Ingersoll-Rand HA3-075 Setup guide

Product Maintenance
Information
Hercu-Link Air Chain Hoist
Models HA3-075 and HA3-100
Save These Instructions
R
Form MHD56243
Edition 4
October 2013
71394464
©2013 Ingersoll-Rand

OnlyallowIngersoll Rand trainedtechnicianstoperformmaintenanceonthisproduct.ForadditionalinformationcontactIngersollRand factoryornearest
Distributor.
For additional supporting documentation refer to Table 1 ‘Product Manuals’ on page 2.
Manuals can be downloaded from http://www.ingersollrandproducts.com.
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.
Original instructions are in English. Other languages are a translation of the original instructions.
Refer all communications to the nearest Ingersoll Rand Office or Distributor.
Table 1: Product Manuals
Publication Part/Document Number Publication Part/Document Number
Product Safety Information Manual MHD56295 Product Information Manual MHD56402
Product Parts Manual MHD56403
INSPECTION
nPeriodic Inspection
Accordingto ASMEB30.16, frequencyof periodicinspection dependsontheseverity
of usage:
NORMAL HEAVY SEVERE
yearly semiannually quarterly-
DisassemblymayberequiredforHEAVYorSEVEREusage.Keepaccumulativewritten
records of periodic inspections to provide a basis for continuing evaluation.
Inspect all the items in “Frequent Inspection.” Also inspect the following:
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, deformation and
cleanliness. If external evidence indicates the need, disassemble. Check gears,
shafts, bearings, sheaves, chain guides, springs and covers. Replace worn or
damaged parts. Clean, lubricate and reassemble.
3. Hooks. Inspect hooks carefully for cracks using magnetic particle or other
suitable non-destructive method. Inspect hook retaining parts. Tighten, repair
or replace if necessary.
4. LoadChainSheaves. Checkfordamageor excessive wear. Replace ifnecessary.
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.Ifperformanceispoor, disassemblemotorandcheckfor wearordamage
tobearings andshafts. Theparts shouldbe cleaned,lubricated andreassembled.
Replace worn or damaged parts.
6. Brake. Raise a load equal to rated capacity of hoist 4 to 6 inches (100 to 150 mm)
off floor and check ability of hoist to hold load without drift. If drift occurs,
disassemble. Remove brake discs as described in the “MAINTENANCE” section.
Check and clean brake parts each time hoist is disassembled. Replace brake
friction discs if thickness is less than 0.072 inch (1.83 mm), or if oil groove pattern
is not clearly visible.
7. Supporting Structure. Check for distortion, wear and continued ability to
support load.
8. TROLLEY(optionalfeature).Checkthattrolleywheelstrackbeamproperlyand
clearance between trolley wheel flanges and beam is correct. Refer to
“INSTALLATION” section. Check that wheels and beam are not excessively worn.
Inspect side plates for spreading due to bending. Do not operate hoist until
problems have been corrected.
9. Labels and Tags. Check for presence and legibility. Replace if necessary.
10. End Anchors (Load Chain). Ensure load chain end is securely attached. Check
chain stopper is correctly installed on free end of load chain.
11. Load Chain. Measure chain for stretching by measuring across five link sections
allalongchain, paying particular attentiontomost frequently reeved links.Refer
to Dwg. MHP0041, A. Gauge Length, on page 2. When any five-link section in
working length reaches or exceeds discard length, listed in Table
3on page 2, replace entire chain. Always use genuine Ingersoll Rand
replacement chain for regular and nickel-diffused load chains. When ordering
loadchain,specifywhichunititwillbeused on.Chainwillthenbecutand tagged
with the right number of links.
12. Chain Container (optional feature). Check for damage or excessive wear and
that chain container is securely attached to hoist. Secure or replace if necessary.
13. Limit Assembly. Check limit arm moves freely.
Table 2: Load Chain Normal and Discard Length
Hoist Model Chain Size Normal Length Discard Length
mm in. mm in. mm
HA3-025
32 17.72 450 18.15 461
HA3-050
HA3-075
HA3-100
Load Chain Length–Inspection
Gauge Length
A
(Dwg. MHP0041)
nRecords 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 on the condition of critical parts as a method of
documentingperiodicinspections. Thesereports should bedated, signedbyperson
who performed inspection, and kept on file where they are readily available for
review.
nLoad Chain Reports
Records should be maintained documenting condition of load chain removed from
service as part of a long-range load chain inspection program. Accurate records will
establish a relationship between visual observations noted during frequent
inspections and actual condition of load chain as determined by periodic inspection
methods.
2 Form MHD56243 Edition 4

INSPECTION REPORT
Ingersoll-Rand HA3 Air Hoist
Model Number: Date:
Serial Number:
Reason for Inspection: (Check Applicable Box) Inspected By:
1. Scheduled Periodic Inspection _____ Quarterly _____ Semiannually _____ Yearly
Operating Environment: Normal ___ Normal ___ Heavy ___ Severe
2. Discrepancy(s) noted during Frequent Inspection
3. Discrepancy(s) noted during maintenance
4. Other: ___________________________
Refer to Product Maintenance Information Manual “INSPECTION” section and to the appropriate National Standards and Codes of practice for general inspection criteria. 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 Sheaves
Chain Guides
Springs ---
Covers
Hooks ---
Top
Actual Hook Throat Width: ________ inches / _________ mm (Refer to Product Information Manual for min./max. acceptable widths.)
Hook Twist ---
Hook Crack Test Method Used: Dye Penetrant ______ Magnetic Particle ______ Other: __________________
Bottom
Actual Hook Throat Width: ________ inches / _________ mm (Refer to Product Information Manual for min./max. acceptable widths.)
Hook Twist ---
Hook Crack Test Method Used: Dye Penetrant ______ Magnetic Particle ______ Other: __________________
Hook Latch ---
Brake (10% Load Test) ---
Brake (Visual Inspection)
Tail Pin (End Anchor)
Load Chain ---
Working length(s) maximum wear: ______ inches / ______ mm (refer to Table 3, on page 2)
Supporting Structure
Labels and Tags ---
Other Components (List in NOTES
section)
Testing: Pass Fail NOTES
1. Operational (No Load)
2. Operational (10% Load)
3. Operational (Maximum Test Load*)
* Refer to ‘Load Test’ in “MAINTENANCE” section for testing information. This page may be photocopied and used by inspectors or maintenance personnel.
Form MHD56243 Edition 4 3

TROUBLESHOOTING
This section provides basic troubleshooting information. Determination of 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 winch symptoms, probable causes and remedies.
Symptom Cause Remedy
Hoist will not operate.
No air supply to hoist, or too little CFM or PSI. CheckPSI(bar) at hoistinlet.Refer to “SPECIFICATIONS”sectionin ProductInformation
Manual for correct CFM (cu.m/min) and PSI (bar).
Valve or limit arm sticking. Check limit arm for free movement.
Emergency valve “OFF”. Reset Emergency valve and push “ON” button.
Pendant malfunction. Check PSI (bar) at pendant. Minimum operating pressure in pendant line is 55 PSI (380
kPa/3.8 bar).
Hoist is overloaded. Reduce load to within rated capacity.
Motor is damaged. Repair or replace. Refer to “MAINTENANCE” section on page 5. Check oil level in
motor and gearbox.
Lubricator is low on oil. Fill lubricator.
Brake is not releasing (“DOWN” direction only). Check brake release circuit and PSI (bar) at brake inlet (55 PSI (380 kPa/3.8 bar)
minimum).
Load continues to move when
hoist is stopped. “UP” direction.
Valve or limit arm sticking. Check limit arm for free movement.
Dump valves not releasing. Check pendant hose dump valves.
Pendant lever sticking. Check lever and restore free movement.
Load continues to move when
hoist is stopped. “DOWN”
direction.
Valve or limit arm sticking. Check limit arm for free movement.
Dump valves not releasing. Check pendant hose dump valves (old style pendants).
Brake is slipping. Check brake springs and brake disc linings for wear. Refer to “MAINTENANCE” section.
Hoist is overloaded. Reduce load to within rated capacity.
Pendant lever sticking. Check lever and restore free movement.
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. CheckPSI(bar) at hoistinlet.Refer to “SPECIFICATIONS”sectionin ProductInformation
Manual for correct CFM (cu.m/min) and PSI (bar).
Main air valve travel is restricted. Check limit arm and linkage for free movement.
Brake is not releasing. Check brake release circuit and PSI (bar) at brake inlet (55 PSI (3.8 bar) minimum).
Exhaust is restricted. Inspect vents and replace muffler.
Motor is damaged. Check for worn motor bearings.
Motor or gearbox is out of oil. Check oil levels in motor and gearbox. Fill to recommended level.
Hook can be lowered but not
raised.
Hoist is overloaded. Reduce load to within rated capacity.
No air supply to hoist or too little CFM or PSI. Check at hoist power supply connection with hoist under load. Raise pressure to rated
capacity.
Pendant malfunction. Check PSI (bar) at air inlet connection (green fitting) on pendant.
Hook can be raised but not
lowered.
Brake is not releasing. No breather in gearbox. Remove solid square head plug in outboard end of gearbox only and install vented (breather) plug. Check PSI (bar) at brake inlet. (55 PSI (380 kPa/
3.8bar) minimum.)Check brakeand pendantdump valves,if used(old stylependants).
Brake piston seals leaking. Install repair kit. Refer to Parts section.
Low air pressure. Check PSI (bar) at valve inlet. Raise pressure to rated capacity.
Pendant malfunction. Check PSI (bar) at yellow fitting connection on pendant.
Load chain jumps on sheave or
is making a snapping sound.
Worn or rusted chain. Refer to “INSPECTION” section in Product Information Manual to determine wear limit.
Replace if necessary.
Incorrect chain. Replace with correct chain.
Worn sheave or chain guide. Replace worn parts.
Capsized hook. Correct as described in “MAINTENANCE” section on page 5.
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. Checktrolleyspacing.Referto“INSTALLATION”sectioninProductInformationManual.
Air-powered trolley does not
operate.
Pendant lever sticking. Check lever and restore free movement.
Emergency valve in “OFF” position. Reset Emergency valve and push “ON” button.
No air supply to trolley or too little CFM (cu. m/min.)
or PSI (kPa/bar). Check PSI (bar) at trolley inlet. Refer to manufacturer’s specifications.
Control valve is sticking. Refer to “MAINTENANCE” section on page 5.
No oil in trolley motor or gearbox. Check oil levels in trolley motor and gearbox and fill to required level.
Wheels are obstructed. Remove obstruction.
Motor is damaged. Repair or replace. Refer to “MAINTENANCE” section on page 5.
4 Form MHD56243 Edition 4

MAINTENANCE
WARNING
• Never perform maintenance on hoist while it is supporting a load.
• Before performing maintenance, tag controls:
•Only allow personnel trained in operation and service of this hoist to
perform maintenance.
•Afterperforminganymaintenanceon hoist dynamically test hoist to100%
of its rated capacity, in accordance with ASME B30.16 standards, before
returninghoist toservice.Testingtomore than100% ofratedcapacitymay
be required to comply with standards and regulations set forth in areas
outside the USA.
• Shut off air system and depressurize air lines before performing any
maintenance.
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.
nMaintenance Intervals
The Maintenance Interval Chart below is based on intermittent operation of
equipment for eight hours each day, five days per week. If equipment is in operation
for more than eight hours a day or is operated in severe applications or
environments, more frequent maintenance should be performed.
Interval Maintenance Check
Start of each shift
Make a thorough visual inspection of hoist for damage.
Do not operate hoist if damage is found.
Operatein bothdirections.Hoistmustoperatesmoothly
without sticking, binding or abnormal noises.
Check operation of pendant control and brake.
Semiannually Inspect disc brake friction linings and sprag clutch
assembly. Clean or replace parts as required.
Yearly
Inspect hoist gearing, shafts and bearings for damage or
wear. Repair or replace as necessary.
Check all of supporting members, including trolley if
used. Repair or replace as required.
nDisc Brake Adjustment
No disc brake adjustment is required. If brake fails to hold load, brake must be
disassembled, inspected, repaired and tested prior to placing hoist in service. When
any part of friction disc thickness measures 0.072 in. (1.83 mm) or less, or if oil groove
pattern is not clearly visible, friction discs must be replaced.
nLoad Chain Replacement
nLoad Chain Weld Placement
It is suggested that a short length of 32 mm 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 sheaves. Refer to
Dwg. MHP0042 on page 5, A. Load Chain; B. Standing Link; C. Load Sheave; D.
Chain Weld.
Load Chain
Standing Link
Load Sheave
Chain Weld
A
B
C
D
(Dwg. MHP0042)
nReplacement Load Chain Link Arrangement
Correct load chain installation requires that load chain have either an even or odd
number of total chain links. Refer to Dwg. MHP2336 on page 5 for illustration of
howto determinechain arrangement;A. ChainLink (ViewFrom Motor);B.25-50-100
Ton Hoist; C. First Link; D. Chain Weld; E. End Link; F. 75 Ton Hoist Only; G. Chain
Weld Located on Back Side.
First
Link
End
Link
Chain
Weld
Chain
Weld
located
on back
side
25–50–100
Ton
Hoists 75
Ton
Hoist
Only
Chain Link
(view facing Motor)
A
B
C
E
D
F
G
(Dwg. MHP2336)
nLoad Chain ‘C’ Link
Load chain replacement for all hoist models can be accomplished efficiently and
easily by using existing load chain to install new load chain.
1. Using an abrasive wheel, cut a section from end link of existing chain to form a
‘C’ link. Refer to Dwg. MHP2337 on page 5, A. ‘C’ Link.
2. Connect new chain to old chain by inserting end of new chain into ‘C’ link. Make
certain welds and links on new chain match positioning of welds and links on
chain being replaced. For model-specific information, refer to the appropriate
hoist model diagram.
1.378 in.
(35 mm)
“C” Link
A
(Dwg. MHP2337)
CAUTION
•Do not distort link in any manner. The link must be able to pass over chain
sheaves without binding.
nDetermining Twisted, Kinked or ‘Capsized’ Load Chain
Ensure chain is not twisted, kinked or ‘capsized’ during installation. Refer to Dwg.
MHP0020 on page 5, A. Appearance of Chain Not Twisted; B. Appearance of Chain
Twisted; and Dwg. MHP0043 on page 6, A. Make certain the bottom block has
NOT been flipped through the chain falls.
Twisted Chain
A
Appearance of
Chain Not Twisted
Appearance of
Chain Twisted
B
(Dwg. MHP0020)
Capsized Chain
Form MHD56243 Edition 4 5

Make certain
bottom block
has NOT been
flipped through
the chain falls
A
(Dwg. MHP0043)
nHA3-025 Hoist
Refer to Dwg. MHP2338 on page 6, A. Weld; B. Feed first link perpendicular to
load sheave; C. Power Head Load Sheave; D. Hoist Motor Side; E. Chain Stopper; F.
Weldonperpendicularchainlink mustfaceaway fromtop sheave.Weldon flatchain
link must face away from hoist motor side; G. Bottom Block.
1. The hoist should be installed and connected to air supply. Reduce hoist air
pressure to 60 psi (4 bar/414 kPa).
2. Remove chain bucket, if used.
3. Remove load chain stopper.
4. Remove bottom block assembly.
5. Cut new load chain to length. Load chain must have an even number of links
(first and last links must be at 90˚ to each other). Refer to Dwg.
MHP2336on page 5.
6. Run hoist slowly in lifting direction until load chain free end is approximately 2
ft. (0.6 m) from hoist.
7. Using a ‘C’ link which is the same size as load chain join new load chain to old
taking care that weld on perpendicular links on new load chain are facing away
from hoist load sheave.
8. Run hoist slowly until new load chain has passed 2 to 3 feet (0.6 to 1 m) through
hoist. Remove ‘C’ link and old chain.
9. Install chain stopper in last link of load chain free end.
10. Install bottom block assembly.
11. Lubricate entire length of load chain before operating hoist. Refer to
“LUBRICATION” section in Product Information Manual.
HA3-025 Chain Reeving
A
B
C
E
D
FG
Bottom
Block
Weld on perpendicular
chain link must face
away from top sheave
Weld on flat chain link
must face away from
hoist motor side
Chain
Stopper
Feed first link
perpendicular
to load sheave
Power Head
Load Sheave
Weld
Hoist Motor
Side
B
A
(Dwg. MHP2338)
nHA3-050 Hoist
Refer to Dwg. MHP2339 on page 6, A. Weld; B. Feed first link perpendicular to
load sheave; C. Power Head Load Sheave; D. Hoist Motor Side; E. Chain Stopper; F.
Weld on perpendicular chain links must face away from sheaves. Weld on flat chain
links must face away from hoist motor side; G. Bottom Block; H. Anchor Chain at this
point.
1. The hoist should be installed and connected to air supply. Reduce hoist air
pressure to 60 psi (4 bar/414 kPa).
2. Remove chain bucket, if used.
3. Remove load chain stopper.
4. Runhoist slowlyinliftingdirectionuntilbottomblockassemblyisapproximately
3 ft. (1 m) from hoist power head. Firmly support and secure bottom block
assembly in this position.
WARNING
• Do not begin chain replacement until bottom block assembly is fully
secured and supported. If bottom block assembly or chain are dropped,
they could cause injury or damage property.
5. Cut new load chain to length. Load chain must have an even number of links
(first and last links must be at 90˚ to each other). Refer to Dwg. MHP2336
on page 5.
6. Remove pins that anchor load chain to power head assembly.
7. Using a ‘C’ link which is the same size as load chain join new load chain to free
end on old chain taking care that weld on perpendicular standing links on new
chain are facing away from hoist load sheave.
8. Run hoist slowly until new load chain has passed through hoist. Continue
running hoist and pull chain by hand through bottom block assembly. Begin
feeding chain at position ‘A’ and work alphabetically. Remove ‘C’ link and old
chain.
9. Anchor end of load chain to power head assembly. Install chain stopper in last
link of load chain free end.
10. Lubricate entire length of load chain before operating hoist. Refer to
“LUBRICATION” section in Product Information Manual.
HA3-050 Chain Reeving
A
BC
E
D
F
G
H
Chain
Stopper
Feed first link
perpendicular
to load sheave
Power Head
Load Sheave
Anchor Chain
at this point
Bottom
Block
Weld on perpendicular
chain links must face
away from sheaves
Weld on flat chain
links must face away
from hoist motor side
Weld
Hoist Motor
Side
A
B
C
(Dwg. MHP2339)
nHA3-075 Hoist
Refer to Dwg. MHP2340 on page 7, A. Feed first link flat to load sheave; B. Weld
on perpendicular chain links must face away from sheaves; C. Chain Stopper; D.
Anchor chain at this point; E. Weld on flat chain links must face away from hoist
motor side; F. Power Head Load Sheave; G. Power Head Idle Sheave; H. Hoist Motor
Side; J. Bottom Block; K. 75 Ton Hoist Only; L. Chain Weld; M. Chain Weld located on
back side.
1. Thehoistmust beinstalledandconnectedtoairsupply.Reducehoistairpressure
to 60 psi (4 bar/414 kPa).
2. Remove chain bucket, if used.
3. Remove chain stopper.
4. Runhoist slowlyinliftingdirectionuntilbottomblockassemblyisapproximately
3 ft. (1 m) from hoist power head. Firmly support and secure bottom block
assembly in this position.
WARNING
• Do not begin chain replacement until bottom block assembly is fully
secured and supported. If bottom block assembly or chain are dropped,
they could cause injury or damage property.
6 Form MHD56243 Edition 4

5. Cut new load chain to length. Load chain must have an odd number of links (first
and last links must be in same plane/parallel to each other). Refer to Dwg.
MHP2336 on page 5.
6. Remove capscrew and cotter pin that anchor load chain to bottom block
assembly.
7. Using a ‘C’ link which is same size as load chain, join new load chain to free end
on old chain taking care that weld on perpendicular standing links on new chain
are facing away from hoist load sheave.
8. Run hoist slowly until new load chain has passed through hoist. Continue
running hoist and pull chain by hand through bottom block assembly. Begin
feeding chain at position ‘A’ and work alphabetically. Remove ‘C’ link and old
chain.
9. Attach end of load chain to bottom block assembly. Install chain stopper in last
link of load chain free end.
10. Lubricate entire length of load chain before operating hoist. Refer to
“LUBRICATION” section in Product Information Manual.
HA3-075 Chain Reeving
75 Ton
Hoist
Only
Chain
Weld
Chain
Weld
located
on back
side
Feed first link
flat to load
sheave
Weld on flat
chain links
must face
away from
hoist motor
side
Bottom
Block
Hoist Motor
Side
Power Head
Idle Sheave
Power Head
Load Sheave
Chain
Stopper
Anchor chain
at this point
A
DB
C
Weld on
perpendicular
chain links
must face
away from
sheaves
A
B
C
E
D
F
G
H
J
K
L
M
(Dwg. MHP2340)
nHA3-100 Hoist
Refer to Dwg. MHP2341 on page 7, A. Feed first link perpendicular; B. Anchor
chain at this point; C. Chain Stopper; D. Weld; E. Power Head Load Sheave; F. Idle
Sheave; G. Hoist Motor Side; H. Bottom Block; J. Weld on perpendicular chain links
must face away from sheaves. Weld on flat chain links must face away from hoist
motor side.
1. Thehoistmust beinstalledandconnectedtoairsupply.Reducehoistairpressure
to 60 psi (4 bar/414 kPa).
2. Remove chain bucket, if used.
3. Remove chain stopper.
4. Runhoist slowlyinliftingdirectionuntilbottomblockassemblyisapproximately
3 ft. (1 m) from hoist power head. Firmly support and secure bottom block
assembly in this position.
WARNING
• Do not begin chain replacement until bottom block assembly is fully
secured and supported. If bottom block assembly or chain are dropped,
they could cause injury or damage property.
5. Cut new load chain to length. Load chain must have an even number of links
(first and last links must be at 90˚ to each other). Refer to Dwg. MHP2336
on page 5.
6. Remove pins that anchor load chain to power head assembly.
7. Using a ‘C’ link which is the same size as load chain join new load chain to free
end on old load chain taking care that weld on perpendicular standing links on
new load chain are facing away from hoist load sheave.
8. Run hoist slowly until the new load chain has passed through hoist. Continue
running hoist and pull chain through bottom block assembly. Begin feeding
chain at position ‘A’ and work alphabetically. Remove ‘C’ link and old chain.
9. Anchor end of load chain to power head assembly. Install chain stopper in last
link of load chain free end.
10. Lubricate entire length of load chain before operating hoist. Refer to
“LUBRICATION” section.
HA3-100 Chain Reeving
Weld on perpendicular
chain links must face
away from sheaves
Weld on flat chain links
must face away from
hoist motor side
Bottom
Block
Hoist Motor
Side
Idle Sheave
Power Head
Load Sheave
Weld
Feed first link
perpendicular
to load sheave
Anchor chain
at this point
Chain
Stopper
A
B
C
D
E
A
B
C
E
D
F
G
H
J
(Dwg. MHP2341)
nGeneral Disassembly
The following instructions provide the necessary information to disassemble,
inspect, repair, and assemble the hoist. Complete assembly drawings of the hoist
components are provided in Product Parts Information Manual.
If 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 hoist
be performed on a bench in a clean dust-free work area.
In the process of disassembling hoist, observe the following:
1. Turn off air system and depressurize air lines before performing any
maintenance. Disconnect hoses from hoist and trolley. Plug or cap openings to
keep out dirt and contaminants.
2. Never disassemble hoist any further than is necessary to accomplish the needed
repair. A good part can be damaged during the course of disassembly.
3. 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.
4. Donot heatapart witha flametofree itfor removal,unlessthepartbeing heated
is already worn or damaged beyond repair and no additional damage will occur
to other parts.
5. In general, hoist is designed to permit easy disassembly and assembly. The use
of heat or excessive force should not be required.
Form MHD56243 Edition 4 7

6. Keep the work area clean to prevent dirt and other foreign matter from getting
into bearings and other moving parts.
7. All seals and ‘O’ rings should be discarded once they have been removed. New
seals and ‘O’ rings should be used when assembling the hoist.
8. When grasping a part in a vise, always use leather or copper covered vise jaws
to protect the surface of part and help prevent distortion. This is particularly true
of machined surfaces, threaded members and housings.
9. Do not remove any part which is press fit in or on a subassembly unless the
removal of that part is necessary for repairs or replacement.
10. To avoid damaging bearings during hoist assembly or disassembly always tap
or press on bearing inner race for shaft fit bearings or outer race for bore fit
bearings.
CAUTION
•Useextremecarewhenperforminganymaintenanceonhoist.Hoistweight
may exceed 7,400 lbs (3357 kg) use appropriately rated equipment for
moving.
nPowerhead Disassembly
Refer to Dwg. MHP2343.
1. Remove chain from hoist, by removing retainer ring (171) and chain anchor pin
(170) from lead stripper (159).
2. Disconnect all hoses from hoist motor. Drain oil from reducer, brake and motor
assemblies.
3. Place powerhead assembly in horizontal position and support on blocks.
4. Remove capscrews (703) and lockwashers (702) from motor assembly.
5. Remove motor assembly using the proper equipment necessary to support
weight of the component.
6. If motor repair or general maintenance is required refer to ‘Motor Disassembly’
section on page 28.
7. Remove limit arm (301) as an assembly by removing capscrew (303) that secures
it to motor end frame (152). It is not necessary to remove valves (312) or spacers
(304) unless damaged.
8. Using side holes in frames (154) and (153), rotate powerhead assembly vertically
with motor end frame (152) down. Place blocks along either side of motor end
frame (152) to protect brake shaft (102) from damage.
9. Remove capscrews (202) and lockwashers (702) that secure reduction gear
assembly (200).
10. Using the proper equipment necessary to support weight of component,
remove reduction gear assembly from reduction gear frame end (154) taking
care not to damage or distort the drive shaft (151).
11. It is not recommended to disassemble reduction gear.
12. Remove drive shaft (151) taking care not to damage teeth or distort shape.
13. It is not recommended to remove bushing (169) from drive shaft (151).
14. Remove capscrews (161) and (162) from reduction gear end frame (154) and pry
from center frame (153).
15. Remove capscrews (166) and wear pads (158) from reduction gear end frame
(154) and center frame (153). Check wear pads (158) for damage or wear. Refer
to “INSPECTION” in Product Maintenance Information Manual.
16. Remove drive sheave (155) and lead stripper (159) at the same time. Carefully
pry from center frame (153) both drive sheave and lead stripper. It may be
necessary to use a rubber mallet to loosen lead stripper from dowel pins (168).
Dowel pins (168) do not need to be removed.
17. Remove ‘O’ rings (163) and (164) and bearings (157) from drive sheave (155).
Discard ‘O’ rings.
18. Using side holes on frames (152) and (153), rotate motor end frame (152) so that
motor end frame side is up, this will make disassembly of brake easier.
NOTICE
• Brake assembly is spring loaded, use care when removing motor adapter
(53).
19. Remove capscrews (109) from brake housing (110), and carefully remove motor
adapter (53), springs are located between reaction ring (101) and piston (104).
20. Remove reaction ring (101) and piston (104).
21. Remove ‘O’ ring (116) and discard.
22. Remove from piston (104), seals (113) and (114), check for damage or wear.
23. Remove brake shaft (102) as an assembly, then remove drive discs (111) and
friction discs (112), check for wear.
24. Remove retainer ring (108) and thrust washer (107) from brake shaft assembly.
25. It is not recommended to remove from brake shaft (102) the hub (103), sprag
clutch (105) or bushings (106), unless damage or wear is visible.
26. Remove brake housing (110) and ‘O’ ring (123) from motor end frame (152).
Discard ‘O’ ring.
27. Remove capscrews (161) from motor end frame (152) and pry center frame (153)
from motor end frame. It is not necessary to remove dowel pins (165).
28. Remove idler sheave assembly (156) from motor end frame (152).
29. Remove ‘O’ rings (163) and (164) and bearings (157) from idler sheave (156).
Discard ‘O’ rings.
nTop Hook Disassembly
Refer to Dwg. MHP2345.
1. Remove hoist from mounting structure.
2. To remove hook and plate assembly (hook cannot be removed before hook
plate) remove capscrews (403) and separate hook plate assembly from power
head.
3. To remove hook (352) from hook plate (400) drive out roll pins (355) and remove
nut (353) from threaded hook end.
4. Remove hook (352) and bearing (354) from hook plate (400).
CAUTION
• Do not use swivel ring hook (401) for lifting load, use for installation only.
nBottom Block Disassembly
HA3-100 Hoist
Refer to Dwg. MHP2344.
1. Always make sure load chain is removed before disassembly.
2. Remove capscrews (356) securing hook blocks (351) to hook center block (350)
and pry hook blocks (351) from both sides of hook center block (350).
(Engagement of dowel pins (165) may make removal difficult).
3. Drive out pins (355) from nut (353) in threaded hook section. Pull hook (352)
from hook center block (350) and remove bearing (354) and nut (353).
4. Remove bearings (157), sheaves (156) and ‘O’ Rings (163) and (164) from hook
blocks (351) and hook center block (350). Discard ‘O’ Rings (163) and (164).
nHoist Motor Disassembly
Refer to Dwg. MHP2348.
1. Remove five capscrews (109) from exhaust flange (744). Do not remove the two
capscrews (747) from throttle valve assembly (260).
2. Removepilot controlvalve housing(621) bypullingitoutofmotorhousing(720)
as an assembly with exhaust flange (744).
CAUTION
• Do not remove the exhaust flange (744) until rotary valve (740) has been
removed from rotary valve housing (739).
3. Remove rotary valve (740) by pulling it out from assembly through the motor
housing end of rotary valve housing (739).
4. Remove exhaust flange (744) and control valve assembly (621) by removing
capscrews (747) and (749), respectively.
5. Remove each cylinder head (705) by removing four capscrews (704). Remove
head gasket (713).
6. Pull cylinder liner (701) straight out.
7. Positionpiston(708) at topofits stroke. Inthisposition, with cylinderlinerpulled
out in step 6, wrist pin (707) can be removed. Remove one retainer ring (709)
from either side of piston (708). Push wrist pin (707) out by hand from one side.
If wrist pin is too tight it is acceptable to carefully heat piston to 200˚ F (93˚ C) or
less and then push wrist pin out.
NOTICE
•If piston, wrist pin, connecting rod or cylinder liner are to be re-assembled,
number each set. Also add radial alignment marks for each piston and
cylinder liner to motor housing.
8. Remove remaining cylinder liners and pistons as described in steps 6 and 7. To
remove crank assembly, all pistons and cylinder liners must be removed.
9. Crank assembly (727) can now be removed with oil slinger (726) by pulling
straight out from motor housing (720). Use care while guiding connecting rods
(710) through inside of motor housing.
n2 Lever Pendant Disassembly
Refer to Dwg. MHP1977.
1. Remove fittings (265) and lifting eye (250).
2. Unscrew plugs (254). Remove springs (255) and balls (256).
3. Tap out pin (257) and remove levers (263).
4. Remove setscrews (260) from pendant handle (264).
5. Remove valve assemblies (262). Remove ‘O’ rings (253) and (259) and protector
(261) from valve assemblies. Discard ‘O’ rings.
6. Remove plug (270) from pendant handle (264).
7. Remove retainer ring (268) and exhaust washer (267).
n4 Lever Pendant Disassembly
Refer to Dwg. MHP1980.
1. Remove fittings (265) and lifting eye (250).
2. Unscrew plugs (254). Remove springs (255) and balls (256).
3. Remove capscrews (280) and (283) and washers (281) from attachment (left)
(286). Remove attachment (left) taking care not to damage pin (284). Separate
pin (284), lever (257) and ‘O’ rings (282) from attachment (left). Discard ‘O’ rings.
4. Repeat step 3 for attachment (right) (287).
5. Tap out pin (257) and remove levers (263).
6. Remove valve assemblies (262). Remove ‘O’ rings (253) and (259) and protector
(261) from valve assemblies. Discard ‘O’ rings.
7. Remove plug (270) from pendant handle (264).
8. Remove retainer ring (268) and exhaust washer (267).
nCleaning, Inspection and Repair
Use the following procedures to clean, inspect, and repair the components of the
hoist.
nCleaning
Clean all hoist component parts in solvent (except for the friction discs). The use of
a stiff bristle brush will facilitate the removal of accumulated dirt and sediments on
thegears andframes.Ifbushingshavebeenremoveditmay benecessarytocarefully
scrape old Loctite® from the bearing bores. Dry each part using low pressure, filtered
compressed air.
8 Form MHD56243 Edition 4

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.
• Do not use trichloroethylene to clean parts.
•If trolley suspension yoke bushings are loose or worn they must be
replaced. Failure to observe this precaution will result in additional
component damage.
nInspection
All disassembled parts should be inspected to determine their fitness for continued
use. Pay particular attention to the following:
1. Inspect all gears for worn, cracked, or broken teeth.
2. Inspect all bushings for wear, scoring, or galling.
3. Inspect shafts for ridges caused by wear. If ridges caused by wear are apparent
on shafts, replace the shaft.
4. Inspect all threaded items and replace those having damaged threads.
5. Measure the thickness of the friction discs (112). If the friction discs are less than
0.072in.(1.83 mm)or ifoilgroove patternisnot clearlyvisible replacethefriction
discs (112).
6. Check mufflers (173) and (176) for damage or excessive dirt.
7. Inspecttrolley yokebushingsforwear,scoring,orgalling. Ifwearexceedsdiscard
dimensions in Table 9 replace bushings.
8. Check bearings for ease of rotation and wear. Replace bearings if rotation is
rough or bearings are excessively worn.
9. Check the sprag clutch assembly for wear, flat spots on the sprags or damage. If
any of these conditions exist, replace parts.
10. Inspect sprag clutch wear area on brake hub (103) and on brake shaft (102) for
ridges or galling. If either condition exists replace parts.
NOTICE
• If brake hub (103), sprag clutch (105) or brake shaft (102) require
replacement,itisrecommendedthatallthreepartsbereplacedatthesame
time.
Table 3: Bushing Inspection Specifications
Hoist Model Item
No. Bushing Part No.
Original Bore Size Discard Bore Size
in. mm in. mm
HA3-025
Contact Factory
3.253 82.6 3.315 84.2
HA3-050 3.437 87.3 3.500 89
HA3-075 4.50 114.3 4.562 116
HA3-100
nRepair
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.
1. Worn or damaged parts must be replaced. Refer to the applicable parts listing
for specific replacement parts information.
2. Inspect all remaining parts for evidence of damage. Replace or repair any part
which is in questionable condition. The cost of the part is often minor in
comparison with the cost of redoing the job.
3. Smooth out all nicks, burrs, or galled spots on shafts, bores, pins, or bushings.
4. Examine all gear teeth carefully, and remove nicks or burrs.
5. Polish the edges of all shaft shoulders to remove small nicks which may have
been caused during handling.
6. Remove all nicks and burrs caused by lockwashers.
7. Replace all seals, 'O' rings and gaskets.
nAssembly Instructions
CAUTION
•Useextremecarewhenperforminganymaintenanceonhoist.Hoistweight
may exceed 7,400 lbs (3357 kg) use appropriately rated equipment for
moving.
Refer to Product Parts Information Manual for assembly drawings and parts lists.
nPowerhead Assembly
Refer to Dwg. MHP2343.
1. Place motor end frame in a vertical position with motor side down, for
procedures 2 through 14.
2. Lubricate and install ‘O’ rings (163) and (164) and bearings (157) to idler sheave
(156).
3. Install idler sheave assembly (156) in motor end frame (152) and install a short
length of chain. Refer to ‘Load Chain Weld Placement’ and Dwg. MHP0042 in
“MAINTENANCE” section ‘’ on page 5.
4. If vertical stripper (160) was removed during disassembly, install and secure
using capscrews (167) to center frame (153).
5. Install pins (165) if removed during disassembly.
6. Align pins (165) in motor end frame (152) with center frame (153) and carefully
lower center frame onto motor end frame using appropriately rated equipment.
7. Install capscrews (161) and torque to approximately 909 to 1030 ft lbs (1299 to
1471 Nm).
8. Install wear pads (158) with capscrews (166) in reduction gear end frame (154)
and center frame (153). Apply a small amount of Loctite® 242 to threads.
9. Lubricate and install ‘O’ rings (163), (164) and bearings (157) on both sides of
drive sheave (155).
10. Install dowel pins (165) and (168) if removed during disassembly.
11. Install drive sheave assembly (155) and lead stripper (159) together. Align dowel
pins (168) in lead stripper with holes in center frame (153).
12. Install a short length of chain around drive sheave (155) and lead stripper (159).
Refer to ‘Load Chain Weld Placement’ and Dwg. MHP0042 in “MAINTENANCE”
section ‘’ on page 5.
13. Install reduction gear end frame (154) onto center frame (153) being careful to
align dowel pins (165) and (168).
14. Install capscrews (161) and (152) in reduction gear frame and torque to
approximately 909 to 1030 ft lbs (1299 to 1471 Nm).
15. Using holes on both sides frames, rotate powerhead assembly so reduction gear
frame (154) side is down for easier installation of brake.
16. Lubricate and install ‘O’ ring (123). Align capscrew holes and position brake
housing (110) on motor end frame (152).
NOTICE
•If hub (103) and sprag clutch (105) were removed from brake shaft (102) be
suretoinstallthisassemblysoteethofhub(103)arepointingtowardmotor
end frame (152).
17. Clean brake shaft assembly and inspect parts for wear before assembling brake.
18. Install on brake shaft (102), hub assembly (103) and thrust washer (107) secure
with retainer ring (108).
19. Inspectandinstalldrivediscs(111)andfrictiondiscs(112)onhub(103).Alternate
discs, starting with friction disc (112) followed by a drive disc (111).
20. Lubricate and install seals (113) and (114) in brake piston (104) grooves so seal
lips face each other. Do not overstretch seals during this procedure. Refer to
Dwg. MHP0139 on page 9.
21. Install brake shaft assembly (102) and piston assembly (104) in brake housing
(110).
22. Installbrake pistonassemblyinbrakehousingsosteppedsideentersfirst.Gently
tap into position using a soft mallet until seated. Refer to Dwg. MHP0139, A. Seal
Lip; B. Seal; C. Brake Piston.
Seal Lip
Seal
Brake
Piston
A
B
C
(Dwg. MHP0139)
23. Install springs (117), ‘O’ ring (116) and reaction ring (101) on brake shaft (102).
24. Install motor adapter (53) to brake housing (110) and secure with capscrews
(109). Torque to approximately 106 to 121 ft lbs (151 to 173 Nm).
25. Using side holes in frames of hoist rotate hoist assembly vertically so motor end
frame (152) is down. Place blocks along either side of motor end frame (152) to
protect brake shaft (102) from damage.
26. Installdriveshaft(151)and bushing(169)through reductiongear endframeside
so it engages with brake shaft. Use care when installing so no damage will occur
to either shaft.
27. Rotate drive shaft (151) clockwise and check for brake shaft (102) to rotate. If
brake shaft does not move, gently rotate drive shaft (151) until teeth engage
brake shaft. Continue this step until brake shaft (102) rotates with drive shaft.
NOTICE
• Use care when installing reduction gear assembly (200) to powerhead
assembly. Damage or distortion to drive shaft (151) may occur if not
properly supported while installing reduction gear assembly.
28. Install reduction gear assembly (200) to reduction gear end frame (154) and
secure with capscrews (202) and lockwashers (702), apply a small amount of
Loctite® 242 to threads of capscrews. Torque to 80 to 90 ft lbs (114 to 129 Nm).
29. Using holes on both sides of frames, rotate powerhead assembly horizontally,
providing blocks on either side for support.
30. Installmotorassembly(700)tomotorendframe(152)andsecurewithcapscrews
(703) and lockwashers (702), apply a small amount of Loctite® 242 to threads of
capscrews. Torque to 80 to 90 ft lbs (114 to 129 Nm).
31. After chain has been reeved, install cotter pin (170) in lead stripper (159) and
secure with retainer ring (171). Refer to Dwg. MHP2341 on page 27.
nHoist Motor Assembly
Refer to Dwg. MHP2348.
1. Assemble pilot control valve assembly (621) and manifold (750) to rotary valve
housing (739) using four capscrews (747) and lockwashers (749). Install two
capscrews (747) and lockwashers (749) that attach exhaust flange (744) to
throttle valve housing.
Form MHD56243 Edition 4 9

2. Tighten capscrews (747) and (749) to 25 ft lbs (34 Nm). Throttle handle should
movefullyleftandrightwithoutstickingorbinding,andshouldcenter(byspring
force) automatically when released.
3. Install two seal rings (741) on each end of rotary valve (740). Place bearing (742)
onto the rear of rotary valve (740) and press into position. Press only on bearing
inner race. With rotary valve housing (739) exhaust flange down, install rotary
valve into housing.
4. Install ‘O’ ring (737) into motor housing (720).
5. Install rotary valve housing gasket (812) onto rotary valve housing. With exhaust
flange down on bench, install motor housing (720) onto rotary valve housing.
Check for any evidence of damage to ‘O’ ring when rotary valve housing is fully
engaged. Install and tighten capscrews (109) to 50 ft lbs (68 Nm).
6. If removed, press crank bearing (724) on crank assembly (727). Apply pressure
only on inner race of bearing.
7. Place crank assembly on a work bench with oil slinger (726) down and slide the
sleeve (728) (with tang up) on crankpin.
8. Slide connecting rod bushing (729) over sleeve (728) and first connecting rod
ring (730) with chamfer up.
9. Install connecting rods (710) in same order as removed, with all feet pointing in
same direction, using first connecting rod ring (730) to hold one side of
connecting rod feet.
10. Slide second connecting rod ring over other side of connecting rod feet with
chamfer on ring facing down (toward stem of connecting rod).
11. Slide crank shaft valve end over crank pin while simultaneously aligning tang on
sleeve (728) with slot in crank shaft.
12. Rotate and position crank shaft valve end relative to crank pin to allow
installation of lock pin (731).
13. Tap lock pin (731) in place and install pin nut (733). Torque nut to 60 ft lbs (81
Nm).
14. Install cotter pin (732) and bend ends over.
15. Install roll pin (734) and bearing (742) into valve end of crank shaft.
16. Check that all connecting rods move freely around crank. Position crank
assembly into motor housing (720). Ensure bearing (724) is seated and
connecting rods (710) are centered in cylinder holes.
NOTICE
•Make certain roll pin (734) and three lugs on rotary valve (740) line up with
corresponding hole and lugs on crank shaft.
•Donotallowrotaryvalvetoslidebackinrotaryvalvehousing(739).Ifrotary
valve slides in too far, seal ring (741) will lock-up in internal grooves of
rotary valve housing (739) and restrict further assembly.
17. Rotate crank assembly until one connecting rod (710) is at the top of its stroke.
Install a piston (708) with its rings (706) and (711) to connecting rod with wrist
pin (707) and retaining rings (709).
18. Install a new cylinder head gasket (713) before installing cylinder liner (701).
19. Install cylinder liner over the piston by compressing both piston rings and with
a single band ring compressor.
20. Install cylinder head (705) over cylinder and secure cylinder head to motor
housing with four capscrews (704). Torque capscrews to 60 ft lbs (81 Nm).
21. Repeat Steps 17 through 20 with remaining cylinders.
22. Rotate motor by hand. Motor should rotate without binding.
23. Install mounting flange (52) and gasket (722) on front of motor housing. Make
sure notches on both parts are aligned.
24. Lightly lubricate ‘O’ ring (737) and install in groove on motor adapter.
25. Temporarily install capscrews and nuts finger tight to retain motor adapter.
26. Install eye bolts and vent cap assembly (715) in motor housing.
27. Ensure oil drain and level plugs (712) are installed.
nTop Hook Assembly
Refer to Dwg. MHP2345.
1. Install hook (352) and bearing (354) in hook plate (400).
2. Install nut (353) on threaded hook end until snug. Back nut (353) off until first
dowel pin hole is lined up. Install pins (355). Do not attempt to drive pins (355)
into nut until holes are aligned or threads on hook (352) will be damaged.
3. Install hook plate assembly on power head with capscrews (403). Torque to
approximately 1288 ft lbs (1840 Nm).
4. Install hoist on mounting structure.
CAUTION
• Do not use swivel ring hook (401) for lifting load, use for installation only.
nBottom Block Assembly
HA3-100
Refer to Dwg. MHP2344.
1. Pack bearing (354) in hook center block (350) cavity.
2. Install threaded hook end into hook center block (350) and through bearing
(354).
3. Install nut (353) being careful that threads are not crossed. Tighten nut (353)
until snug then back nut (353) off until first dowel pin hole is lined up. Install pins
(355) until flush with nut (353) diameter. Do not attempt to drive pins (355) into
nut until holes are aligned or threads on hook (352) will be damaged.
4. Lubricate and install ‘O’ rings (163) and (164) on sheaves (156) in grooves
provided.Usinga pressagainstthe innerraceof bearing(157)press the bearings
(157) onto both sides of sheaves (156).
5. Install the assembled sheaves in the hook center block (350). Pack cavities in
hook center block (350) and hook blocks (351) with grease.
6. Tap dowel pins (165) into position. Install hook blocks (351) over bearings (157)
and sheaves (156) making sure dowel holes are lined up. Secure hook blocks
(351)withcapscrews (356)using Loctite®242.Torque to681-772ft lbs(973-1103
Nm).
7. Install grease fittings (360) and (363) and fill block with grease. Refer to
“LUBRICATION” section in Product Information Manual.
n2 Lever Pendant Assembly
Refer to Dwg. MHP1977.
1. Assemble protectors (261) and ‘O’ rings (253) and (259) on valves (262).
2. Insert valve (262) assemblies into pendant handle (264).
3. Install screws (260) into pendant handle.
4. Install balls (256), springs (255) and plugs (254) into pendant handle.
5. Install plug (270) into pendant handle.
6. Install fittings (265) and lifting eye (250) into top of pendant handle.
7. Facing pendant handle operation side, place levers (263) such that lever
direction indicators show ‘UP’ on left hand side and ‘DOWN’ on right hand side.
Install pin (257) ensuring pin inserts through levers and locates on opposite side
of pendant handle.
8. Install exhaust washer (267) and secure with retainer ring (268).
9. Attachhosestofittingslocatedontopofpendanthandle.Locatehosestofittings
as shown in the “INSTALLATION” section in Product Information Manual.
NOTICE
• Screws (258) are installed in pendant levers allowing adjustment of
pendant levers.
n4 Lever Pendant Assembly
Refer to Dwg. MHP1980.
1. Assemble protectors (261) and ‘O’ rings (253) and (259) on valves (262).
2. Insert valve (262) assemblies into pendant handle (264) and attachments (right)
(287) and (left) (286).
3. Install screws (260) in pendant handle and attachments (right) and (left).
4. Install balls (256), springs (255) and plugs (254) into pendant handle and
attachments (right) and (left).
5. Install plug (270) into pendant handle.
6. Installfittings (265)into topofpendanthandleandattachments(right)and(left).
Install lifting eye (250) into top of pendant handle.
7. Facing pendant handle operation side, place levers (263) such that lever
direction indicates ‘UP’ on left hand side and ‘DOWN’ on right hand side. Install
pin (257) ensuring pin inserts through levers and locates on opposite side of
pendant handle.
8. Lubricate and install ‘O’ rings (282) in recesses on sides of pendant handle (264).
9. Install attachment (right) (287) and (left) (286) to pendant handle (264) and
secure with washers (281) and capscrews (280) and (283). Install shorter screws
in back, longer screws in front.
10. Facing pendant handle operation side, place levers (285) such that lever
direction indicates ‘LEFT’ on left hand side and ‘RIGHT’ on right hand side. Install
pins (284) ensuring pins insert through levers and locate on side of pendant
handle.
11. Install exhaust washer (267) in pendant handle and secure with retaining ring
(268).
12. Attachhosestofittingslocatedontopofpendanthandle.Locatehosestofittings
as shown in the “INSTALLATION” section in Product Information Manual.
nLoad Test
Prior to initial use, all new, extensively repaired, or altered hoists shall be load tested
by or under the direction of personnel instructed in safety, maintenance and
operation of this hoist. A written report must be maintained on record confirming
the rating of the hoist.
1. Operate the hoist fully in both directions without a load. Hoist must operate
smoothly, without evidence of binding. Response to operating controls must be
quick and accurate.
2. Place a 10% load on hoist and operate hoist fully in both directions. Hoist must
operate smoothly, without evidence of binding. Response to operating controls
must be quick and accurate.
3. Dynamicallyloadtesthoistto100%ofitsratedcapacityinaccordancewithASME
B30.16 standards. Hoist must operate smoothly, without evidence of binding.
Response to operating controls must be quick and accurate.
NOTICE
•Testingto morethan100%maybenecessarytocomplywith standardsand
regulations set forth in areas outside of the USA.
10 Form MHD56243 Edition 4

TORQUE CHART
Standard Coarse Thread Torque
Size SAE Grade 5 SAE Grade 8
Dry Lubricated PTFE Dry Lubricated PTFE
1/4-20 8-10 6-7 4 12-14 9-10 5-6
5/16-18 17-20 13-15 8-9 25-28 18-21 11-13
3/8-16 31-35 23-26 14-16 44-49 33-37 20-22
7/16-14 49-56 37-42 22-25 70-79 52-59 31-36
1/2-13 75-85 57-64 34-38 106-121 80-90 48-54
9/16-12 109-123 82-92 49-55 154-174 115-130 69-78
5/8-11 150-170 113-128 68-77 212-240 159-180 95-108
3/4-10 267-302 200-227 120-136 376-426 282-320 169-192
7/8-9 429-487 322-365 193-219 606-687 455-515 273-309
1-8 644-729 483-547 290-328 909-1030 681-772 409-463
1 1/8-7 794-900 596-675 357-405 1288-1460 966-1095 580-657
1 1/4-7 1121-1270 840-952 504-571 1817-2059 1363-1545 818-927
Standard Fine Thread Torque
Size SAE Grade 5 SAE Grade 8
Dry Lubricated PTFE Dry Lubricated PTFE
1/4-20 10-11 7-8 4-5 14-15 10-12 6-7
5/16-24 19-22 14-16 9-10 27-31 20-23 12-14
3/8-24 35-40 26-30 16-18 49-56 37-42 22-25
7/16-20 55-63 41-47 25-28 78-88 58-66 35-40
1/2-20 85-96 64-72 38-43 120-136 90-102 54-61
9/16-18 121-137 91-103 55-62 171-194 128-146 77-87
5/8-18 170-193 127-144 76-87 240-272 180-204 108-122
3/4-16 297-337 223-253 134-152 420-476 315-357 189-214
7/8-14 474-537 355-403 213-242 669-758 502-568 301-341
1-12 704-798 528-599 317-359 995-1127 746-845 448-507
1 1/8-12 1023-1159 767-869 460-572 1444-1637 1083-1227 650-736
1 1/4-12 1425-1615 1069-1211 641-727 2012-2280 1509-1710 905-1026
Metric Coarse Thread Torque
Size Class 8.8 / 9.8 Class 10.9
Dry Lubricated PTFE Dry Lubricated PTFE
M6x1 9-10 6-7 4 11-12 8-9 5-6
M8x1.25 21-23 16-18 9-11 26-30 20-22 12-13
M10x1.5 41-47 31-35 19-21 53-60 39-45 24-27
M12x1.75 71-81 54-61 32-36 91-103 68-77 41-46
M14x2 115-130 86-98 52-59 147-166 110-125 66-75
M16x2 165-187 124-140 74-84 227-257 170-193 102-116
M20x2.5 321-364 241-273 144-164 443-502 332-376 199-226
M22x2.5 439-497 329-373 197-224 605-686 454-514 272-309
M24x3 556-630 417-473 250-284 767-869 575-652 345-391
M30x3.5 1103-1250 827-938 496-563 1521-1724 1141-1293 685-776
Metric Fine Thread Torque
Size Class 8.8 / 9.8 Class 10.9
Dry Lubricated PTFE Dry Lubricated PTFE
M8x1 22-25 17-19 10-11 28-32 21-24 13-14
M10x1.25 44-49 33-37 20-22 56-63 42-47 25-28
M12x1.25 78-89 59-67 35-40 100-113 75-85 45-51
M14x1.5 125-141 93-106 56-64 159-180 119-135 72-81
M16x1.5 176-200 132-150 79-90 243-276 183-207 110-124
M18x1.5 257-291 193-219 116-131 355-402 266-302 160-181
M20x1.5 358-406 268-304 161-183 494-559 370-420 222-252
M22x1.5 484-548 363-411 218-247 667-756 500-567 300-340
M24x2 609-690 456-517 274-310 839-951 630-713 378-428
M30x2 1227-1390 920-1043 552-626 1692-1918 1269-1438 761-863
Notes:
1. Definitions:
DRY: Cadmium plate, zinc plate, and oiled fasteners.
LUBRICATED: Molysulfide paste, carnaba wax, molysulfide grease and
copper-based anti-seize coated fasteners.
PTFE: 2% minimum PTFE coated fasteners.
2. All torque values foot-pounds unless noted.
3. SAE grade 5 equivalent to ASTM A325 Type 2 and ASTM A449.
4. SAE grade 8 equivalent to ASTM A354 Grade BD, ASTM A490 Type 1.
5. If mixing fasteners use lowest torque value.
6. Torque values 75 to 85% of fastener proof load ref.
Form MHD56243 Edition 4 11

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