό: (ES) Aprobado por: (ET) Kinnitatud: (FI) Hyväksytty: (FR) Approuvé par:
(HU)Jóváhagyta:(IT) Approvato da: (LT) Patvirtinta: (LV) Apstiprinâja: (NL) Goedgekeurd door: (NO) Godkjent av: (PL)Zatwierdzone przez: (PT) Aprovado por:
(RO)Aprobatăde: (RU)Утверждено: (SK)Schválil: (SL)Odobril: (SV) Godkänt av:
Kevin Heinrichs
Engineering Manager – Assembly Tools and Material Handling Jean-Luc Faillon Regional Engineering Manager Europe

Distributed by Tri-State Equipment Company Inc. | [email protected] | [phone] | www.tsoverheadcrane.com

Product
Maintenance
Information
Compact Lift Air Chain Hoist
Models
CL125K, CL250K and CL500K
(Dwg. MHP2967)
Save These Instructions
Form MHD56408
Edition 1
January 2010
45550209
©2010 Ingersoll-Rand Company
Distributed by Tri-State Equipment Company Inc. | [email protected] | [phone] | www.tsoverheadcrane.com

2Form MHD56408 Edition 1
Only allow Ingersoll Rand trained Technicians to perform maintenance on this product. For additional information contact Ingersoll Rand
factory or nearest Distributor.
For additional supporting documentation refer to Table 1on page 2for Product Information Manuals.
The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased performance and increased maintenance and will invalidate
all warranties.
The original language ofthis manual is English.
Refer all communications to the nearest Ingersoll Rand Office or Distributor.
Table 1: Product Manuals
OPERATIONAL CONDITIONS, INSPECTION AND REPAIRS
The CLK Series air chain hoist has been developed and classified in accordance with
the guidance set for by FEM/ISO. Service life of hoist is approximately ten years, but
the actual life is dependent on conditions of service. In accordance with those
procedures this series of lifting devices are classified as a mechanism; it has been
qualified with a 1Am/M4 mechanism classification. Accordingly, time between
overhaul is a factor of the relative duration and mass of the lifted loads. The
theoretical time between overhauls for normal loading, L2 load spectrum is 3200
hours; this corresponds to 800 full-load hours. The implication of this classification
on maintenance is further detailed in the section entitled ‘State of Loading’.
The CLK Series hoist has also been designated with an Air Chain Hoist Duty Service
Classification of A4. According to ASME HST-5, 1999, Performance Standards for Air
Chain Hoists, an A4 rating includes hoists designed for ‘Loads normally less than
50% of rated load with a running time up to continuous; or Loads normally above
50% of rated load with running time up to 50% of work period’. Regardless, the next
section should be used to determine the necessary maintenance intervals.
State of Loading
When considering maintenance intervals and operational life it is necessary to
consider the conditions of service to which the hoist is subjected. The following
factors influence mechanical performance of the hoist, and should be considered in
the course of determining service intervals and product life-cycle.
These include:
-Operational Time: Actual running time (determine by when the chain is
actually in motion) of hoist per hour or per work period.
-Load Distribution: Actual distribution or proportion of full or partial loads to
be handled by equipment.
-Work Distribution: Work may be concentrated during a short span, or uniformly
distributed over a work period. Work distribution is not a principle factor when
determining mechanical wear, but needs to be considered when calculating
operational time and periodic maintenance.
-Environmental Conditions: CLK Hoists are designed to operate in ambient
temperatures between -4° F (-20° C) and 122° F (50° C), and in atmospheres
with increased concentration of dust and soot, and high humidity. The product
is suitable for ATEX environments as noted on the product identification plate,
located on end of the hoist. When protected from weathering, the hoist is
suitable for permanent installation in outdoor locations, although
maintenance may be increased. The CLK series hoist is not designed for
permanent installation in outdoor marine environments.
Load Factor
Some hoist installations, such as assembly line operation, lifted load is repetitive
and easily recorded. Other the load is random and not easily characterized. The Mean
Effective Load Factor, also referred to as the Load Spectrum, refers to a theoretical
single load value that has the same effect on the hoist as various loads lifted by the
hoist during a specified time period. The mean effective load factor, LF, can be
expressed as:
Where:
LF = Mean Effective Load Factor (Load Spectrum): Mean effective load factor is
the ratio of mean effective load to rated load.
W = Load Magnitude: Load Magnitude is the ratio of the hoist operating load to
the hoist rated capacity. No load operation must be included in this
calculation. It is also necessary to take into account the weight of any dead
load used to facilitate rigging the load to the hoist hook.
P = Load Probability: Load probability is the ration of running time under each
load magnitude to the total hoist running time. The sum of all of load
probabilities used in the above equation must equal 1.0.
NOTICE
• Randomly distributed loads - A unit subjected to a random distribution of
loading will be assumed to lift load distributed evenly within the rated load of
the hoist in decreasing step of 20% of the previous load value. For the purposes
of maintenance, such units should be assumed to have a mean effective load
factor of 0.65.
Periodic Inspection
Refer to Table 2 “Inspection Classifications” on page 2 for suggested inspection
classifications for Periodic Inspection Intervals. Select conditions most appropriate
to application.
Maintain written records of periodic inspections to provide an accumulative basis for
continuing evaluation. Inspect all items listed in ‘Frequent Inspection‘ in the Product
Information Manual. Also inspect the following at the suggested intervals
recommended in Table 5 “Periodic Maintenance/Inspection Interval” on page 3.
1. Fasteners. Check all rivets, split pins, capscrews and nuts. Replace if missing or
tighten if loose.
2. All Components. Inspect for wear, damage, distortion, deformations and
cleanliness. If external evidence indicates damage, disassemble as required to
conduct a detailed inspection. Check gears, shafts, bearings, sheaves, chain
guides, springs and covers. Replace worn or damaged parts. Clean, lubricate and
reassemble.
3. Hooks. Inspect hooks carefully for cracks using magnetic particle or other
suitable non-destructive method. Inspect hook retaining parts. Tighten or repair
if necessary.
4. Load Chain Sprocket. Check for damage or excessive wear. Replace if necessary.
Observe the action of load chain feeding through hoist. Do not operate a hoist
unless load chain feeds through hoist and hook block smoothly and without
audible clicking or other evidence of binding or malfunctioning.
5. Motor. If performance is poor, disassemble motor and check for wear or damage
to bearings and shafts. Parts should be cleaned, lubricated and reassembled.
Replace worn or damaged parts.
6. Brake. Raise a load equal to rated capacity of hoist a few inches (cms) off the
floor. Verify hoist holds the load without drift. If drift occurs, disassemble.
Remove brake discs as described in “MAINTENANCE” on page 6. Check and clean
brake parts each time hoist is disassembled. Replace brake disc if thickness is
less than 7.0 mm (0.275 in.).
Publication Part/Document Number Publication Part/Document Number
Product Safety Manual MHD56295 Product Parts Information Manual MHD56407
Product Information Manual MHD56406
LF = W P + W P + W P + ... + W P
33
11
3
22
3
23
3
nn
Table 2: Inspection Classifications
Conditions Usage Load Characterization
Normal < = 25% duty cycle Regular
Heavy > 25% duty cycle Usually medium loads,
frequent max. loads
Severe Loads normally less than 50% of rated load with running time up to continuous; or, Loads normally above 50% of rated load
with running time up to 50% of work period.
Table 3: Hook Throat Normal and Discarded Width
Hoist
Model Capacity (metric tons)
Throat Width * Discard Width *
in. mm in. mm
CL125K 0.060
0.945 24 1.087 27.6CL250K 0.125
CL500K 0.250
* Dimensions are without latch.

Form MHD56408 Edition 1 3
WARNING
• Worn or improperly functioning brakes may cause excessive heat build up
and sparks.
7. Supporting Structure. Check for distortion, wear and continued ability to
support hoist and rated load.
8. Trolley (if equipped). Check that the trolley wheels track beam properly and
trolley is correctly adjusted in accordance with manufacturer’s literature. Check
that wheels and beam are not excessively worn and inspect side plates for
spreading due to bending. Do not operate hoist until problem has been
determined and corrected.
9. Load Chain End Anchors. Ensure both ends of load chain are securely attached.
Secure if loose, repair if damaged, replace if missing. Check chain stoppers are
correctly installed and functional.
10. Load Chain. Check the chain for stretching. Measure the load chain over eleven
link sections all along chain, paying particular attention to the most frequently
worked links. Refer to Dwg. MHP3118 on page 3, A. Gauge Length. When any
eleven links in the working length reaches or exceeds the discard length, replace
entire chain. Refer to Table 4 “Load Chain Normal and Discard Length” on page
3. Always use genuine Ingersoll Rand replacement chain. Zinc plated load chain
is standard on hoists.
(Dwg. MHP3118)
11. Chain Container (optional feature). Check for damage or excessive wear and
that chain container is securely attached to the hoist. Secure or replace if
necessary.
12. Limit Switch. Check limit switches function correctly.
13. Emergency Stop. During hoist operation verify emergency shut-off by activating
button. All operation must stop quickly. Stop button must reset properly.
14. Labels and Tags. Check for presence and legibility. Replace if necessary.
Records and Reports
•Inspection records, listing all points requiring periodic inspection should be
maintained for all load bearing equipment. Written reports based on severity of
service, should be made of the condition of critical parts as a method of
documenting periodic inspection. These reports should be dated, signed by the
person who performed the inspection, and kept on file where they are readily
available for review.
Maintenance Schedule
After considering the previous section, regarding loading, it is possible to determine
the necessary maintenance intervals. Given that the load spectrum has been
determined and the duration of use has been recorded, the following chart is
intended to be used to determine service intervals for major overhauls and unit gear
box lubrication. Accordingly, the following table is given:
Periodic Maintenance
While the information in the preceding section is used for major service intervals,
many items need to be checked at greater frequency depending on usage. The
following information is provided for that purpose, but it is important to note that
the information in the preceding section, regarding hours of service, is applicable in
all conditions of use. Refer to Table 5 “Periodic Maintenance/Inspection Interval” on
page 3.
Table 5: Periodic Maintenance/Inspection Interval
Table 4: Load Chain Normal and Discard Length
Hoist
Model Chain Normal Length Discard Length
in. mm in. mm
CL125K
4 x 12 DAT 5.197 132.0 5.276 134.0CL250K
CL500K
Load Spectrum
(LF) Characterization Timebefore
Overhaul
(hours)
Check Oil
Level (*)
(hours)
L1 - Light
0 < LF < = 0.50
Hoist is usually subject to very
small loads and in exceptional
cases only to maximum loads. 6,300
400
L2 - Medium
(normal)
0.5 < LF < = 0.63
Hoist is usually subject to small
loads but rather often to
maximum loads. 3,200
L3 - Heavy
0.63 < LF < = 0.80
Hoist is usually subject to
medium loads but frequently to
maximum loads. 1,600
L4 - Heavy
0.80 < LF < = 1.00
Hoist is usually subject to
maximum or almost maximum
loads. 800
(*) Operation specifics may warrant modification to this interval.
Gauge Length
A
Item Conditions
Normal Heavy Severe
Requirements of frequent inspection Annually Semi-
annually Quarterly
Evidence of loose bolts, nuts, rivets,
snap rings Annually Semi- annually Quarterly
Evidence of worn corroded, distorted,
or cracked parts such as suspension
housing, chain attachments, clevises,
yokes, suspension bolts, shafts,
gears, bearings, pins, rollers, and
locking and clamping devices
Annually Semi-
annually Quarterly
Evidence of damage to hook retaining
nuts or collars or pins, and welds or
rivets used to secure the retaining
members
Annually Semi-
annually Quarterly
Evidence of excessive wear, or
damage, to load sprockets Annually Semi- annually Quarterly
Evidence of excessive wear on motor
or load brake Annually Semi-
annually Quarterly
Evidence of damage to supporting
structure, and/or trolley, if used. Annually Semi- annually Quarterly
Product and safety label for legibility Annually Semi-
annually Quarterly
End connections of load chain Annually Semi-
annually Quarterly

4Form MHD56408 Edition 1
INSPECTION REPORT
* Maximum test load should never exceed 125% of rated capacity.
This form may be photocopied and used as an inspection record.
Ingersoll Rand CLK Air Hoist
Model Number: Date:
Serial Number: Inspected by:
Reason for Inspection: (Check Applicable Box)
1. Scheduled Periodic Inspection
(___ Quarterly ___ Semiannually ___ Yearly) Operating Environment:
Normal ___ Heavy ___ Severe ___
Calculated Load Factor Run Time ___ hours Since Last Overhaul
Total ___ hours
2. Discrepancy(s) noted during Frequent Inspection
3. Discrepancy(s) noted during maintenance
4. Other: ___________________________
Refer to the Performance Information Manual for frequent “INSPECTION” criteria. Also, refer to appropriate National Standards and Codes of practice. If in doubt about an
existing condition contact the nearest Ingersoll Rand Distributor or factory for technical assistance.
COMPONENT CONDITION CORRECTIVE
ACTION NOTES
Pass Fail Repair Replace
Fasteners
Gears
Shafts
Bearings ---
Load Bearing Sheave
Hook Block/Double-Reeved Pocket
Wheel
Chain Guides
Springs ---
Covers, Housings
Hooks ---
Top
Actual Hook Throat Width: ________ inches / ________ mm
(Refer to Table 1 in Product Information Manual for minimum/maximum acceptable widths.)
Hook Twist --- (maximum 10%)
Hook Crack Test Method Used: Dye Penetrant ________ Magnetic Particle ________ Other: ________
Bottom
Actual Hook Throat Width: ________ inches / ________ mm
(Refer to Table 1 in Product Information Manual for minimum/maximum acceptable widths.)
Hook Twist --- (maximum 10%)
Hook Crack Test Method Used: Dye Penetrant ________ Magnetic Particle ________ Other: ________
Hook Latch ---
Brake (100% Load Test) ---
Brake (Visual Inspection)
Tail Pin (End Anchor)
Load Chain: ---
Working length(s) maximum wear: ________ inches / ________ mm (Refer to Table 4 “Load Chain Normal and Discard Length” on page 3)
Supporting Structure
Labels and Tags ---
Other Components
(List in NOTES section)
Testing: Pass Fail NOTES
Operational (No Load)
Operational (100% Load)
Operational (Maximum Test Load*)

Form MHD56408 Edition 1 5
TROUBLESHOOTING
This section provides basic troubleshooting information. Specific causes to problems are best identified by thorough inspections performed by personnel instructed in safety,
operation and maintenance of this equipment. The chart below provides a brief guide to common hoist and trolley symptoms, probable causes and remedies.
Symptom Cause Remedy
Hoist will not operate.
No air supply to hoist, or too little CFM or PSI. Check PSI (bar) at hoist inlet. Refer to “SPECIFICATIONS” section in Product
Information Manual for correct CFM (cu.m/min) and PSI (bar).
Pendant lever sticking. Check pendant lever and restore free movement.
Pendant malfunction. Check PSI (bar) at pendant. Minimum operating pressure in pendant line is 60
PSI (4 bar).
Hoist is overloaded. Reduce load to within rated capacity.
Motor is damaged. Repair or replace. Refer to “MAINTENANCE” section on page 6.
Limit switch sticking. Check limit switch button moves freely. Clean and lubricate if sticking.
Brake is not releasing. Check brake release circuit and PSI (bar) at brake inlet (60 PSI (4 bar)
minimum).
Load continues to move when hoist is
stopped. ‘UP’ direction. Pendant lever sticking. Check lever and restore free movement.
Load continues to move when hoist is
stopped. ‘DOWN’ direction.
Pendant lever sticking. Check lever and restore free movement.
Hoist is overloaded. Reduce load to within rated capacity.
Brake is slipping. Check brake springs and brake disc linings for wear. Refer to the
“MAINTENANCE” section on page 6.
Hoist will not lift rated capacity.
Hoist is overloaded. Reduce load to within rated capacity.
No air supply to hoist or too little CFM or PSI
(cu. m/min or bar). Check PSI (bar) at hoist inlet. Refer to “SPECIFICATIONS” section in Product Information Manual Form for correct CFM (cu.m/min) and PSI (bar).
Brake is not releasing. Check brake release circuit and PSI (bar) at brake inlet (60 PSI (4 bar)
minimum).
Exhaust is restricted. Inspect vents and clean or replace muffling material.
Motor is damaged. Check for worn motor bearings.
Hook lowers but will not raise.
Hoist is overloaded. Reduce load to within rated capacity.
No air supply to hoist or too little CFM or PSI
(cu. m/min or bar). Check supply pressure at hoist inlet with hoist running at maximum lifting speed with no load.
Pendant malfunction. With up lever depressed verify airflow from pendant to hoist.
Load chain jumps on sprocket or is
making a snapping sound.
Worn or rusted chain. Refer to “OPERATIONAL CONDITIONS, INSPECTION AND REPAIRS” section on
page 2 to determine wear limit. Replace if necessary.
Incorrect chain. Replace with correct chain.
Worn pocket wheel or chain guide. Replace worn parts.
Capsized hook. Correct as described in “MAINTENANCE” section on page 6.
Hoist not in line with load. Align hoist with load. Do not “yard” or “side pull”.
Incorrectly reeved load chain. Check load chain is correctly reeved.
No oil on load chain. Lubricate load chain.
Trolley
(optional feature)
Trolley will not stop or trolley wheels slip.
Damaged beam. Repair or replace beam.
Excessive oil, grease or paint on track of
beam. Clean off oil, grease or paint.
Trolley not spaced for beam clearance. Check trolley spacing. Refer to the manufacturer’s literature.
Air-powered trolley does not operate.
Pendant lever sticking. Check lever and restore free movement.
No air supply to trolley or too little CFM or PSI
(cu. m/min or bar). Check pressure at trolley inlet. Refer to manufacturer’s specifications.

6Form MHD56408 Edition 1
MAINTENANCE
WARNING
• Never perform maintenance on the hoist while it is supporting a load.
• Before performing maintenance, tag controls:
WARNING - DO NOT OPERATE EQUIPMENT BEING REPAIRED.
• Only allow Ingersoll Rand trained technicians to perform maintenance.
• After performing any maintenance on the hoist dynamically test the hoist to
100% of its rated capacity, in accordance with ASME B30.16 standards, before
returning hoist to service. Static test at 125% of rated load required to validate
brake.
• Shut off air system and depressurize air lines before performing any
maintenance.
• Use of other than genuine Ingersoll Rand replacement parts may result in
safety hazards, decreased performance and increased maintenance and will
invalidate all warranties.
Maintenance
Correct disassembly (to prevent loss or damage of good parts), repair, assembly,
testing and adjusting are critical to proper product operation. Maintenance
procedures are technical in nature and require training and experience to accomplish
correctly. In addition, repair and testing require specialized equipment that is not
typically found at the hoist-mounting site.
Proper use, inspections and maintenance increase the life and usefulness of your
Ingersoll Rand equipment. During assembly, lubricate gears, nuts, capscrews and all
machined threads with applicable lubricants. Use of antiseize compound and/or
thread lubricant on capscrew and nut threaded areas prevents corrosion and allows
for easy disassembly of components.
It is extremely important that anyone involved with maintaining the hoist be
familiar with the servicing procedures of these products, and be physically capable of
conducting the procedures. These personnel shall have skills that include:
1. Proper and safe use and application of mechanics common hand tools as well as
special Ingersoll Rand or recommended tools.
2. Safety procedures, precautions and work habits established by accepted industry
standards.
Ingersoll Rand cannot know of, or provide all the procedures by which product
operations or repairs may be conducted and the hazards and/or results of each
method. If operation or maintenance procedures not specifically recommended by
the manufacturer are conducted, it must be ensured that product safety is not
endangered by the actions taken. If unsure of an operation or maintenance
procedure or step, personnel should place the product in a safe condition and
contact supervisors and/or the factory for technical assistance.
Maintenance Intervals
Refer to Table 5 ‘Maintenance Interval Chart’ on page 3 for recommended
maintenance schedule.
Adjustments
Disc Brake
Disc brake adjustment is not required.
If disc brake does not hold rated load, disassemble and repair. If brake slippage
occurs during tests prior to placing hoist in service or during normal use of hoist,
follow hoist disassembly procedure and check disc brake assembly (90) thickness.
Disc brake assembly thickness should be a minimum of 7.00 mm [0.275 in]. If this
dimension is less than recommended, the disc brake assembly (90) must be replaced.
Use the following procedure to replace the disc brake assembly.
Disassembly:
1. Remove the air supply from the hoist.
2. Position the hoist with the brake end facing up.
3. Loosen and remove the four capscrews (1) and lockwashers (2) in an alternating
pattern to evenly decrease the spring force between the piston housing (3) and
the piston (6). Set the capscrews and lockwashers (2) to the side.
4. Remove the piston housing (3) and six springs (4). Slide the piston (6) off the
gear case (14).
5. Remove the brake disc assembly (90) from the hex shaft. Inspect the brake disc
assembly for wear. If brake disc assembly thickness is uneven or less than 7.00
mm [0.275 in], replace the brake disc assembly.
6. Remove, discard and replace brake ‘O’ rings (7), (10), and (11).
7. For brake service only, no further disassembly is required.
Assembly:
1. Clean all parts removing all brake dust and any other contaminants.
2. Install replacement brake ‘O’ rings (7), (10), and (11). Apply ‘O’ ring lubricant to
‘O’ ring and ‘O’ ring contact surfaces prior to assembly.
3. Slide brake disc assembly (90) over hex shaft.
4. Align three holes in piston (6) with the three pins (87) extending from the gear
case brake friction surface and slide over ‘O’ rings until piston brake friction
surface contacts the disc brake assembly (90).
5. Position six springs into the counter bores on the piston (6). A small amount of
‘O’ ring lubricant may be used on the end of the springs to assist in positioning
the springs into their respective counter bores.
6. Align the piston housing (3) with the piston (6) and press firmly down on the
piston housing until it contacts the piston. While maintaining pressure on the
piston housing, Insert the four capscrews (1) and lockwashers (2) and tighten in
an alternating pattern. Torque to 4.5-5.5 Nm (40.0-48.5 in-lbs).
Load Chain Replacement
WARNING
• NEVER splice a load chain except when installing a new load chain by the
following method. Always discard link used to connect old chain with new.
Excessive chain wear cannot be detected by casual observation. Chain is case
hardened and once the case hardening is worn through, wear will progress rapidly
and the strength of the chain will be considerably reduced. Further, the chain will no
longer fit the chain sprocket properly, greatly increasing the chance of malfunction
and chain breakage. One pocket wheel will outlast several chains if chain is replaced
as recommended. The use of a worn chain will cause the chain sprocket to wear
rapidly. If the chain is visibly damaged, examine pocket wheel, chain guide and
splitter. Install a new pocket wheel if the old one is visibly worn. Install a new guide
if old one is broken or distorted.
It is suggested that a short length of load chain be available when replacing hoist
load chain. Feeding a short length of load chain through bottom block assembly or
power head assembly prior to installing new load chain may simplify installation.
Weld on perpendicular load chain must always face away from hoist pocket wheel.
Refer to Dwg. MHP0472 on page 7, A. Load Chain; B. Chain Wheel; C. Chain Weld To
Outside On Powered Chain Wheels; D. Standing Link.
NOTICE
• For ease of installation, do not remove old chain from hoist. Use the old
chain to feed new chain through hoist.
1. Hoist must be hung and connected to air supply. Reduce air pressure to 60 psi (4
bar).
2. Remove chain container, if used.
3. Disconnect chain end from hoist body if attached.
4. Remove capscrew (101) and chain stop (100), if equipped.
5. Remove load hook.
6. Run hoist slowly in lifting direction until chain free end is approximately 2 ft (60
cm) from hoist.
7. Using an abrasive wheel, cut a section from the last link as shown in Dwg.
MHP0817 on page 6, A. ‘A‘ dimension; B. ‘C‘ Link. Use a ‘C‘ link which is the same
size as the chain. Refer to Table 6 ‘ ‘C‘ Link Dimension’ on page 6.
(Dwg. MHP0817)
CAUTION
• Do not distort link in any manner. Link must be able to pass over the chain
sprocket and idler wheels without binding.
8. Connect new chain to old chain by hooking end of new chain onto ‘C‘ link. Make
certain welds and links on new chain match positioning of welds and links on
chain being replaced.
9. Slowly run hoist in raise direction, running off old chain and reeving new chain
over the chain wheel. The first link of new chain over the chain wheel must be a
standing link. Refer to Dwg. MHP0472 on page 7.
Table 6: ‘C’ Link Dimension
Hoist Model Chain Size ‘A’ Dimension
mm in. mm
CL125K
4 x 12 0.236 6CL250K
CL500K
A
B
‘C’ Link
‘A’ Dimension

Form MHD56408 Edition 1 7
(Dwg. MHP0472)
NOTE: Dwg. MHP0472 is a reference only, pocket wheel may differ in look.
10. Reinstall load hook to load side of chain. Connect free end of chain to hoist
body.
WARNING
• Ensure chain does NOT become twisted during reeving. All chain welds must
align while chain is hanging free.
Refer to Dwg. MHP3113 on page 7 for single reeve and MHP3114 on page 7 for
double reeve.
Single Reeve
(Dwg. MHP3113)
Double Reeve
(Dwg. MHP3114)
To feed load chain through bottom hook assembly:
1. Install the ‘C’ link in the last link of the load chain extending from the hoist (A).
Connect the new load chain to the ‘C’ link. The end link must be a standing link
(perpendicular to the axle of hoist sprockets).
2. Run the hoist to feed the chain through the hoist body and down to (C) on the
hook block.
3. The axis of the pocket wheel (27) in the hook block assembly must be
perpendicular to the rotational axis of the pocket wheel (27) of the hoist
4. Insert the last link of the load chain in the opening to bottom block (C). The
first link must be inserted parallel to the axis. The sprocket of bottom hook
assembly and the following standing links must have the welds turned to the
outside position with the sprocket. Refer to Dwg. MHP0472 on page 7.
5. After exiting the bottom hook assembly at (D), position the standing link of the
chain at (D) in the slot of the attachment link (44) and press spring pin (43)
through to capture the load end of the chain.
6. Assemble attachment link (44) into the pocket under the loaded side of the
hoist. Slide a shoulder screw (48) through capturing the attachment link. Thread
a flange nut (31) onto the shoulder screw until it contacts the screw shoulder.
Thread a jam nut (30) onto the shoulder screw and torque to 4.5-5.5 Nm (40.0-
48.5 in-lbs).
WARNING
• The chain must not be twisted at any point.
7. On the free end of the load chain, position the standing link of the chain in the
slot of the attachment link (44) and press spring pin (43) through to capture the
free end of the chain.
8. Assemble the attachment link (44) into the pocket opposite the loaded side of
the hoist. Slide a shoulder screw (48) through capturing the attachment link.
Thread a flange nut (31) onto the shoulder screw until it contacts the screw
shoulder. Thread a jam nut (30) onto the shoulder screw and torque to 4.5-5.5
Nm (40.0-48.5 in-lbs).
Chain
Wheel
Chain Weld
To Outside On
Powered Chain
Wheels
Standing
Link
Load Chain
A
D
B
C
Weld
19.5 mm
(0.77 in.)
Weld
Facing
Down
Weld Weld
Weld
34.7 mm
(1.37 in.)

8Form MHD56408 Edition 1
Determining Twisted, Kinked or ‘Capsized‘ Load Chain
Ensure chain is not twisted, kinked or ‘capsized‘ during installation. Refer to Dwg.
MHP0020 on page 8, A. Appearance of Chain Not Twisted; B. Appearance of Chain
Twisted.
(Dwg. MHP0020)
Disassembly
General Disassembly Instructions
Refer to the Product Parts Information Manual for drawings and item numbers
referenced in the “MAINTENANCE” section, unless otherwise noted.
The following instructions provide the necessary information to disassemble, inspect,
repair, and assemble the hoist. Parts drawings are provided in the Product Parts
Information Manual.
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 in a clean dust free work area. 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 flame to free it for removal, unless the part being
heated is already worn or damaged beyond repair and no additional damage will
occur to other parts. 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, gaskets and ‘O‘ rings should be discarded once they have been removed.
New seals, gaskets and ‘O‘ 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, machined surfaces and housings.
7. Do not remove any part which is a press fit in or on a subassembly unless the
removal of that part is necessary for repairs or replacement.
8. When removing ball bearings from shafts, it is best to use a bearing puller. When
removing bearings from housings, drive out the bearing with a sleeve slightly
smaller than the outside diameter of the bearing. The end of the sleeve or pipe
which contacts the bearing must be square. Protect bearings from dirt by keeping
them wrapped in clean cloths.
Hoist Disassembly
NOTICE
• It is recommended to remove load chain and chain bucket for a complete
hoist disassembly.
1. Shut off, bleed down air supply then disconnect and tag air lines.
2. Remove hoist from its mounting and place in clean work area on a sturdy
workbench.
3. Position several blocks of wood on the work bench and stand the hoist in a
vertical position with the motor end up.
Chain Bag Container Disassembly
Refer to Dwg. MHP2788
1. Remove capscrews (201) and lockwashers (2) and pull chain bag container sub-
assembly from the hoist.
2. Remove capscrews (204), lockwashers (203) and nuts (202) that secure brackets
(203) to chain bag container (209).
Bottom Hook Disassembly
Model CL125K and CL250K Single Fall
Refer to Dwg. MHP2961
1. Remove capscrews (116) and nuts (122).
2. Separate the two halves of the bottom blocks (102) and remove the load chain
(99).
3. Remove the bottom hook (115), keepers (113), thrust washers (111,112) and
thrust bearing (110). Slide the thrust washers and thrust bearing down the
bottom hook shank shoulder to remove the keepers. Slide the thrust washers and
thrust bearing off of the bottom hook shank.
Model CL500K Double Fall Disassembly
Refer to Dwg. MHP2969
1. Remove capscrews (116), lockwashers (109), capscrew (103) and nut (122).
2. Separate the two halves of the bottom blocks (108) and remove the load chain
(99).
3. Remove the pocket wheel (107) and thrust washers (105).
4. Remove the bottom hook (115), keepers (113), thrust washers (111,112), thrust
bearing (110). Slide the thrust washers and thrust bearing down the bottom
hook shank shoulder to remove the keepers. Slide the thrust washers and thrust
bearing off of the bottom hook shank.
Top Hook Disassembly
Model CL125K and CL250K Single Fall and CL500K Double Fall
Refer to Dwg. MHP2951
1. Remove two jam nuts (30) and two flange nuts (31) and slide the two shoulder
screws (48) from the hoist.
2. Pull the top hook (93) sub-assembly from the pocket in the top of the hoist.
Remove the capscrew (98) and separate the left hook block (96) from the right
hook block (95) to remove the top hook (93).
3. Pull the alignment plate (97) from the pocket in the top of the hoist.
Valve Disassembly
Refer to Dwg. MHP2952
1. Position the hoist with the valve end facing up.
2. Remove capscrews (85) and pull the limit switch lever (84) from the hoist.
3. Remove capscrews (67) and lockwashers (2) from the valve cover (65). Pull the
valve sub-assembly from the rear of the hoist.
4. Lift the motor gasket (81) off of the motor housing (47).
5. Using a pick, remove the ‘O’ ring (11) from the counter bore of the motor
housing (47).
6. Remove the retaining ring (50) from the valve chest (57). Remove the inlet cap
(52), buffer (53), spring (54) and washer (55) from the valve chest. Remove the
‘O’ ring (51) from the inlet cap. Repeat for other side.
7. Remove the retaining ring (50), muffler screen (56) and muffler (25) from the
rear of the valve cover (65).
8. Remove the retaining ring (50), valve cap (83) and ‘O’ ring (51) from the bottom
of the valve chest (57).
9. Remove the capscrews (1) and lockwashers (2) from the valve cover (65) and
separate the valve cover from the valve chest (57). Remove the gasket (64) and
pull the muffler (79) out of the valve chest.
10. Slide the limit switch shaft (63) out of the valve chest (57) and remove the pivot
arm sub-assembly from the bottom of the valve chest.
11. Inspect the pivot arm sub-assembly for wear. If necessary, press the dowel pin
(39) out of the lower pivot arm (82) and upper pivot arm (80) to separate the
two.
12. Slide the valve (62) out of the valve cartridge (61).
13. Remove the capscrew (85) from the valve chest (57). Slide the valve cartridge
(61) from the valve chest and remove the four s (60) from the valve cartridge.
14. Remove the retaining ring (50) shuttle valve cartridge (59) and ball (58) from
the valve chest (57). Remove the ‘O’ ring (51) from the shuttle valve cartridge.
15. Remove the retaining ring (50) and muffler screen (56) from the valve chest
(57).
16. Press the bushing (71) from the valve chest (57).
Motor Disassembly
Refer to Dwg. MHP2952
1. Pull the dowel pin (78) from the rear endplate (77) protruding from the motor
housing (47).
2. Pull the motor sub-assembly out of the motor housing (47) bore.
3. Remove the motor clamp ‘O’ ring (69) from the motor housing (47) bore.
4. Orient the motor sub-assembly with the rotor (75) spade end facing up. Hold the
cylinder (74) and using a rubber hammer carefully tap the rotor spade end until
the press on the front rotor bearing (70) releases. This will allow the rotor and
rear endplate (77) to fall free. Remove the front rotor bearing from the front
endplate (73).
5. Remove the six vanes (76) from the rotor.
6. Position the rotor and rear endplate in a press on the rear endplate face with the
rotor spade end facing down. Press the rotor out of the rear rotor bearing (70).
Remove the rear rotor bearing from the rear endplate.
A
Appearance of
Chain Not Twisted
Appearance o
f
Chain Twisted
B

Form MHD56408 Edition 1 9
Brake Disassembly
Refer to Dwg. MHP2953
1. Position the hoist with the brake end facing up.
2. Loosen and remove the four capscrews (1) and four lockwashers (2) in an
alternating pattern to evenly decrease the spring force between the piston
housing (3) and the piston (6).
3. Remove the piston housing (3) and six springs (4). Slide the piston (6) off the
gear case (14).
4. Remove the set screw (5) from the piston housing (3).
5. Remove the brake disc assembly (90) from the hex shaft protruding from the gear
case (14).
6. Remove brake ‘O’ ring (7) from the piston (6).
7. Using a pick, remove the ‘O’ ring (11) from the counter bore of the gear case.
Transmission Disassembly
Refer to Dwg. MHP2953 and MHP2951
1. Position the hoist so the bottom is facing up.
2. Remove the magnetic drain plug (29) from the gear housing (34). Invert the
hoist over a container and drain the fluid from the transmission. Remove the fill
plug (35) and breather plug (36) from the gear housing.
3. Position the hoist so the motor housing (47) is facing up.
4. Remove the external retaining ring (17) from the pocket wheel (27).
5. Remove the four capscrews (1) and four lockwashers (2) form the motor housing
(47).
6. Separate the motor housing from the gear case (34).
7. Using a pick, remove the ‘O’ ring (11) from the counter bore of the gear housing
(34).
8. Remove the two dowel pins (39) from the splitter (38) and slide the splitter out
of the pocket wheel (27).
9. Remove the chain guide (40) from the gear housing (34).
10. Position the hoist so the gear case (14) is facing up.
11. Remove the four capscrews (86) and four lockwashers (2) from the gear case
(14). Turn the gear case approximately 45 degrees. While pushing on the hex
protruding from the gear case, pull the gear case from the gear housing (34).
12. Using a pick, remove the ‘O’ ring (11) from the counter bore of the gear housing
(34).
13. Remove the gear frame assembly (16) from the pocket wheel (27).
14. Pull the pocket wheel (27) sub-assembly from the gear housing (34).
Pocket Wheel Disassembly
Refer to Dwg. MHP2951 and MHP2953
1. Remove the bearing (28) (inner race press) from the pocket wheel (27).
2. Support the pocket wheel (27) in a press with the gear end facing down and
press the seal (15) out of the pocket wheel.
Gear Case Disassembly
Refer to Dwg. MHP2951
1. Remove the two ‘O’ rings (7) and ‘O’ ring (10) from the gear case (14).
2. Support the gear case (14) with the gear end facing down and press the seal (15)
out of the gear case.
3. It is not recommended the three dowel pins (87) be removed from the gear case
(14). If the dowel pins are damaged, the gear case, seal (15) and three dowel
pins should be replaced.
Motor Housing Disassembly
Refer to Dwg. MHP2951
1. Remove the retaining ring (41) from the motor housing (47).
2. Position the motor housing (47) in a press with the motor bore facing up and
press the bearing (42) from the motor housing.
3. Press the bushing (71) from the motor housing (47).
Gear Housing Disassembly
Refer to Dwg. MHP2951
1. Remove the ‘O’ ring (7) from the gear housing (34).
2. It is not recommended the two dowel pins (37) be removed from the gear
housing (34). If the dowel pins are damaged, the gear housing and two dowel
pins should be replaced.
Cleaning, Inspection and Repair
Use the following procedures to clean, inspect, and repair the components of the
hoist system.
Cleaning
CAUTION
• Bearings that are loose, worn or rotate in the housing 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. 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 may be necessary to carefully
scrape old Loctite® from the bushing bore. Dry each part using low pressure, filtered
compressed air.
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 all bearings for play, distorted races, pitting and roller or ball wear or
damage. Inspect bearings for freedom of rotation. Replace bearings if rotation is
rough or bearings are excessively worn.
4. Inspect shafts for ridges caused by wear. If ridges caused by wear are apparent
on shafts, replace the shaft. Inspect all surfaces on which oil seal lips seat.
These surfaces must be very smooth to prevent damage to the seal lip.
5. Inspect all threaded items and replace those having damaged threads.
6. Inspect the brake for warpage or other damage, and replace as necessary.
7. Measure the thickness of the brake. The brake must show an even wear pattern.
If the brake is 0.275 in. (7 mm) or less, replace.
Repair
Actual repairs are limited to the removal of small burrs and other minor surface
imperfections from gears and shafts. Use a fine stone or emery cloth for this work.
Do not use steel wool.
1. Worn or damaged parts must be replaced. Refer to the applicable Product Parts
Information manual 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.
7. Replace all gaskets, oil seals, and ’O’ rings removed during hoist disassembly.
Hoist Assembly
Gear Housing Sub-assembly
Refer to Dwg. MHP2951
1. Press two dowel pins (37) into gear housing (34) until dowel pins bottom out in
the holes.
2. Apply ‘O’ ring lubricant to ‘O’ ring (7) and the internal ‘O’ ring groove of the gear
housing (34). Insert ‘O’ ring into gear housing ‘O’ ring groove.
Motor Housing Sub-assembly
Refer to Dwg. MHP2951
1. Support the motor housing (47) with the chain guide end facing up. Press
bushing (71) into motor housing until flush with surface.
2. Press the bearing (42) (outer race press) into the motor housing (47) until it
contacts the shoulder.
3. Insert the retaining ring (41) into the groove of the motor housing (47).
Gear Case Sub-assembly
Refer to Dwg. MHP2951
1. Support the gear case (14) in a press with the gear end facing up. With the lip
side facing up, press seal (15) into the gear case until flush with surface.
2. Invert the gear case (14) in the press so the gear end is facing down. Press three
dowel pins (87) into the gear case until the dowel pins bottom out in the holes.
3. Apply ‘O’ ring lubricant to ‘O’ rings (10), two (7) ‘O’ rings and the ‘O’ ring grooves
of the gear case (14). Insert ‘O’ rings into gear case ‘O’ ring grooves.
Pocket wheel Sub-assembly
Refer to Dwg. MHP2951 and MHP2953
1. Support the pocket wheel (27) in a press with the gear end facing up. With the
lip side facing up, press seal (15) into the pocket wheel until flush with surface.
2. Invert the pocket wheel (27) in the press so the gear end is facing down. Press
the bearing (28) (inner race press) onto the pocket wheel until it contacts the
shoulder.
Motor Sub-assembly
Refer to Dwg. MHP2952
1. Prior to assembly, soak six vanes (76) in IR #10 oil or equivalent air line lube.
2. Support rotor (75) body in a press with the spade end facing down. Position the
rear endplate (77) over the rear rotor shaft. Using an offset punch, press bearing
(70) (inner race press) onto rotor shaft. Rotor should spin freely with no drag on
the endplate. Refer to Dwg. MHP3115 on page 10.

10 Form MHD56408 Edition 1
Motor Bearing Offset Punch
(Dwg. MHP3115)
3. Invert the motor sub-assembly and position cylinder (74) over the rotor (75)
aligning the exhaust holes to the correct orientation. When looking at the motor
assembly from the spade end of the rotor, the dowel pin hole in the rear
endplate (77) and cylinder should be at bottom center and the exhaust holes in
the cylinder should be in the upper right quadrant.
4. Install six vanes (76) into the rotor (75) slots. Coat all surfaces liberally with IR
#10 oil or equivalent air line lube.
5. Support the rear shaft of the rotor (75) in a press. Position the front endplate
(73) over the front rotor shaft. Using the offset punch, press bearing (70) (inner
race press) onto rotor shaft.
6. Insert the dowel pin (78) into the motor sub-assembly. Place the motor sub-
assembly in a 'V' block. The rotor (75) should spin freely in assembly with no
drag between parts.
Pivot Arm Sub-assembly
Refer to Dwg. MHP2952
1. Support the lower pivot arm (82) in a press with the chamfer in the small hole
facing up. Position the upper pivot arm (80) into the slot of the lower pivot arm
and insert the dowel pin (39) into the hole. Using a punch, press the dowel pin
until it contacts the face supporting the lower pivot arm in the press.
Valve Sub-assembly
Refer to Dwg. MHP2952
1. Support the valve chest (57) in a press with the motor bore side facing up. Press
the bushing (71) into the valve chest until flush with the surface.
2. Insert the muffler screen (56) into the exhaust bore of the valve chest (57).
Insert the retaining ring (50) into the groove of the valve chest (57).
3. Apply ‘O’ ring lubricant to two ‘O’ rings (51) and the ‘O’ ring grooves of the
shuttle valve cartridge (59). Insert ‘O’ rings into shuttle valve cartridge ‘O’ ring
grooves.
4. Insert the ball (58) into the shuttle valve bore of the valve chest (57). Assemble
the shuttle valve cartridge (59) and ‘O’ rings (51) into the shuttle valve cartridge
bore of the valve chest. Insert the retaining ring (50) into the groove of the
valve chest (57).
5. Apply ‘O’ ring lubricant to four ‘O’ rings (60) and the ‘O’ ring grooves of the valve
cartridge (61). Insert ‘O’ rings into valve cartridge ‘O’ ring grooves.
6. Apply a liberal amount ‘O’ ring lubricant to the valve cartridge bore of the valve
chest (57) and outside diameter of the valve cartridge (61). Align the valve
cartridge with the valve cartridge bore of the valve chest with the flat section
facing down and using constant pressure, slide the valve cartridge into the valve
chest until it is centered. Thread the capscrew (85) into the valve chest through
the alignment hole in the valve cartridge and torque to 4.5-5.5 Nm [40.0-48.5
in-lbs].
7. Position the valve chest (57) with the bottom hole facing up. Coat the valve
cartridge (61) bore and outside diameter of the valve (62) with IR #10 oil or
equivalent air line lube. Orient the hole in the valve vertically and slide the valve
into the valve cartridge.
8. Apply ‘O’ ring lubricant between the joint of the lower pivot arm (82) and upper
pivot arm (80). Insert the pivot arm sub-assembly into the valve chest (57)
opening allowing the upper pivot arm to engage the vertically oriented hole in
the valve (62).
9. Apply IR #10 oil or equivalent air line lube to the inside diameter of the bushing
(71) pressed into the valve chest (57). With the valve chest hole still facing up,
orient the flat on the limit switch shaft (63) facing up and slide the limit switch
shaft into the valve chest and internal hex of the lower pivot arm (82). Carefully
actuate the limit switch shaft to check for smooth valve operation. There should
be no drag between the parts.
10. Apply ‘O’ ring lubricant to the ‘O’ ring (51) and ‘O’ ring counter bore of the valve
chest (57). Insert ‘O’ ring into valve chest ‘O’ ring counter bore. Insert the valve
cap (83) into the valve chest and using constant pressure, push the valve cap
into the valve chest. Insert the retaining ring (50) into the groove of the valve
chest (57).
11. Taking care to prevent the limit switch shaft (63) from becoming disengaged
from the lower pivot arm (82), position the valve chest (57) with the motor bore
end facing down.
12. Insert the muffler (79) into the valve chest (57). Push the muffler into the slot
until it is completely below the surface. Position the gasket (64) and valve cover
(65) onto the valve chest. Install the two capscrews (1) and lockwashers (2)
through the valve cover (65) and torque to 2.7-3.3 Nm [24.0-29.0 in-lbs].
13. Insert the muffler (25) and muffler screen (56) into the exhaust bore of the
valve cover (65). Insert the retaining ring (50) into the groove of the valve cover
(65).
14. Insert washer (55), buffer (53) and spring (54) into valve chest (57). Apply ‘O’
ring lubricant to ‘O’ ring (51) and the ‘O’ ring groove of the inlet cap (52). Insert
‘O’ ring into valve cap ‘O’ ring groove. Insert the inlet cap (52) into the valve
chest and using constant pressure, push the inlet cap into the valve chest. Insert
the retaining ring (50) into the groove of the valve chest (57). Repeat for other
side.
15. Position the limit switch lever (84) over the limit switch shaft (63). Apply thread
locking adhesive to two capscrews (85) and thread into limit switch shaft.
Torque to 2.7-3.3 Nm [24.0-29.0 in-lbs].
Neutered Hoist Body Assembly
Refer to Dwg. MHP2951 and MHP2953
1. Support the pocket wheel (27) sub-assembly in a press with the gear end facing
down. Position the gear housing (34) sub-assembly over the bearing (28) and
using constant pressure, press the gear housing onto the bearing until it
contacts the shoulder.
2. Align the holes of the splitter (38) with the holes of the gear housing (34) and
slide the splitter into the groove of the pocket wheel (27). Insert two dowel pins
(39) through the splitter and gear housing.
3. Assemble the chain guide (40) into the gear housing (34).
4. Apply ‘O’ ring lubricant to the ‘O’ ring (11) and ‘O’ ring counter bore of the gear
housing (34). Insert ‘O’ ring into gear housing ‘O’ ring counter bore.
5. With the pocket wheel (27) still supported, slide the motor housing (47) sub-
assembly over the bearing (42) until the gear housing (34) and motor housing
contact.
6. Assemble the retaining ring (68) onto the pocket wheel (27).
7. Install the four capscrews (1) and lockwashers (2) through the motor housing
(47) and torque to 4.5-5.5 Nm [40.0-48.5 in-lbs].
8. Position the gear case assembly on a work surface with the motor housing (47)
facing down.
9. Coat the lip of seal (15) in the pocket wheel (27) sub-assembly and the seal
contact surfaces of the gear frame assembly (16) with ‘O’ ring lubricant. With the
slotted shaft end facing down and taking care not to damage the seal, slide the
gear frame assembly into the pocket wheel (27) until the bearing contacts the
shoulder.
10. Apply ‘O’ ring lubricant to the ‘O’ ring (11) and ‘O’ ring counter bore of the gear
housing (34). Insert ‘O’ ring into gear housing ‘O’ ring counter bore.
11. Coat the lip of seal (15) in the gear case (14) sub-assembly and the seal contact
surfaces of the gear frame assembly (16) with ‘O’ ring lubricant. With the gear
end facing down and taking care not to damage the seal, slide the gear case sub-
assembly over the hex end of the shaft and into the gear housing (34) until it
contacts the shoulder.
12. Install the four capscrews (86) and lockwashers (2) through the gear case (14)
and torque to 4.5-5.5 Nm [40.0-48.5 in-lbs].
13. Invert the hoist body sub-assembly so the motor housing (47) is facing up.
14. Coat rotor (75) spade end and the gear frame assembly (16) slotted shaft end
with IR # 80179138 Grease. Wipe all excess from the motor bore in the motor
housing (47).
15. Place motor clamp ‘O’ ring (69) in the bore of the motor housing (47).
16. Remove the dowel pin (78) from the motor sub-assembly and replace with an
extended pin approximately twice as long. Position the extended dowel pin in
the motor housing (47) alignment hole and slide the motor sub-assembly into
the motor housing. If necessary the hex end of the gear frame assembly (16)
shaft can be rotated to align the slot with the spade end of the rotor (75).
Remove the extended dowel pin and replace with the dowel pin (78).
17. Apply ‘O’ ring lubricant to the ‘O’ ring (11) and ‘O’ ring counter bore of the motor
housing (47). Insert ‘O’ ring into motor housing ‘O’ ring counter bore.
18. Position motor gasket (81) over the rear endplate (77) protruding from the
motor housing (47).
19. Apply IR #10 oil or equivalent air line lube to the inside diameter of the bushing
(71) pressed into the motor housing (47).
20. Pilot the valve sub-assembly over the rear endplate (77) protruding from the
motor housing (47) while aligning the limit switch shaft (63) with the bushing
(71). Install the four capscrews (67) and lockwashers (2) through the valve
cover (65). Torque the four capscrews (67) and two capscrews (1) and tighten in
an alternating pattern. Torque to 4.5-5.5 Nm [40.0-48.5 in-lbs].
21. Slide brake disc assembly (90) over hex shaft.
22. Apply ‘O’ ring lubricant to ‘O’ ring (7) and the ‘O’ ring groove of the piston (6).
Insert ‘O’ ring into piston ‘O’ ring groove.
23. Apply ‘O’ ring lubricant to the ‘O’ ring (11) and ‘O’ ring counter bore of the gear
case (14). Insert ‘O’ ring into gear case ‘O’ ring counter bore.
24. Align three holes in piston (6) with the three dowel pins (87) extending from the
gear case brake friction surface and slide over ‘O’ rings until piston brake friction
surface contacts the disc brake assembly (90).
25. Position six springs into the six counter bores on the piston (6). A small amount
of ‘O’ ring lubricant may be used on the end of the springs to assist in
positioning the springs into their respective counter bores.
26. Apply thread locking adhesive or equivalent to set screw (5) and thread into
piston housing (3). Torque to 2.7-3.3 Nm [24.0-29.0 in-lbs]. Remove any excess
thread locking adhesive from the piston housing.
27. Align the piston housing (3) with the piston (6) and press firmly down on the
piston housing until it contacts the piston. While maintaining pressure on the
piston housing, Insert the four capscrews (1) and lockwashers (2) and tighten in
an alternating pattern. Torque to 4.5-5.5 Nm [40.0-48.5 in-lbs].
0.013 mm
(0.0005 in.)

Form MHD56408 Edition 1 11
28. Align the holes in the nameplate (91) with the holes on the front of the piston
housing (3) and adhere it in place. Tap four rivets (12) to secure the nameplate
to the piston housing.
29. Apply IR # SMB-441 thread sealant to the threads of all plugs. Thread the
magnetic drain plug (29) into the bottom hole of the gear housing (34) and the
level plug (35) into the side hole of the gear housing. Torque the two plugs to
hand tight plus 1 to 1 ½ turns.
30. Fill the transmission through the top fill hole with 39.0 ml [1.3 oz] of Dexron VI
ATF.
31. Apply IR #SMB-441 thread sealant to the threads of the breather plug (36) and
thread into the gear housing (34). Care must be taken to prevent the leaking
fluid from the breather plug.
32. Clean all surfaces of the hoist of any contaminants such as grease or oil and if
necessary, apply two appropriate capacity labels (46) on the motor housing (47)
and the warning label (33) to the gear case (34).
Pendant Hose Attachment
Refer to Dwg. MHP2964 and MHP2952
1. Apply IR # SMB-441 thread sealant to the threads of three adapters (137) and
thread into the valve cover (65). Torque to hand tight plus 1 to 1-1/2 turns.
2. Apply IR # SMB-441 thread sealant to the threads of three adapters (137) and
thread into the pendant assembly (114). Torque to hand tight plus 1 to 1-1/2
turns.
3. When looking at the neutered hoist body assembly from the valve cover (65) end
the ‘UP’ inlet is on the right and the ‘DOWN’ inlet is on the left. The ‘UP’ and
‘DOWN’ inlets are over their corresponding button on the pendant assembly
(114). The supply line is in the center on both the neutered hoist body assembly
and pendant assembly. Torque all connections to 18.00-20.00 Nm [159.00-
177.00 in-lbs].
4. Attach the supply line with the warning card closest to the pendant assembly
(114) to the center inlet of both the neutered hoist body assembly and pendant
assembly. Attach the ‘UP’ and ‘DOWN’ inlets to both the neutered hoist body
assembly and pendant assembly.
5. Attach s-hook (138) to the pendant assembly (114) and strain relief in hose
assembly (139) closest the pendant assembly and crimp both ends to secure to
both.
6. Slide the support (66) through the end of the strain relief in the hose assembly
(139) closest the neutered hoist body assembly. Assemble the two lockwashers
(2) to the two capscrews (86). Insert the two capscrews and two lockwashers
through the support and thread into the valve cover (65) to secure the strain
relief to the neutered hoist body assembly. Torque to 4.5-5.5 Nm [40.0-48.5 in-
lbs].
Top Hook Assembly
Model CL125K and CL250K Single Fall
Refer to Dwg. MHP3116 on page 11 and Dwg. MHP2951.
1. Apply IR # 67 grease to top hook (93) shank.
2. Assemble top hook (93) into hook block (95) and hook block (96). Slide two
shoulder screws (48) through holes to align the hook blocks. Thread capscrew
(98) into hook blocks and torque to 9.0-11.0 Nm [79.5-97.5 in-lbs]. Remove the
two shoulder screws and rotate the top hook in the sub-assembly, there should
be no drag between the parts.
Single Fall Top Hook Position
(Dwg. MHP3116)
3. There are two mounting options available when mounting the top hook (93) to
the hoist. Refer to Dwg. MHP3113 on page 7 for centerline of hoist.
a. Swivel Mount - Place the alignment plate (97) into the pocket on top of the
hoist with the diameter closest to the centerline of the hoist.
b. Rigid mount - Place the alignment plate (97) into the pocket on top of the
hoist with the square shape closest to the centerline of the hoist.
4. Insert the top hook sub-assembly into the pocket on top of the hoist with the
top hook (93) closest to the centerline of the hoist. If a rigid mount is being
utilized, be sure the hook is oriented in one of the desired 90 degree increments.
5. Assemble two shoulder screws (48) into the gear housing (34) through the hook
sub-assembly and motor housing (47). Thread two flange nuts (31) onto the
shoulder screws until they contact the screw shoulder. Thread two jam nuts (30)
onto the shoulder screws and torque to 4.5-5.5 Nm [40.0-48.5 in-lbs].
6. Insert two plugs (13) into the two lower left reeving points when looking from
valve cover (65) end of the hoist.
Model CL500K Double Fall
Refer to Dwg. MHP3117 on page 11 and Dwg. MHP2951.
1. Apply IR # 67 grease to top hook (93) shank.
2. Assemble top hook (93) into hook block (95) and hook block (96). Slide two
shoulder screws (48) through holes to align the hook blocks. Thread capscrew
(98) into hook blocks and torque to 9.0-11.0 Nm [79.5-97.5 in-lbs]. Remove the
two shoulder screws and rotate the top hook in the sub-assembly, there should
be no drag between the parts.
Double Fall Top Hook Position
(Dwg. MHP3117)
1. There are two mounting options available when mounting the top hook (93) to
the hoist. Refer to Dwg. MHP3114 on page 7 for centerline of hoist.
a. Swivel Mount - Place the alignment plate (97) into the pocket on top of the
hoist with the diameter farthest from the centerline of the hoist.
b. Rigid mount - Place the alignment plate (97) into the pocket on top of the
hoist with the square shape farthest from the centerline of the hoist.
2. Insert the top hook sub-assembly into the pocket on top of the hoist with the
top hook (93) farthest from the centerline of the hoist. If a rigid mount is being
utilized, be sure the hook is oriented in one of the desired 90 degree increments.
3. Assemble two shoulder screws (48) into the gear housing (34) through the hook
sub-assembly and motor housing (47). Thread two flange nuts (31) onto the
shoulder screws until they contact the screw shoulder. Thread two jam nuts (30)
onto the shoulder screws and torque to 4.5-5.5 Nm [40.0-48.5 in-lbs].
Bottom Hook Assembly
Model CL125K and CL250K Single Fall
Refer to Dwg. MHP2961
1. Apply IR # 67 grease to all surfaces of thick thrust washer (112), thrust bearing
(110) and thin thrust washer (111).
2. Assemble thick thrust washer (112) onto the bottom hook (115) shank to the
hook shoulder with the chamfer side facing away from the hook. Assemble the
thrust bearing (110) and thin thrust washer (111) onto the bottom hook shank.
3. Apply IR # 67 grease to the bottom hook (115) shank and assemble the two
keepers (113) to the bottom hook shank. Slide the thick thrust washer (112),
thrust bearing (110) and thin thrust washer (111) up to capture the keeper on
the bottom hook shank.
4. Place bottom hook (115) sub-assembly into bottom block (102).
5. Turn the last link of the load chain (99) so the weld is facing down and insert
into the bottom block (102). Attach the other bottom block and position two
nuts into the cast hex shapes of the bottom blocks and thread the two capscrews
(116) into the nuts. Torque to 9.0-11.0 Nm [79.5-97.5 in-lbs]. The hook should
rotate freely in the assembly with no drag between the parts.
6. Clean all surfaces of the bottom blocks (102) of any contaminants such as grease
or oil and if necessary, apply two appropriate capacity labels (104) into the label
window.
Model CL500K Double Fall
Refer to Dwg. MHP2969
1. Apply IR #67 grease to all surfaces of two thrust washer (105) and assemble to
the pocket wheel (107). Assemble pocket wheel sub-assembly into the bushing
of bottom block (108).
2. Apply IR #67 grease to all surfaces of thick thrust washer (112), thrust bearing
(110) and thin thrust washer (111).
3. Assemble thick thrust washer (112) onto the bottom hook (115) shank to the
hook shoulder with the chamfer side facing away from the hook. Assemble the
thrust bearing (110) and thin thrust washer (111) onto the bottom hook shank.
4. Apply IR # 67 grease to the bottom hook (115) shank and assemble the two
keepers (113) to the bottom hook shank. Slide the thick thrust washer (112),
Product Identification End View
Position Top Hook
to Left When
Viewed From
Product
Identification
End
Product Identification End View
Position Top Hook
to Right When
Viewed From
Product
Identification
End

12 Form MHD56408 Edition 1
thrust bearing (110) and thin thrust washer (111) up to capture the keeper on
the bottom hook shank.
5. Place bottom hook (115) sub-assembly into bottom block (108).
6. Attach the other bottom block (108). Assemble two lockwashers (109) to the
two capscrews (116). Assemble the two capscrews and the two lockwashers into
the bottom block bottom holes. Assemble capscrew (103) and nut (122) through
top hole. Torque to 9.0-11.0 Nm [79.5-97.5 in-lbs]. The hook should rotate
freely in the assembly with no drag between the parts.
7. Clean all surfaces of the bottom blocks (108) of any contaminants such as grease
or oil and if necessary, apply two capacity labels (104) into the label window.
Chain Bag Container Assembly
Refer to Dwg. MHP2788
1. Hold the chain bag container (209) with the seam facing the assembler. Orient
the bracket (203) to be assembled to the right side of the bag so the two bottom
holes are closest the assembler. Assemble two capscrews (204) through the
bracket and chain bag container. Assemble two washers (203) and nuts (202) to
the two capscrews and torque to 4.5-5.5 Nm [40.0-48.5 in-lbs]. Repeat the
assembly for the left side with the exception that the two mounting holes on the
bracket are to be away from the assembler.
2. Position the chain bag container on the hoist with the seam facing the center
line of the hoist. Assemble the two lockwashers (2) to the two capscrews (201).
Insert the two capscrews and two lockwashers through the brackets (203) and
thread into the gear housing (34) and motor housing (47) to secure the chain
bag container sub-assembly to the hoist. Torque to 4.5-5.5 Nm [40.0-48.5 in-
lbs].
PENDANT DISASSEMBLY AND REASSEMBLY
Pendant Disassembly
Refer to Dwg. MHP2916 and MHP3106.
Pendant removed from service with all hoses and strain relief removed.
1. Remove four screws (117) and remove pendant guard (123).
2. Drive pin (125) out and remove ‘UP’ and ‘DOWN’ levers (119, 120).
3. Remove retaining screw (116).
4. Remove valve assemblies by tapping housing on non marring surface such as a
wood block to unseat valve assemblies.
5. Separate valve (129) from valve bushing (122) and spring (121).
For general repair of the pendant handle no further disassembly is required.
Cleaning, Inspection and Repair
Cleaning
CAUTION
• Do not dip cushioned handle into solvent when cleaning other components.
Damage to handle will occur.
Remove and discard all ‘O’ rings and clean components in solvent.
Inspection
All disassembled parts should be inspected to determine their fitness for continued
use.
Pay attention to the following:
1. Inspect all bushings and valves for wear, scoring or galling.
2. Specifically inspect the valve tips for wear.
3. Inspect the housing, ‘UP’ and ‘DOWN’ levers for damage.
4. Inspect all threads for damage.
Repair
Actual repairs are limited to the removal of small burrs and other minor surface
imperfections. Use a fine stone or emery cloth for this work. Do not use steel wool.
1. Worn or damaged parts must be replaced. Refer to the applicable Product Parts
Information manual for specific replacement parts information.
2. Inspect all remaining parts for evidence of damage. Replace or repair any parts in
questionable condition.
3. Smooth out all nicks, burrs and galled spots on parts as necessary.
4. Remove any nicks due to lockwashers.
5. Replace all ‘O’ rings.
Pendant Assembly
1. Lube all ‘O’ rings.
2. Slide valves (129) into valve bushings (122) taking care not to nick ‘O’ rings.
3. Install springs (121) onto ends of valves and slip valve, valve bushing and spring
into pendant housing.
4. Install retaining screw (116).
5. Install ‘UP’ and ‘DOWN’ levers (119, 120) and then tap pin (125) into place.
6. Check for proper movement and return to original position of lever and valves.
7. Install guard (123) using four screws (117).
8. Reconnect to hoist and supply air and check for leaks in static position. There
should be no audible leakage. Actuate hoist several times, again there should be
no detectable leakage. The pendant should have no delay in activation or
deactivation of the hoist.
Optional Emergency Stop Disassembly
Refer to Dwg. MHP3106.
If optional Emergency Stop device is incorporated into pendant the following
additional instructions apply:
Emergency Stop Disassembly
Pendant removed from service with all hoses and strain relief removed.
1. Remove two screws (146), two screws (1) and four lockwashers (2) and remove
from main pendant assembly.
2. Remove E-Stop threaded button (141). Note this will minimize spring tension
(147).
3. Remove retaining ring (142), (there will still be some spring pressure) and valve
cap (148).
4. Remove valve (144).
Cleaning, Inspection and Repair
Cleaning
CAUTION
• Do not dip cushioned handle into solvent when cleaning other components.
Damage to handle will occur.
Remove and discard all ‘O’ rings and clean components in solvent.
Inspection
All disassembled parts should be inspected to determine their fitness for continued
use.
Pay attention to the following:
1. Inspect housing bore and valve for wear, scoring or galling.
2. Inspect the housing, E-stop button and spring for damage.
3. Inspect all threads for damage.
Repair
Actual repairs are limited to the removal of small burrs and other minor surface
imperfections. Use a fine stone or emery cloth for this work. Do not use steel wool.
1. Worn or damaged parts must be replaced. Refer to the applicable Product Parts
Information manual for specific replacement parts information.
2. Inspect all remaining parts for evidence of damage. Replace or repair any parts in
questionable condition.
3. Smooth out all nicks, burrs and galled spots on parts as necessary.
4. Remove any nicks due to lockwashers.
5. Replace all ‘O’ rings.
Emergency Stop Assembly
1. Lube all ‘O’ rings and housing bore with Parker ’O’ ring lube.
2. Slide valve (144) into bore of housing (145) taking care not to nick ‘O’ rings.
3. Install spring (147) into valve and install end cap (148) into housing.
4. Install retaining ring (142).
5. Thread E-Stop button (141) into housing until button makes contact with
housing shoulder. Hand tighten only.
6. Ensure three ‘O’ rings (161) are in their respective counter bores, align to spring
pins and reinstall Emergency stop assembly to pendant housing using two screws
(146), two screws (1) and four lockwashers (2). Torque to 4.5-5.5 Nm [40.0-48.5
in-lbs].
7. Reconnect hoses and strain relief and test for proper function of Emergency stop.
Depress ‘UP’ and ‘DOWN’ lever and then actuate Emergency stop button. Supply
airflow should stop. Twist to reset button, supply air should be restored with
pendant controls working as normal.