Ingersoll-Rand LC2A015SM Setup guide

Product Maintenance
Information
Liftchain Mining Air Hoist
Models
LC2A015SM, LC2A030DM, LC2A040SM, LC2A060SM,
LC2A080DM, and LC2A120DM
(Dwg. MHP2684)
Save These Instructions
R
Form MHD56308
Edition 4
October 2013
71455778
©2013 Ingersoll-Rand

OnlyallowIngersoll Rand trainedtechnicianstoperformmaintenanceonthisproduct.ForadditionalinformationcontactIngersollRand factoryornearest
Distributor.
For additional supporting documentation refer to Table 1 ‘Product Information 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 Information Manuals
Publication Part/DocumentNumber Publication Part/Document
Number
Product Safety Information Manual MHD56295 Product Information Manual MHD56307
Product Parts Information Manual MHD56309
INSPECTION
Perform frequent inspections on equipment in regular service. Refer to Product
Information Manual.
nPeriodic Inspection
Refer to Table 2 ‘Inspection Classifications’ on page 2 for suggested inspection
classifications for Periodic Inspection Intervals. Select conditions most appropriate
to application.
Table 2: Inspection Classifications
Conditions Normal Heavy Severe
Typical Use (operating time) Infrequent Regular Continual/Constant
Load Range Usually light loads, occasional max. loads Usually medium loads, frequent max.
loads Usually max. loads or almost max. loads
Installation Protected/Enclosed/Dry Not Sheltered/Exterior Full Exposure
Atmosphere Clean/Non-Corrosive Dirty/Non-Corrosive/Freshwater Marine Dirty/Corrosive/Saltwater Marine
Climate Dry/Stable Temperature Wet/Moderate Temperature Fluctuations Wet/Severe Temperature Fluctuations
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 ‘Maintenance Interval Chart’ 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,springsand covers. Replacewornor damaged parts.Clean,lubricateand
reassemble.
3. Hooks. Inspect hooks carefully for cracks using magnetic particle or other
suitablenon-destructivemethod.Inspect hook retaining parts.Tightenor repair
if necessary.
Table 3: Hook Throat Normal and Discarded Width
Hoist
Model Capacity metric tons Throat Width Discard Width
in. mm in. mm
LC2A015S 1.5 1.26 32 1.45 36.8
LC2A030D 3 1.50 38 1.72 43.7
LC2A040S 4
LC2A060S 6 1.89 48 2.17 55.2
LC2A080D 8 2.08 53 2.4 61
LC2A120D 12 2.56 65 2.94 74.8
4. LoadChainSprocket.Checkfordamageorexcessivewear.Replaceifnecessary.
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
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 5. Check and
clean brake parts each time hoist is disassembled. Replace brake discs if grooves
are no longer visible.
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. LoadChainEnd Anchors.Ensurebothends of load chainaresecurely attached.
Secure if loose, repair if damaged, replace if missing. Check chain stoppers are
correctly installed and functional.
9. Load Chain. Check the chain for stretching. Measure the load chain over five
link sections all along chain, paying particular attention to the most frequently
reeved links. Refer to Dwg. MHP0041 on page 2, A. Gauge Length. When any
five 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 2. Always use genuine Ingersoll Rand replacement chain. Zinc
plated load chain is standard on Liftchain hoists.
Table 4: Load Chain Normal and Discard Length
Hoist Model Chain Size Normal Length Discard Length
mm in. mm in. mm
LC2A015S 8 x 24 4.72 120 4.8 122
LC2A030D
LC2A040S 13 x 36 7.09 180 7.2 183
LC2A060S 16 x 45 8.85 225 8.90 228
Gauge Length
A
(Dwg. MHP0041)
10. Emergency Stop. During hoist operation verify emergency shut-off by
activating button. All operation must stop quickly. Stop button must reset
properly.
11. Labels and Tags. Check for presence and legibility. Replace if necessary.
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
documenting periodic inspections. These reports should be dated, signed by the
person who performed the inspection, and kept on file where they are readily
available for review.
nMaintenance Intervals
Refer to ’Periodic Maintenance’ and Table 5 on page 3 for maintenance interval
guidance.
2 Form MHD56308 Edition 4

PERIODIC MAINTENANCE
Table 5: Maintenance Interval Chart
Normal Application
The following work can be completed by owner maintenance personnel
System Air Filter Inspect system air filter every 45 days or 125 hours.
Grease Fittings Lubricate grease fittings every 180 days or 500 hours.
Gearbox Oil Level Check oil level in gearbox every 180 days or 500 hours. Replace oil yearly.
It is recommended that the following work be completed by an Ingersoll Rand trained technician.
Standard Components 1 Year or
1,000 hrs 2 years or 2,000 hrs 3 years or 3,000 hrs 4 years or 4,000 hrs 5 years or
5,000 hrs 6 years or 6,000 hrs 8 years or 8,000 hrs
Inspect Motor X X X X
Inspect Disc Brake X X
Inspect Gearbox X X
Inspect Controls X X X X
Optional Components
Emergency Shut-Off Valve X X X X XXX
Overload Device X X X X
Heavy Application
The following work can be completed by owner maintenance personnel
System Air Filter Inspect system air filter every 30 days or 100 hours.
Grease Fittings Lubricate grease fittings every 90 days or 250 hours.
Gearbox Oil Level Check oil level in gearbox every 90 days or 250 hours. Replace oil yearly.
It is recommended that the following work be completed by an Ingersoll Rand trained technician.
Standard Components 1 Year or
1,000 hrs 2 years or 2,000 hrs 3 years or 3,000 hrs 4 years or
4,000 hrs 5 years or 5,000 hrs 6 years or 6,000 hrs 8 years or 8,000 hrs
Inspect Motor X X X X
Inspect Disc Brake X X X
Inspect Gearbox X X X
Inspect Controls X X X X
Optional Components
Emergency Shut-Off Valve X X X X X X
Overload Device X X X X
Severe Application
The following work can be completed by owner maintenance personnel
System Air Filter Inspect system air filter every 30 days or 100 hours.
Grease Fittings Lubricate grease fittings every 90 days or 250 hours.
Gearbox Oil Level Check oil level in gearbox every 90 days or 250 hours. Replace oil yearly.
It is recommended that the following work be completed by an Ingersoll Rand trained technician.
Standard Components 1 Year or
1,000 hrs 2 years or 2,000 hrs 3 years or
3,000 hrs 4 years or 4,000 hrs 5 years or 5,000 hrs 6 years or 6,000 hrs 7 years or 7,000 hrs
Inspect Motor X X X X X X
Inspect Disc Brake X X X X
Inspect Gearbox X X X
Inspect Controls X X X X X X
Optional Components
Emergency Shut-Off Valve X X XXXXX
Overload Device X X X X X
Note 1: Hours are for actual hoist operation. Perform an annual hoist load test for all applications.
Recommend complete general overhaul.
Form MHD56308 Edition 4 3

INSPECTION REPORT
Ingersoll Rand Liftchain Mining 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 ___
2. Discrepancy(s) noted during Frequent Inspection
3. Discrepancy(s) noted during maintenance
4. Other: ___________________________
Refer to the Product Information and Parts Information Manual and “INSPECTION” section for the general 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 the factory for technical assistance.
COMPONENT CONDITION CORRECTIVE ACTION NOTES
Pass Fail Repair Replace
Fasteners
Gears
Shafts
Bearings ---
Load Bearing Sheave
Chain Guides
Springs ---
Covers, Housings
Hooks ---
Top
Actual Hook Throat Width: ________ inches / ________ mm
(Refer to Table 3 ‘Hook Throat Normal and Discarded Width’ on page 2 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 3 ‘Hook Throat Normal and Discarded Width’ on page 2 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 2.)
Supporting Structure
Labels and Tags ---
Other Components (List in NOTES
section)
* Testing to more than 100% of rated capacity may be required to set overload device.
This page may be photocopied and used by inspectors or maintenance personnel.
4 Form MHD56308 Edition 4

TROUBLESHOOTING
This section provides basic troubleshooting information. Determination of specific causes to problems are best identified by thorough inspections performed by
Ingersoll Rand trained technicians. 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” on page 5.
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
“MAINTENANCE” on page 5.
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 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 muffler.
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 at hoist power supply connection with hoist under load. Raise pressure to rated capacity.
Pendant malfunction. Check psi (bar) at air inlet connection on pendant.
Load chain jumps on sprocket or is making
a snapping sound. Worn or rusted chain. Refer to “INSPECTION” on page 2 to determine wear limit. Replace if necessary.
Incorrect chain. Replace with correct chain.
Worn sprocket or chain guide. Replace worn parts.
Capsized hook. Correct as described in “MAINTENANCE” 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.
Form MHD56308 Edition 4 5

MAINTENANCE
WARNING
• Never perform maintenance on the product 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. Testing to more than 100% of rated
capacity is required to set overload device and may 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.
• Use of other than genuine Ingersoll Rand replacement parts may result in
safety hazards, decreased performance and increased maintenance and
may invalidate all warranties.
nMaintenance
Correct disassembly (to prevent loss or damage of good parts), repair, assembly,
testingandadjustingare critical to properhoistoperation. 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.
Itisextremely importantthatanyone involvedwithmaintaining the hoistbe 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.
nMaintenance Intervals
Refer to Table 5 ‘Maintenance Interval Chart’ on page 3 for recommended
maintenance schedule.
nAdjustments
nDisc Brake
Disc brake adjustment is not required. If disc brake does not hold rated load,
disassemble and repair.
Ifbrakeslippage occursduringtests prior toplacinghoist inserviceor during normal
use of the hoist, follow the hoist disassembly procedure and check friction plates
(66) and (72) thickness as shown in Dwg. MHP2638 on page 6, A. Piston; B. Friction
Plate; C. Drive Plate; D. Reaction Plate; E. 0.047 inch (1.2 mm) minimum. If this
dimension is less than shown, the friction plates (66) and (72) must be replaced.
Use the following procedure to remove the brake.
1. Remove the motor as described in
‘Motor and Disc Brake Removal’ on page 8.
2. Remove the reaction plate (68), friction plates (66) and (72), drive plates (67) and
piston (63).
3. Inspect the friction plates (66) and (72) for wear. If friction plate thickness is
uneven or is less than 0.047 in (1.2 mm) replace friction plate.
4. Remove, discard and replace ‘O‘ rings on piston (63).
No further disassembly is required, if only the brake is to be serviced.
Piston
Friction
Plate
Drive
Plate
0.047 inch minimum
(1.2 mm minimum)
B
C
Reaction
Plate
D
E
A
(Dwg. MHP2638)
NOTICE
• Original brake friction plate thickness is 0.059 in (1.5 mm).
WARNING
• Ensure drive plates make full contact with the friction plates, without
interference with spring clips.
Drive Plate
Friction Plate
D
B
C
Do not push spring clips
to point of interference
with Drive Plate
Spring Clip
A
(Dwg. MHP3046)
nOverload Device (optional feature on non EC hoists)
CAUTION
• Overload is factory set and should not be adjusted without consulting an
Ingersoll Rand trained technician.
6 Form MHD56308 Edition 4

Securing
Screw
Adjustment
Screw
A
B
(Dwg. MHP2683)
Refer to Dwg. MHP2683 on page 7.
1. Connect hoist to an air supply.
2. Release securing screw (102) and regulating screw (192) in order to increase or
decreasetheSWL(increaseSWLbytighteningtheregulatingscrew).Adjustment
must be made for an overload of 125% maximum of SWL.
3. Tighten securing screw.
4. Check hoist operation at rated load. If necessary repeat adjustment.
NOTICE
• Do not change factory settings unless hoist is tested and recertified at an
Ingersoll Rand authorized service center.
nLoad 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 chain sprocket 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 chain sprocket and chain guide. Install a
new chain sprocket 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 chain sprocket. 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.
•Thechainbuffer(128)andlimitstopwasher(8)arenotrequiredon thenon-
metallic chain container.
1. Hoist must be hung and connected to air supply. Reduce air pressure to 60 psi
(4 bar).
2. Disconnect chain end from hoist body if attached.
3. Remove chain buffer (4) and limit stop washer (110).
4. Remove load hook.
5. Run hoist slowly in lifting direction until chain free end is approximately 2 ft
(60 cm) from hoist.
6. Using an abrasive wheel, cut a section from the last link as shown in Dwg.
MHP0817 on page 7, 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 7.
A
B
‘C’ Link
‘A’ Dimension
(Dwg. MHP0817)
Table 6: ‘C‘ Link Dimension
Hoist Model Chain Size ‘A‘ Dimension
mm in. mm
LC2A015S 8 x 24 0.4 10
LC2A030D
LC2A040S 13 x 36 0.6 16
LC2A060S 16 x 45 0.8 20
LC2A080D 13 x 36 0.6 16
LC2A120D 16 x 45 0.8 20
CAUTION
•Do not distort link in any manner. Link must be able to pass over the chain
sprocket and idler wheels without binding.
7. 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.
8. 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.
Chain
Wheel
Chain Weld
To Outside On
Powered Chain
Wheels
Standing
Link
Load Chain
A
D
B
C
(Dwg. MHP0472)
9. Reinstallload hook,chainbuffer andlimit stopwasher.Connectfreeend ofchain
to hoist body.
WARNING
• Ensure chain does NOT become twisted during reeving. All chain welds
must align while chain is hanging free.
nDetermining Twisted, Kinked or ‘Capsized‘ Load Chain
Ensure chain is not twisted, kinked or ‘capsized‘ during installation. Refer to Dwg.
MHP0020 on page 7, A. Appearance of Chain Not Twisted; B. Appearance of Chain
Twisted.
A
Appearance of
Chain Not Twisted
Appearance of
Chain Twisted
B
(Dwg. MHP0020)
Form MHD56308 Edition 4 7

nChain Reeving
Single Fall
Bottom Block
Anchor
Chain
End
A
B
(Dwg. MHP2664)
Double Fall
Bottom Block
Anchor
Chain
End
A
B
(Dwg. MHP2665)
nDisassembly
NOTICE
• Refer to the Product Parts Information Manual for drawings unless
specified elsewhere.
nGeneral Disassembly Instructions
The following instructions provide the necessary information to disassemble,
inspect,repair, andassemblewinch.PartsdrawingsareprovidedintheProductParts
Information Manual.
If product 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
winch be performed in a clean dust free work area.
In the process of disassembling the product, observe the following:
1. Never disassemble product any further than is necessary to accomplish needed
repair. A good part can be damaged during the course of disassembly.
2. Never use excessive force when removing parts. Tapping gently around
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 part being heated is
already worn or damaged beyond repair and no additional damage will occur
to other parts.
In general, product is designed to permit easy disassembly and assembly. The
use of heat or excessive force should not be required.
4. Keep 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
product.
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 that 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 bearing with a sleeve slightly
smallerthanoutside diameter ofbearing.The end ofsleeveorpipe that contacts
bearing must be square. Protect bearings from dirt by keeping them wrapped
in clean cloths.
nHoist 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 work
bench.
3. Position several blocks of wood on the work bench and stand the hoist in a
vertical position with the motor end up.
nMotor and Disc Brake Removal
Refer to Dwgs. MHP3200, MHP3201, MHP3204 and MHP3205.
Use the following procedure to remove the motor.
1. Removefourcapscrews(74)andlockwashers(75)thatsecureairmotorassembly
to the hoist body (36) and remove motor assembly.
2. Remove and discard gasket (7).
3. Store motor in a clean and dry area until further disassembly is necessary.
nMotor Disassembly
3.5 HP
Refer to Dwg. MHP3201.
1. Remove motor and disc brake assembly as described in
‘Motor and Disc Brake Removal’ on page 8.
2. Remove capscrews (34) and cover plate (92).
NOTICE
•It is not necessary to remove check valve (77) unless replacing ball (47) and
‘O‘ rings (53).
•It is not necessary to remove pendant adapter plate (605) or (613) unless
valves (86) require replacement.
3. Remove and discard gasket (91).
4. Remove check valve (77), ‘O‘ rings (53) and ball (47).
5. Remove capscrews (90) and remove motor cover (83) from motor housing (76).
6. Remove and discard ‘O‘ rings (70).
7. Remove exhaust washers (81) from motor cover (83).
8. Remove valve assemblies (86) and springs (84).
9. Remove ‘O‘ rings located on valves (86) if necessary, (to remove ‘O‘ rings, it is
necessary to cut them).
NOTICE
•Twobearings(78)mountingin themotorhousingarebonded withLoctite®
603 or equivalent. Remove idle gear (79) and drive gear (80) only if
necessary,useabearingpunch(IngersollRandpn:96441232)orastandard
drift punch and a hammer. Refer to Dwg. MHP2644 on page 12.
10. Remove drive gear (80) and idle gear (79) from housing (76)
11. Remove bearings (78) from drive gear (80) and idle gear (79) only if replacement
is necessary (use a suitable bearing extractor).
12. It is necessary to remove plug (1) and washer (151) from housing (76).
13. Remove capscrews (62) securing brake to motor housing.
6 HP
Refer to Dwg. MHP3204.
1. Remove motor and disc brake assembly as described in
‘Motor and Disc Brake Removal’ on page 8.
2. Remove capscrews (34) and cover plate (92).
3. If hoist is equipped with an emergency stop refer to Dwg. MHP3205 for removal.
NOTICE
•It is not necessary to remove check valve (77) unless replacing ball (47) and
‘O’ rings (53).
•It is not necessary to remove pendant adapter plate (605) or (613), or rope
control block (313) or (405), unless valve assemblies (86) require
replacement.
4. Remove and discard gasket (91).
5. Remove check valve (77), ‘O’ rings (53) and ball (47).
6. Remove capscrews (90) and remove motor cover (83) from motor cover (222).
7. Remove and discard ‘O’ rings (70).
8. Remove idle gear (79) and drive gear (154).
9. Remove valve assemblies (86) and spring (221) from motor cover (83).
10. Remove motor casing (222) from motor housing (76).
11. Loosen setscrews (156) to remove exhaust pipes (60) and ‘O’ rings (45).
NOTICE
• Two bearings (78) in motor housing are bonded with Loctite® 603 or
equivalent. Remove idle gear (79) and drive gear (80) only if replacement
is necessary, use a bearing punch (IR pn: 96441232) or a standard drift
punch and a hammer. Refer to Dwg. MHP2644 on page 12.
12. Remove bearings (78) from drive gear (80) and idle gear (79) only if replacement
is necessary (use a suitable bearing extractor).
8 Form MHD56308 Edition 4

13. It is necessary to remove plug (1) and washer (151) from housing (76) this will
release the brake housing (61).
14. Remove capscrews (62) securing brake to motor housing.
nEmergency Stop and Overload Adapter Disassembly
Refer to Dwgs. MHP3201 and MHP3204.
1. Remove ‘O’ rings (70) and discard.
2. Remove setscrew (180) from emergency stop end cover (183).
3. Remove capscrews (103).
4. Remove emergency stop end cover (183) and gasket (91).
5. Remove ball (47).
6. Remove valve seat (186).
7. Remove seal (189) and axle (188) and ‘O’ rings (187) from valve seat (186).
8. Remove spring (193).
9. Unscrew tightening setscrew (102).
10. Unscrew regulating screw (192). Remove ‘O’ ring (191) and discard.
11. Remove valve seat (205).
12. Remove spring (213) from cap (202).
13. Remove capscrew (62).
14. Remove caps (202) and (211), washers (208) and (206), spacer tube (209) and
diaphragm (212).
15. Remove seals (203) and (210).
16. Pull plunger (198) with diaphragm (196) and nut (194) from base plate (199).
17. Unscrewnut (194)and removeplunger (198),diaphragm (196)and washer(195).
18. Remove ‘O’ rings (204) and discard.
19. Install a screw (dia. M5) in threaded hole on base plate (199) and pull it from
motor cover (83).
20. Remove seal (189) and ‘O’ ring (201).
nDisc Brake Disassembly
1.5 ton Single and 3 ton Double
Refer to Dwg. MHP2692.
1. Remove plug (1) and washer (151).
2. Remove capscrews that secure brake housing (61) to motor housing.
3. Remove and discard gasket (7) and ‘O’ ring (6).
NOTICE
•Before removing the drive and friction plates make note of stacking order
for reassembly. Refer to Dwg. MHP2638 on page 6.
4. Remove reaction plate (68), splined hub (65) and piston (63) from brake housing
(61). It may be necessary to apply a small amount of low pressure air to release
piston (63) and brake reaction plate (68).
5. Remove friction plates (72), (66) and drive plates (67) from housing (61).
6. Remove and discard ‘O’ rings (6) and (64) from piston (63).
7. Remove and discard ‘O’ ring (157) and gasket (7) from hoist body side of brake
housing.
4 ton and 6 ton Single, 8 ton and 12 ton Double
Refer to Dwg. MHP3204 and MHP3205.
1. Remove plug (1) and washer (151).
2. Remove capscrews (62) that secure brake housing (61) to motor housing (76).
3. Remove brake housing (61) from motor housing (76).
4. Remove and discard gasket (7) and ‘O’ ring (6).
NOTICE
•Before removing the drive and friction plates make note of stacking order
for reassembly.
5. Remove reaction plate (68), splined hub (65) and piston (63) from housing. It
may be necessary to apply a small amount of low pressure air to release piston
(63) and brake reaction plate (68).
6. Remove friction plates (66), (72) and drive plates (67) from housing.
7. Remove and discard ‘O’ rings (6) and (64) from piston (63).
nReduction Gear Disassembly
1.5 ton Single and 3 ton Double
Refer to Dwg. MHP2692.
1. Motor, disc brake assembly and retainer ring (10) must be removed from pinion
shaft (25) before reduction gear assembly can be removed from hoist body.
2. Remove fill plug (1) from reduction gear end cover (5) and drain oil from
reduction gear into a suitable container.
3. Remove capscrews (4) that secure reduction gear assembly to hoist body (36).
4. Remove reduction gear end cover (5) from reducer housing (23).
5. Remove retainer ring (2) and exhaust washer (3) from reduction gear end cover
(5).
6. Remove and discard ‘O’ ring (6) and gasket (7).
7. Remove retainer ring (10) from pinion shaft (25).
8. Turn reduction gear over so that stop ring (24) is facing up.
9. Remove reduction gear assembly and reducer housing (23) with ring gear (19)
from hoist body (36).
NOTICE
• It is not necessary to disassembly planet support assembly (341), unless
replacing parts.
10. Tap pinion shaft (25) from planetary gear carrier (17).
11. Remove cover (27), ‘O’ ring (6), stop ring (24) and ring gear (19) from reducer
housing (23).
12. Remove and discard oil seal (20) from cover (27).
13. Remove planet support assembly (341) from ring gear (19).
14. Remove bearing (18) from gear carrier (17).
15. Remove retainer ring (10) and bearing (11) from planetary carrier (17).
16. Tapoutplanet axles(16) and removeplanet gears(13),bearing rings(14),needle
bearings (15) and spacers (12).
4 ton and 6 ton Single, 8 ton and 12 ton Double
Refer to Dwgs. MHP3163 and MHP3164.
1. Motor, disc brake assembly, ‘O’ rings (40), spacer (97) and retainer ring (10) must
be removed from pinion shaft (25) before reduction gear assembly can be
removed from hoist body.
2. Remove drain plug (143) and drain oil from reduction gear into a suitable
container.
3. Removecapscrews (4)and lockwashers(44) thatsecure reductiongear assembly
to hoist body (36).
4. Remove reduction gear end cover (5) and ‘O’ ring (6) from ring gear (23).
5. Remove ‘O’ ring (138) and bearings (132) and (137).
6. Turn reduction gear end cover over so that retainer ring (24) is facing up.
7. Remove stop ring (24), dampeners (135), ‘O’ ring (29), and exhaust washer (3)
from muffler cover (136).
8. Unscrew muffler cover (136) from reduction gear end cover (5) and remove ‘O’
ring (64).
9. Remove primary gear assembly (126) and sun gear (152).
10. Remove ring gear (23), planet support assembly (341), sun gear (153) and ring
gear (19).
11. Remove retainer ring (14) and bearing (11).
12. Remove pinion shaft (25) from planet support assembly (341).
13. Remove bearing (11) from gear carrier (17).
NOTICE
• It is not necessary to disassembly planet support assembly (341), unless
replacing parts.
a. 4 and 8 ton Hoists:
Tap out planet axles (16) and remove planet gears (140), needle bearings
(142), (147) and spacers (141), (144) and (145).
b. 6 and 12 ton Hoists:
Tap out planet axles (16) and remove planet gears (140), needle bearings
(142) and (144), bearing rings (141), spacers (146) and (147) and ring (148).
14. Remove reducer housing (22) from hoist body (36).
15. Remove and discard ‘O’ rings (6).
nPowerhead Body Disassembly
1.5 and 3 ton Hoists
Refer to Dwgs. MHP2692.
1. Ensure reduction gear, disc brake and motor assemblies have been removed.
2. Remove chain limit stop washer (110) from load chain. Remove load chain from
hoist body (36).
3. Remove capscrews (41), nut (42) and pins (43) from hoist body using drift pin
and hammer.
4. Remove chain stripper (31). Pull sprocket assembly (30) from hoist body (36).
5. Remove and discard oil seal (20) and ‘O’ ring (29) from sprocket (30).
6. Remove bearing (8) and (39) from sprocket if necessary.
7. Remove and discard oil seal (37) from sprocket (30).
4 ton and 6 ton Single, 8 ton and 12 ton Double Fall
Refer to Dwgs. MHP3163 and MHP3164.
1. Ensure reduction gear, disc brake and motor assemblies have been removed.
2. Remove chain limit stop washer (110) from chain. Remove load chain from hoist
body (36).
3. Remove pins (43) from hoist body using drift pin and hammer.
4. Remove chain stripper (31). Pull sprocket assembly (30) from hoist body (36).
Remove adapter ring (59) on 6 ton and 12 ton hoists.
5. Remove oil seal (20) and discard.
6. Remove bearings (8) and (39) from sprocket if necessary.
7. Remove ‘O’ rings (6) and (104).
nRemote Two Function Pendant Disassembly
Refer to Dwg. MHP3039 or MHP3040.
1. Remove fittings (603) and lifting eye (501).
2. Unscrew plugs (518). Remove springs (46) and balls (47).
3. Tap out pin (502) and remove levers (503).
4. Remove setscrew (173) from pendant handle (514).
5. Remove valve assemblies (165). Remove ’O’ rings (53) and (171) and protectors
(170). Discard ’O’ rings.
6. Remove plug (615) or emergency stop valve (164) from pendant handle.
7. Remove retainer ring (512) and exhaust washer (513).
nBottom Hook Disassembly
1.5 ton Single and 3 ton Double Fall
Refer to Dwg. MHP2657.
1. Remove nuts (123), lockwashers (122) and capscrews (56) from half hook blocks.
2. Separate half hook blocks (118) and (121).
3. Remove sprocket (120) and bearings (119).
4. Remove thrust bearing (125) and ring halves (124) from hook (106).
4 and 6 ton Single Fall
Refer to Dwg. MHP3006.
1. Remove nuts (123), lockwashers (122) (6 ton hoist only) and capscrews (56) from
half hook blocks.
2. Separate half hook blocks (118) and (218).
3. Remove load chain, thrust bearing (125), ring halves (124) and hook (106).
8 and 12 ton Double Fall
Refer to Dwg. MHP3006.
1. Remove nuts (123), lockwashers (122) and capscrews (56) from half hook blocks.
2. Separate half hook blocks (118) and (218).
3. Remove sprocket (120) and bearings (119).
4. Remove thrust bearing (125) and ring halves (124) from hook (106).
5. Pull bearings (119) from sprocket (120) and remove ‘O’ rings (129).
Form MHD56308 Edition 4 9

nCleaning, Inspection and Repair
nCleaning
CAUTION
•Abearing thatappears looseor doesnot rotatesmoothlymustbereplaced.
Failure to observe this precaution will result in bearing and/or hoist
component damage.
Clean all hoist component parts in solvent (except for the brake friction discs). 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
necessarytocarefullyscrape old Loctite® from thebushingbore.Dry each part using
lowpressure,filteredcompressedair.Cleanthebrakefriction discsusinga wirebrush
or emery cloth. Do not wash the brake friction discs in liquid. If the brake friction
discs are oil soaked, they must be replaced.
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 all bearings for play, distorted races, pitting and roller or ball wear or
damage. Inspect bearings for freedom of rotation.
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 drive plates and friction discs for oil. If the friction discs have
become oil-soaked, replace them. If the drive plates have become glazed, sand
them lightly using fine emery cloth and a flat surface as backing. Inspect the
remainingbrakeparts forwarpageor otherdamage,and replacedamagedparts
as necessary. Replace the input pinion shaft oil seal.
7. Measure the thickness of the brake friction disc. The brake friction disc must
show an even wear pattern. If the brake friction disc is 0.047 in (1.2 mm) or less,
replace discs.
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.
Do not use steel wool.
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 gaskets, oil seals, and ‘O’ rings removed during hoist disassembly.
nHoist Assembly
nReduction Gear Assembly
1.5 ton Single and 3 ton Double Fall
Refer to Dwgs. MHP2692.
1. Installexhaustwasher(3)inreductiongear endcover(5)andsecure withretainer
ring (2).
2. Lubricate and install 'O' ring (6) in reducer housing (23).
3. Assemble planetary gear assemblies. Install spacer (12), bearing rings (14) and
needle bearings (15) in three planetary gears (13). Install planetary gear
assemblies into planetary carrier (17). Ensure that planetary gears (13) are
installed with the smaller gear head diameter nearest the ring gear (19).
4. Align planetary gear assemblies with small holes in planetary carrier and install
planet axles (16). Flat surface of pin should be facing in toward inner diameter
of carrier to allow installation of bearing (18).
5. Time planet gears as shown in drawing MHP1406 on page 10, A. Planetary
Support; B. Timing Marks; C. Planet Gear. Use the pinion shaft (25) to maintain
timing position.
6. Install bearing (18) in gear carrier and tap into place.
7. Install bearing (11) on opposite side of gear carrier and secure with retainer ring
(9).
8. With pinion shaft (25) still in place, install planet support assembly in ring gear
(19) carefully remove pinion shaft without removing planet support assembly
and place ring gear flat on surface with planet support assembly facing up.
9. Align gears with housing (23) and install over planet support assembly and ring
gear.
10. Install pinion shaft through reduction gear housing assembly secure with
retainer ring (10).
11. Install stop ring (24) in gear housing (23).
12. Lubricate and install ‘O’ ring (6) and oil seal (20) on cover (27). Ensure oil seal
inner spring is facing hoist body.
13. Install cover (27) in reduction gear housing (23).
4 ton Single and 8 ton Double Fall
Refer to Dwg. MHP3163.
1. Lubricate and install ‘O’ rings (6) and (138) and bearing (137) in reduction gear
end cover (5).
2. Assemble planetary gear assemblies. Install spacer (141), needle bearings (142)
and(147),spacers(145) and (144) in threeplanetarygears (140). Install planetary
gear assemblies into planetary carrier (17). Ensure that planetary gears (140) are
installed with the smaller gear head diameter nearest the ring gear (19).
3. Install bearings (11) and retainer ring (14) on sun gear (153).
4. Time planet gears as shown in Dwg. MHP3048 on page 11, A. Aligned Teeth;
B. Timing Mark; C. Offset Teeth and Timing Mark. Use the assembled sun gear
(153) to maintain timing position.
5. With sun gear (153) still in place, install planetary assembly in ring gear (19)
carefully place ring gear flat on surface with planet support assembly facing up.
6. Align gears with housing (23) and install over planet support assembly and ring
gear.
7. Install primary gear assembly (126) on planet housing (17).
8. Install pinion shaft (25) through reduction gear housing assembly so it locates
in the sun gear (152) of primary gear assembly (126).
9. Align capscrew holes and install reduction gear end cover (5) on ring gear (23).
10. Install bearing (132) on primary gear assembly (126) with three drops of Loctite
® 603 on external ring of bearing.
11. Install exhaust washer (3), ‘O’ ring (29), and dampeners (135) in muffler cover
(136) and secure with retainer ring (24).
12. Install ‘O’ ring (64) on muffler cover and thread muffler cover into reduction gear
end cover (5).
13. Install capscrews (4) and lockwashers (44) through reduction gear assembly
parts. Refer to “TORQUE CHART” on page 14 for torque requirements.
6 ton Single and 12 ton Double
Refer to Dwgs. MHP3164.
1. Lubricate and install ‘O’ rings (6) and (138) and bearing (137) in reduction gear
end cover (5).
2. Assemble planet support assembly (341). Install bearings (147), internal bearing
rings (141), needle bearings (142) and (144), spacers (146) and rings (148) in four
planetarygears(140).Installplanetarygearassembliesintoplanetarycarrier(17).
Ensure that planetary gears (140) are installed with the smaller gear head
diameter nearest the ring gear (19).
3. Align planetary gear assemblies with small holes in planetary carrier and install
planet axles (16).
4. Time planet gears as shown in Dwg. MHP3049, on page 11, A. Aligned Teeth;
B. Timing Mark; C. Offset Teeth and Timing Mark. Use the sun gear (153) to
maintain timing position.
5. Install bearings (11) and retainer ring (14) on sun gear (153).
6. With sun gear (153) still in place, install planetary assembly in ring gear (19)
carefullyremovesun gear(153)without removingplanetaryassembly andplace
ring gear flat on surface with planetary assembly facing up.
7. Align gears with ring gear (23) and install over planetary assembly and ring gear.
8. Install assembled sun gear (152) in primary gear assembly (126).
9. Install assembled primary gear assembly (126) on planet housing (17).
10. Install bearing (132) on primary gear assembly (126) with three drops of Loctite
® 603 on external ring of bearing.
11. Install pinion shaft (25) through reduction gear housing assembly so it locates
in the sun gear of primary gear assembly.
12. Lubricate and install ‘O’ ring (6) in reduction gear end cover (5).
13. Align capscrew holes and install reduction gear end cover (5) on ring gear (23).
14. Install ‘O’ ring (64) on muffler cover and thread muffler cover into reduction gear
end cover (5).
15. Install exhaust washer (3), ‘O’ ring (29), and dampeners (135) in muffler cover
(136) and secure with retainer ring (24).
16. Install capscrews (4) and lockwashers (44) through reduction gear assembly
parts.
1.5 ton Single Fall, 3 ton Double Fall and 6 ton Quad Fall
B
A
C
(Dwg. MHP1406)
10 Form MHD56308 Edition 4

4 ton Single Fall and 8 ton Double Fall
Aligned Teeth Timing Mark
Timing Mark
Offset Teeth
and Timing
Mark
Timing Mark
A
B
B
B
C
(Dwg. MHP3048)
6 ton Single Fall and 12 ton Double Fall
Aligned Teeth
Aligned Teeth
Timing Mark
Timing Mark
Offset Teeth
and Timing
Mark
A
A
C
B
B
(Dwg. MHP3049)
nPower Head Body Assembly
1.5 ton Single and 3 ton Double Fall
Refer to Dwg. MHP2692.
1. Lubricate and install ‘O’ ring (29) onto sprocket (30).
2. Lubricate and install ‘O’ ring (6) and oil seal (20) on cover (27) with lip of seal
towards hoist body.
3. Install bearing (8) on sprocket (30) on shaft end with external gear teeth.
4. Install oil seal (37) and bearing (38) in sprocket (30).
5. Tap cover (27) onto shaft of sprocket (30) against bearing (8) with oil seal lip
towards bearing.
6. Tap sprocket (30) into hoist body.
7. Install chain stripper (31) and tap pins (43) in until flush.
8. Align and install reducer assembly.
9. Install gasket (7) and align with capscrew holes.
10. Align and install reduction gear end cover (5) to reducer housing (23) and secure
with capscrews (4). Torque to 1,7 Nm and refer to
“TORQUE CHART” on page 14. Use an alternating pattern.
11. Fill with recommended oil. Refer to “LUBRICATION” section in Product
Information Manual. Install plug (1) in reduction gear end cover (5).
12. Clean the reducer cover (5).
Replacement for New Muffler 1.5t and 3t
- Remove retainer ring (2) from old style, refer to edition 1.
- Remove the exhaust washer (3) from old style, refer to edition 1.
13. Install the plate stop (96) and capscrew (94) onto adapter support (95).
14. Install the sub-assembly of adapter support (95), plate stop (96) and capscrew
(94), and press in reducer cover (5). Secure with the capscrew (94).
NOTICE
•Ensurelocationof“V”shapeonplatestop(96)isinstalledintheupposition.
Refer to Dwg. MHP3089 on page 11, A. Capscrew; B. Adapter Support;
C. Plate Stop.
Capscrew
Adapter
Support Plate
Stop
MHP3089
6/4/09 dw
A
C
B
(Dwg. MHP3089)
15. Install the retainer ring (93) in the groove of the reducer cover (5).
16. Apply a small amount of Loctite® “Instajoint 574” or equivalent on entire surface
offlatring (89),smoothout on entiresurface,press flatring(89) on reducercover
(5).
NOTICE
•Do not use force when installing muffler assembly (88). Hand tighten only.
17. Install the muffler assembly (88) in adapter support (95).
18. Install limit stop valve assemblies (340).
19. Lubricate and install load chain, limit stops and load hook. Refer to procedures
in ‘Load Chain Replacement’ on page 7.
4 ton and 6 ton Single, 8 ton and 12 ton Double Fall
Refer to Dwgs. MHP3163 and MHP3164.
1. Lubricate and install ‘O’ ring (6) on hoist body (36)
2. Install oil seal (20) in hoist body (36) with lip of seal towards sprocket.
3. Install bearing (8) on sprocket (30) on shaft external gear teeth end.
4. Install two oil seals (37) in bore of sprocket (30). Seal lips must face away from
each other.
5. Install bearing (38) in sprocket bore and secure with retainer ring (9).
6. Tap sprocket (30) into hoist body (36).
7. Install bearing (39) or (8) on sprocket and in bore of hoist body.
8. Install chain stripper (31) and tap pins (43) in until flush.
9. Align and install reducer assembly on hoist body. Secure with capscrews (4).
Torque to 47 Nm and refer to “TORQUE CHART” on page 14. Use an alternating
pattern.
10. Install limit stop valve assemblies (340).
11. Fill with recommended oil. Refer to “LUBRICATION” section in Product
Information manual. Install plug (1) in reducer housing (22).
12. Lubricate and install load chain, limit stops and load hook. Refer to procedures
in ’Load Chain Replacement’ on page 7.
nDisc Brake Assembly
1.5 ton Single, 3 ton Double Fall and 6 ton Quad Fall
Refer to Dwgs. MHP2692.
1. Lubricate and install ‘O’ ring (6) on brake housing (61).
2. Press piston assembly in brake housing (61). Internal ‘O’ ring (64) must enter
brake housing first. Avoid damaging ‘O’ rings.
3. Install plates in brake housing (61) in the following order: Friction plate without
clips (66) then drive plate (67) then friction plate with clips (72) then drive plate
(67). Repeat this plate sequence finishing with a friction plate with clips (72).
Align drive plate splines with slots in splined hub (65).
4. Install splined hub (65).
5. Lubricate and install ‘O’ rings (64) and (6) on piston (63) and reaction plate (68).
6. Align holes and install gasket (7) with grease on brake housing (61).
7. Ensure retainer ring (10) is installed on spline of drive gear (80).
8. Install springs (69) in motor housing (76).
9. Temporarily install the motor on the brake housing. Partially lift out and turn the
motor to align splines in the splined hub (65) and on drive gear (80). For a correct
assembly the brake housing must be completely inside motor housing. Remove
the motor and install brake springs (69). Reinstall the motor and check position
is correct.
10. Install plug (1) and washer (151) in brake housing and secure with capscrews
(62). Install capscrews (62) with Loctite® 243 or equivalent.
4 ton and 6 ton Single, 8 ton and 12 ton Double
Refer to Dwg. MHP3204 and MHP3205.
1. Lubricate and install ‘O’ ring (6) on brake housing (61).
2. Press piston assembly in brake housing (61). Internal ‘O’ ring (64) must enter
brake housing first. Avoid damaging ‘O’ rings.
3. Install plates in brake housing (61) in the following order: Friction plate without
clips (66) then drive plate (67) then friction plate with clips (72) then drive plate
(67). Repeat this plate sequence finishing with a friction plate with clips (72).
Align drive plate slots with slots in splined hub (65).
4. Install splined hub (65).
5. Lubricate and install ‘O’ rings (64) and (6) on piston (63) and reaction plate (68)
into brake housing (61).
6. Align holes and install gasket (7) on brake housing (61).
7. Ensure retainer ring (10) is installed on spline of drive gear (80).
8. Install springs (69) in motor housing (76).
Form MHD56308 Edition 4 11

9. Carefully install assembled brake in motor housing (61) and secure with
capscrews (62). Install capscrews (62) with Loctite® 243 or equivalent. Splined
hub must locate on motor drive gear (80) and remain engaged in drive plates.
Refer to “TORQUE CHART” on page 14 for torque requirements. For a correct
assembly the brake housing must be completely inside the motor housing.
10. Install plug (1) and washer (151) in brake housing.
11. Mount motor and brake assembly on end cover (73).
nMotor Assembly
3.5 HP Motor
Refer to Dwg. MHP3200.
1. Clean the grease from bearings (78).
2. Cleaninterior andexterior diameterof bearingswith Loctite®7063 orequivalent.
3. Put a continuous thin film of Loctite® 603 or equivalent on interior diameter of
bearing (78). Refer to Dwg. MHP2644 on page 12, A. Use a continuous thin film
of Loctite® 603 or equivalent to bond one bearing on each gear. Apply where
arrows indicate; B. Do not bond bearings on this side of gears; C. Use a
continuous thin film of Loctite® 603 or equivalent; D. Note: Wait 10 minutes with
the housing in this position, to ensure proper bond; E. Install brake hub and
rotate to ensure a proper bond; for correct application locations.
4. Put a continuous thin film of Loctite® 603 or equivalent on bearing diameter on
drive gear (80) and install bearing (78).
5. Install a second bearing (78), not bonded, on drive gear (80).
6. Put a continuous thin film of Loctite® 603 or equivalent on interior diameter of
bearing (78).
7. Put a continuous thin film of Loctite® 603 or equivalent on bearing diameter on
idle gear (79) and install bearing (78).
8. Install a second bearing (78), not bonded, on idle gear (79).
9. Put a continuous thin film of Loctite® 603 or equivalent on bore for bearings in
the motor housing (76).
10. Install drive gear (80) and idle gear (79) into motor housing, ensure the drive
gear and idle gear are completely inside motor housing and leave the motor
housing in a position as shown on Dwg. MHP2644 on page 12 for 10 minutes.
11. Install splined hub (65) and turn the gears with a tool. Check bearings do not
rotate on bonded diameters and gears rotate freely.
12. Install pins (82) on motor cover (83).
13. Install exhaust washer (81) with a point of Loctite® 601 or equivalent on motor
cover.
14. Install motor cover (83) on motor housing and secure with capscrews (90). Refer
to “TORQUE CHART” on page 14 for torque requirements. Install capscrews (90)
with Loctite® 243 or equivalent.
15. Check valve (86) and (87) ‘O’ rings are not damaged.
16. Install springs (84), valves (86) and (87) in motor cover (83).
(Dwg. MHP2644)
NOTICE
• Before following instructions A and C on dwg. MHP2644 place Loctite®
“Activator” 7649 on all gear axles and holes in housing gears go through.
6 HP Motor
Refer to Dwg. MHP3204.
1. Clean the grease from bearings (78) and install bearings (78) on drive gears (80),
(154) and idle gears (79) if replacement is necessary. Follow instructions 3 to 12
for bearing installation.
2. Cleaninterior andexterior diameterof bearingswith Loctite®7063 orequivalent.
NOTICE
•Refer to Dwg. MHP2644 for instructions on Loctite placement, follow these
instructions for all bearings on each gear. Place Loctite® “Activator” 7649
on all gear axles and holes in housing gears go through.
3. Put a continuous thin film of Loctite® 603 or equivalent on interior diameter of
bearings (78). Refer to Dwg. MHP2644 on page 12, A. Use a continuous thin film
of Loctite® 603 or equivalent to bond one bearing on each gear. Apply where
arrows indicate; B. Do not bond bearings on this side of gears; C. Use a
continuous thin film of Loctite® 603 or equivalent; D. Note: Wait 10 minutes with
the housing in this position, to ensure proper bond; E. Install brake hub and
rotate to ensure a proper bond; for correct application locations.
4. Put a continuous thin film of Loctite® 603 or equivalent on bearing diameters on
drive gears (80) and (154) then install bearings (78).
5. Install a second bearing (78), not bonded, on drive gears (80) and (154).
6. Put a continuous thin film of Loctite® 603 or equivalent on interior diameter of
bearings (78).
7. Put a continuous thin film of Loctite® 603 or equivalent on bearing diameters on
idle gears (79) and install bearings (78).
8. Install a second bearing (78), not bonded, on idle gears (79).
9. Put a continuous thin film of Loctite® 603 or equivalent in bearing bores in the
motor housing (76).
10. Install drive gear (80) and idle gear (79) into motor housing, ensure the drive
gear and idle gear are completely inside motor housing and leave the motor
housing in a position as shown on Dwg. MHP2644 on page 12 for 10 minutes.
11. Turn the gears with splined hub and a tool. Check bearings do not rotate on
bonded diameters and gears rotate freely.
12. Install exhaust pipes (60) with ‘O’ rings (45).
13. Lubricate and install ‘O’ rings (70) on motor housing (76).
14. Lubricate and install ‘O’ rings (71) in motor case (222).
15. Install motor cover (222) on motor housing (76).
16. Install and tighten screws (156). Install screw with Loctite® 243 or equivalent.
17. Install valve (86), valve (87) and spring assembly (221) in motor cover (83).
18. Put a continuous thin film of Loctite® 603 or equivalent in bearing bores in the
motor cover (222).
19. Install drive gear (154) and idle gear (79) into motor cover, ensure the drive gear
and idle gear are completely inside motor cover and leave the motor cover in a
position as shown on Dwg. MHP2644 on page 12 for 10 minutes.
20. Turn the gears with splined hub and a tool. Check bearings do not rotate on
bonded diameters and gears rotate freely.
21. Install motor cover (83) on motor cover (222). Install capscrews (90) with Loctite®
243 or equivalent. Refer to “TORQUE CHART” on page 14 for torque
requirements.
22. If removed during disassembly install overload valve (77), ‘O’ rings (53) and ball
(47).
nMotor Emergency Stop and Overload Assembly
Refer to Dwgs. MHP3037 and MHP3038.
1. Lubricate and install seal (189) and ‘O’ ring (201) on base plate (199).
2. Lubricate and install ‘O’ ring (197) on plunger (198).
3. Install diaphragm (196) on plunger and secure with nut (194) and washer (195).
4. Install plunger assembly on base plate and ensure plunger slides easily in the
bore of the base plate.
5. Install spring (213) on motor cover (83).
6. Install seal (210) on cap (202).
7. Install seal (203) on cap (211).
8. Install cap (202), washer (206), spacer tube (209), washer (208), cap (211),
diaphragm (212), and washer (206) into valve seat (205) and secure with
capscrew (62). Apply Loctite® 243 or equivalent to capscrew (62) threads. Do not
over tighten, apply torque for snug fit.
9. Lubricate and install ‘O’ rings (204) on valve seat (205).
10. Lubricate and install ‘O’ ring (191) on regulating screw (192).
11. Screw regulating screw (192) into emergency stop end cover (183).
12. Lubricate spring (193) with grease and install into regulating screw (192).
13. Install setscrew (102) with Loctite® 243 or equivalent onto emergency stop end
cover.
14. Install seal (189) on axle (188).
15. Install axle (188) into valve seat (186).
16. Install the second seal (189) on axle (188).
17. Lubricate and install ‘O’ rings (187) on valve seat (186).
18. Install valve assembly into emergency stop end cover.
19. Lubricate ball (47) with grease and install into emergency stop end cover.
20. Install gasket (91) with grease on motor cover.
21. Install emergency stop end cover assembly on motor cover and secure with
capscrews (103). Refer to “TORQUE CHART” on page 14 for torque
requirements.
22. Lubricate and install ‘O’ rings (70) on emergency stop end cover.
23. Install setscrew (180).
24. Install plug (182).
nRemote Two Function Pendant Assembly
RefertoDwg.MHP3039 with emergency stoporMHP3040 without emergency stop.
1. Lubricate and install ’O’ rings (53) and (171) along with protector (170) on valves
(165). Install valve assemblies in handle (514).
2. Install setscrews (173).
3. Install levers (503) in pendant handle (514) with pin (502). Stake pin in pendant
handle at both ends to secure.
12 Form MHD56308 Edition 4

4. Install screws (504) in levers.
5. Install balls (47) and springs (46) in handle (514). Secure in position with plugs
(518).
6. On pendants with emergency stop, install emergency stop button (164). On
pendants without emergency stop, install plug (615).
7. Install exhaust washer (513) and secure in handle with retainer ring (512).
8. Lubricate and install new ’O’ rings (70) on motor cover (83) for pendant or rope
control assembly.
9. Ensure valves move freely in the bores of the motor cover.
10. Align gasket (607) with motor cover (83). Ensure ’O’ rings are not damaged.
11. Align and install adapter plate (605) with capscrews (604) and lockwashers (75)
to motor cover (83).
12. Adjustment:
a. Connect the inlet of the pendant to 100 psi (7 bar) air supply.
b. Connect a manometer at the outlet of the lever to be adjusted.
c. Apply a small amount of Loctite® No. 243 on the adjustment screw (504).
d. Tightentheadjustmentsetscrewtoobtainapressureof15psi(1bar)without
actioning the lever.
e. Release the adjustment setscrew by a half turn (pressure must fall to zero).
f. Pushthe lever.Checkthat pressurereaches 93+/-7psi (6.5+/- 0.5bar).Check
that there is no leak at the exhaust.
g. Release the lever, exhaust must occur and result in rapid pressure reduction.
h. Repeat operations ‘f’ and ‘g’, 2 to 3 times.
i. Disconnect the manometer. Check to ensure that there are no leaks when
the lever is not activated.
j. Repeat the operations from ‘12b’ to ‘12i’ with each lever.
nBottom Hook Assembly
1.5 ton Single and 3 ton Double Fall
Refer to Dwg. MHP3203.
1. Install bearings (119) on sprocket (120).
2. Install thrust bearing (125) and ring halves (124) on hook (106).
3. Position sprocket and hook assemblies between hook block halves (118) and
(121).
4. Tap half hook blocks together and install capscrews (56), lockwashers (122) and
nuts (123). Refer to “TORQUE CHART” on page 14 for torque requirements.
4 ton and 6 ton Single Fall
Refer to Dwg. MHP3006.
1. Install thrust bearing (125) and ring halves (124) on hook (106).
2. Place load chain and hook assembly between hook block halves (118) and (218).
3. Press half hook blocks (118) and (218) together.
4. Install capscrews (56), lockwashers (122) (6 ton only) and nuts (123). Refer to
“TORQUE CHART” on page 14 for torque requirements.
8 ton and 12 ton Double Fall
Refer to Dwg. MHP3006.
1. Install ‘O’ rings (129) and bearings (119) on sprocket (120).
2. Install thrust bearing (125) and ring halves (124) on hook (106).
3. Position sprocket and hook assemblies between hook block halves (118) and
(218).
4. Tap half hook blocks together and install capscrews (56), lockwashers (122) and
nuts (123). Refer to “TORQUE CHART” on page 14 for torque requirements.
nLoad Test
Prior to initial use, all extensively repaired hoists shall be load tested by or under the
direction of an Ingersoll Rand trained technician and a written report furnished
confirming the rating of the tested equipment.
Dynamically load test hoist to 125% of its rated capacity in accordance with ASME
B30.16 standards. Testing to more than 125% is required to set overload device and
maybe necessarytocomplywithstandardsandregulationssetforthinareas outside
the USA.
Form MHD56308 Edition 4 13

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.
14 Form MHD56308 Edition 4

SERVICE NOTES
Form MHD56308 Edition 4 15

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