Ingersoll-Rand PAL250K User manual

Form MHD56298
• A copy of our “Safe Operating Practices” Manuals are always available free of charge either by downloading it from our
Technical Publications website @ www.airwinch.com or by contacting the Factory at [phone] for North America and
[phone] for International. The Safe Operating Practices manual must be read prior to anyone operating a
Ingersoll-Rand winch or hoist. The manual form numbers are as follows:
“Safe Operating Practices Non-Man Rider™ Winches” Manual, Form No. MHD56250
“Safe Operating Practices for Man Rider™ Winches” Manual, Form No. MHD56251
“Safe Operating Practices for Pneumatic, Hydraulic and Electric Hoists” Manual, Form No. MHD56295
• Available winch options may require additional supplements to the basic winch manual.
• For Man Rider™ winches ensure a copy of the Man Rider™ supplement is made available to the operator prior to winch
operation.
• We strongly recommend that ALL maintenance on Ingersoll-Rand equipment be carried out by personnel certified by
Ingersoll-Rand, or by Ingersoll-Rand Authorized Service Centers.
• Contact the Factory if in doubt about installation, operation, inspection and maintenance instructions.
• Use only Genuine Ingersoll-Rand parts when maintaining or repairing a winch, hoist or any component of a winch or hoist.
• ANSI / ASME recommends that a winch or hoist (or any components of a winch or hoist) that has been repaired be tested
prior to being placed into service:
Winch Man Rider™Supplements:
Model: Publication No. Model: Publication No.
FA2, FA2.5,
FH2, FH2.5 MHD56046 LS500RLP SAM0011
LS1000RLP SAM0012
FA5 MHD56042 and
MHD56220
LS150RLP SAM0082
LS150RLP/500/
1000 SAM0115
FA10 MHD56252
FA2.5A MHD56236 LS150RLP and
LS150PLP-PH SAM0120
FA2B and
HU40A MHD56207 LS500RLP-E SAM0122
FH10MR MHD56212 LS150RLP-
DP5M-F SAM0184
Fulcrum Electric MHD56277
LS500HLP/
LS1000HLP SAM0004 LS150HLP SAM0222
*Winches-ANSI / ASME B30.7 (BASE MOUNTED DRUM HOISTS) Refer to section 7.2.2 - Testing.
*Hoists - ANSI / ASME B30.16 (OVERHEAD HOISTS - UNDERHUNG) Refer to section 16.2.2 - Testing.
Form MHD56298
Edition 2
November 2004
71441844
© 2004 Ingersoll-Rand Company
IMPORTANT INFORMATION:

PARTS AND MAINTENANCE MANUAL
FOR
PALAIR PLUS
AIR CHAIN HOIST MODELS
With standard load chain:
PAL250K / PAL500K and PAL1000K
PAL250KV / PAL500KV and PAL1000KV
With stainless steel chain (X):
PAL250K / PAL310K and PAL630K
PAL250KV / PAL310KV and PAL630KV
READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual
contains important maintenance information. Make this manual
available to all persons responsible for the maintenance of these
products.
Do not use this hoist for lifting, supporting, or transporting people or lifting or supporting loads over
people.
Always operate, inspect and maintain this hoist in accordance with European Security Rules and any
other applicable safety codes and regulations.
Refer all communications to the nearest INGERSOLL-RAND Material Handling Products Office or
Distributor.
Form SAM0071
Edition 4
January 1997
96090263
MATERIAL HANDLING

Description PageNo.
Maintenance
MaintenanceIntervals
...................................................................................................................................................... 3
General
Disassembly....................................................................................................................................................... 4
DisassemblyInstructions
.................................................................................................................................................. 4
Air GearMotorsdisassembly................................................................................................................................ .5
PendantsControldisassembly............................................................................................................................... .5
Cleaning,InspectionandRepair
....................................................................................................................................... 5
AssemblyInstructions..................................................................................................................................................... .6
Air GearMotorsAssembly................................................................................................................................... .7
PendantsControl Assembly................................................................................................................................... 7
PendantControlAdjustment.
................................................................................................................................. 7
Parts
Motor AssemblyDrawing................................................................................................................................................. 8
Motor AssemblyPartsList ............................................................................................................................................... 9
Motor with emergencystopvalve AssemblyDrawing....................................................................................................... 10
Motor with emergencystopvalve AssemblyPartList ....................................................................................................... 11
Motor with overloadandemergencystopvalve AssemblyDrawing.................................................................................. 12
Motor with overloadandemergencystopvalve AssemblyPartList .................................................................................. 13
HoistAssemblyDrawing.................................................................................................................................................. 14
HoistAssemblyPartsList. ................................................................................................................................................ 15
HookAssemblyDrawing
..................................................................................................................................................
16
HookAssemblyPartsList................................................................................................................................................. 17
PHS2Remote
ControlAssemblyDrawing......................................................................... ..:............................................ 18
PHS2Remote
ControlAssemblyPartsList. ...................................................................................................................... 19
PHS2URemote
Controlwith Emergency
StopAssemblyDrawing .................................................................................. .20
PHS2URemote
Controlwith Emergency
StopAssemblyPartsList
.................................................................................
.21
ChainbucketAssemblyDrawing andPartsList .............................................................................................................. .22
Parts Ordering Information
Warranty... . _.. .... ___._ __ _.... . ........___..._..._..._.._...... _..._._._.._._.._.._....... ......_... .._..._.._......_... _.___... ...._.. .. ..... . .23
OfficeLocation
____..______.__....______________________.__._____.__......._.._..._............................................................................................
24
2

l Never perform maintenance on the hoist while it is
supporting a load.
l Before performing maintenance, tag controls : DANGER
- DO NOT OPERATE - EQUIPMENT BEING
REPAIRED.
l Only allow service personnel trained in the operation and
service of this hoist to perform maintenance.
l After performing any maintenance on the hoist, test hoist
to 125% of its rated capacity before returning to service.
l Turn off air system and depressurize air lines before
performing any maintenance.
INTERVAL MAINTENANCE CHECKS
Start of each shift
6 Months
Make a thorough visual inspection
of the hoist for damage. Do not
operate the hoist if damage found.
Check the operation of the brake.
Inspect the disc brake friction
linings. Clean or replace parts as
required. Lubricate brake spring
washers.
Inspect the gearing, shafts, and
bearings for damage or wear.
Check all of the supporting
members, including the trolley
ifused.
Disk Brake
Adjustment
No brake adjustment is required
*When any part of the brake disc thickness measures 0.098
in. (2.5 mm) or less, brake disc must be replaced.
Brake Disc Replacement
To check or replace the brake friction disc (83) use the
following procedure.
1. Loosen capscrews (78) one turn at a time progressively
round the cover (77) until brake spring load is relaxed.
Remove capscrews (78) holding cover to the brake cover
(73).
2. Remove cover (77), spring washers (SO) and brake disc
(79).
3. Pull brake fiction disc (83) from pinion (112).
4. Replace brake friction disc (83) so spline locates on
pinion (ll2).
5. Install brake disc (79). Place spring washers (SO) on
brake disc starting with a dished surface toward the brake
disc. Alternate spring washers (SO) (dished up/dished
down).
6. Align pin (82) in brake disc (79) with hole in cover (77)
then install cover (77) and pull down evently with
capscrews (78).
l The brake will not operate properly if there is oil or
grease on the brake disc.
(Dwg. D6090011)
Chain Replacement
(Ref. Dwg. D6090009)
1. The hoist must be hung and connected to the air supply.
Reduce air pressure to 60 psi (4 bar).
2. Remove chain bucket, if used.
3. Remove free end of chain from hoist body “A”, if
attached. Remove chain stop buffer (133) with buffer ring
( 134).
4. Run hoist slowiy in the lifting direction until the chain
free end is approximately 2 ft (60 cm) from the hoist.
(Dwg. D6090009)
5. Using a ‘C’ link which is the same size as the chain join
the new chain to the old taking care that the weld on the
“standing” links on the new chain are facing away from
the hoist load sheave.
6. Run de hoist slowly until the new chain has passed 24 to
36 in. (60 to 90 cm) through the hoist.
7. Install buffer (152) or (133) with the buffer ring (134), on
the hook fall of the load chain+ The offset shoulder of the
buffer must be toward the hose connection end of the
hoist. The buffer actuates the top limit switch.

Single chain fall hoists.
8. Remove retainer wire (130), hook ring (129) and hook
anchor pin (128). Position the last link of the chain in the
hook slot. Replace hook anchor pin (128), hook ring (129)
and retainer wire (130).
9. Install buffer (133) with buffer ring (134) on opposite
chain end so offset shoulder of buffer is facing the
bottom of the hoist motor. Place buffer 6 in. (15 cm)
from the chain end. This buffer activates the bottom limit
switch.
10. Secure buffer (133) in position with capscrew (137) and
nut (136).
11. Attach the last chain link to the hoist with capscrew (78)
and washer (114).
.
Check that the chain is not twisted.
Double chain fail hoists
12. Feed the chain end with a nylon string into the hook block
(127). Take care that the “standing" links on the new
chain are facing away from the hook block sheave.
13. Secure the last link on the chain to the hoist body with
capscrew (117) and washer (116).
(Dwg. D6090010)
14. Secure the opposite end of the chain as previously
described for the single chain fall hoists.
In the event that the chain has been completely removed from
the hoist it will be necessary to remove the hoist brake. Refer
to the instructions for “Brake Disc Replacement” (Ref. Dwg.
D6090010).
Insert the first link in “D” so link is parallel to pinion (112).
Ensure welded side of second chain link faces away from
sprocket (107).
Rotate pinion (112) by hand to install chain until it appears at
“C”
. Do not attempt to install the chain by powering the hoist.
Attach the chain at “A” after installing buffer (133).
Reinstall the brake and complete chain installation as
previously described.
General Disassembly
The following instructions provide the necessary information
to disassemble, inspect, repair, and assemble the hoist. Parts
drawings of the hoist assembly are provided in the Parts
section
If a hoist is being completely disassembled for any reason,
follow the order of the topics as they are presented.
It is recommended that all maintenance work on the hoist be
performed on a bench in a clean dust free work area. In the
process of disassembling the hoist, observe the following :
1.
2.
3.
4.
5.
6.
7.
Never disassemble the hoist any further than is necessary
to accomplish the needed repair. A good part can be
damaged during the course of disassembly.
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.
Do not heat a part with a flame to free it for removal,
unless the part being heated is already worn or damaged
beyond repair and no additional damage will occur to
other parts.
In general, the hoist is designed to permit easy
disassembly and assembly. The use of heat or excessive
force should not be required
Keep the work area as clean as practical, to prevent dirt
and other foreign matter from getting into bearings or
other moving parts.
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.
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.
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.
Disassembly Instructions
(Ref. Dwg. D6090001)
1.
2.
6.
7.
8.
9.
Disconnect all hoses from hoist motor. Position hoist
vertically so brake end is down Remove the four
capscrews and pry motor assembly from gear casing (61).
Set motor assembly to one side for later disassembly. Pull
coupling (110) from pinion (ll2).
Remove capscrews (6), pull out tubes (57) and screen
(58) from gear casing (61). Reposition hoist in a vertical
position so motor end is down
Progressively loosen capscrews (78) in cover (77) one
turn at a time each, until the brake spring load is relaxed.
Remove spring washers (80). Lift off brake disc (79) and
brake friction disc (83).
Remove capscrews (115) and pry brake cover (73) and
gasket (90) from gear casing (61). Lift off spring washer
(88).
Pull piston (76) with ‘O’rings (74) and (75) from brake
cover (73).
Pry bearing (89) from planet support (64).
Set hoist in a horizontal position and from the motor end
of the gear casing (61) carefully tap on the end of pinion
(112) to remove planet assembly.
Remove retainer ring (85) and tap out pinion (112).
4

10. If planet assembly requires disassembly slide out planet
axle (93) and separate planet gears (96), spacers (94) and
bearings (92).
11. Remove ring gear (91) from gear casing (61).
4. Remove the valve cone assembly (18-16-21-17-2).
5. Remove the spring (23), the spring recever (15) and the
ball (14).
6. Remove the nut (12) the Usit-ring (13) and the screw
(47).
l Check that load chain has been removed before
attempting to remove sprocket (107).
12.
13.
14.
15.
16.
17.
Remove retainer ring (105) from the motor side and tap
on sprocket from the brake end of gear casing (61) to
drive out sprocket (107) and bearing (106) with ring (60).
Lift out ring gear (63) and bearing (62).
Remove retainer ring (105) from gear casing (61) bore
and tap out bearing (106) with ring (60) from brake side.
Remove setscrew (11 S) from chain holder (97). Tap out
pins (101) , remove chain holder (97) with chain guide
stop (98).
Remove screws (100) and washers (99) from chain holder
(97).
Remove shafts (56) from gear casing (61) and slide out
chain guide (59).
Air Gear Motor Disassembly
(Ref. Dwg. D6340003)
Refer to disassembly instructions to remove motor assembly
from gear casing.
1. Remave capscrews (8).
2. Remove the motor cover (11). If necessary, remove
retainer rings (39) and bearings (41), ‘0’rings (38) and
pins (43).
3. Remove the motor housing (46) spring (9) slide valve
(44), stop (36) side valve (10) and quad-ring (4248).
4. Immobilize the motor rotors with a rod between the teeth
and remove nuts (3).
5. Remove the motor rotors (7,45).
6. Remove the screw (6) and the washer (5).
7. Remove bearing (4).
Motor with emergency stop valve Disassembly
(Ref. Dwg. D6340002)
Refer to air gear motor disassembly to begin.
For emergency stop valve disassembly:
1. Remove screws (3 1).
2. Remove the cover (50) with the spring (52).
3. Remove ‘O’ring (5 1) from the cover (50).
4. Remove screws (33-37-40).
5 Remove the cover (22).
6. Remove the diaphragm (24).
7. Immobilize the valve cone (25) by its hole with a rod in a
orifice of the cover (11) and remove the screw (29).
8. Remove the valve cone (30-25) with the joint (26) and the
distance ring (28) with the washer (27).
Motor with overload and emergency stop valve
Disassembly
(Ref. Dwg. D6340001)
Refer to motor with emergency stop valve disassembly
instructions to begin.
For overload valve disassembly:
1. Remove the screw (20) and the joint (19)
2. Remove screws (33-37-40).
3. Remove the cover (22).
PHS2 Pendant Control Disassembly
(Ref Dwg. D6090018)
1. Remove the fittings (32) and the eyebolt (162).
2. Remove the retainer rings (173).
3. Pull out rear covers (172) with the’O’ring (171).
4. Remove the springs (170).
5. Remove the slide valve (169) with the quad ring (168).
6. Remove the spring (167).
7. Remove the valve cone ass’y (166).
8. Remove the setscrew (164).
9. Tap out pm (165) to remove the levers (163).
PHS2U Pendant Control With Emergency Stop
Disassembly
(Ref. Dwg. D6340012)
Refer to PHS 2 Control Disassembly to begin PHS 2U
Disassembly
10. Remove the emergency buttom (188).
11. Remove the setscrews (185).
12. Remove the spools (187).
13. Pull out the shuttle valve stop (183) with ball (184).
14. Remove the ‘O’ring (182) from shuttle valve stop (183)
and spool (187).
Cleaning, Inspection and Repair
Use the following procedures to clean, inspect and repair the
components of the hoist.
Cleaning
l Bearings that are loose, worn or rotate in the frame must
be replaced. Failure to observe this precaution will result
in additional component damage.
l Do not use trichloroethylene to clean parts.
Clean all hoist component parts in solvent (except for the brake
disc). The use of a stiff bristle brush will facilitate the removal
of accumulated dirt and sediments on the gears and frames. If
bushings have been removed it may be necessary to carefully
scrape old Loctite ® from the bearing bores. Dry each part
using low pressure, filtered compressed air.
Inspection
All disassembled parts should be inspected to determine their
fitness for continued use. Pay particular attention to the
following :
1. Inspect all gears for worn cracked, or broken teeth.
2. Inspect all bushings for wear, scoring, or galling.
3. Inspect 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

5. Inspect the brake disc for oil and wipe clean as required.
If the brake disc is glazed, sand it lightly using fine
emery cloth.
6. Measure the thickness of the brake disc. Ifthe brake disc
is less than 0.098 in. (2.5 mm) replace the brake disc
(83).
7. Check screen (58) and silencer (68) for damage or
excessive dirt.
Repair
Actual repairs are limited to the removal of small burrs and
other minor surface imperfections from gears and shafts. Use a
fine stone or emery cloth for this work.
1. Worm 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 lo&washers.
Assembly instructions
(Ref. Dwg. D6090001)
i.
2.
7.
8.
9.
Install retainer ring (105) tap bearing (106) with ring (60)
from the motor side of gear casing (61). Extreme care is
required during this operation to ensure bearing (106)
remains square.
Install second bearing ( 106) with ring (60) on sprocket
(107). Slide chain guide (59) into gear casing (61). Tap or
press assembled sprocket (107) into gear casing (61)
from the motor side.
At motor side, install bearing (111) with quad-ring (108)
into sproket (107) and retainer ring (105).
Install shafts (56) in gear casing (61). Jiggle chain guide
(59) to aid installation
Install the chain guide stop (98) on the chain holder (97)
with the screws (100) and washer (99).
Position hoist vertically with the motor end down. Slide
chain guide (98) with chain holder (97) into gear casing
(61), intall pins (101) and secure with setscrew (118).
Lubricate and install ‘O’ring (95) in the groove on the
outside of ring gear (63). Install ring gear (63) on spline
of sprocket (107). Install bearing (62) on sprocket (107).
Install pinion (112), bearing (87) and retainer rings (85)
and (86) in planet carrier (64).
Install load chain Refer to chain installation procedures
in the “MAINTENANCE” section.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Maintenance of the planet gear assembly should be limited
to general cleaning and greasing of the planet pars (96)
and bearings (92). If the planet gear assembly was
removed during hoist disassembly it will be necessary to
line up the timing marks on the planet gears correctly.
Assemble planet assembly so planet gears (96) mesh
with pinion (112). Position planet gears (96) so the ‘0
marks engraved on the planet gears are in line. Ref. Dwg.
D6090012.
Install assembled planet assembly with pinion (112) in
gear casing (61).
Install ring gear (91) with notches outward.
(Dwg. D6090012)
Install bearing (89) on planet carrier (64).
Install gasket (90) on brake cover (73). Place spring
washer (88) on bearing (89) so dished side is toward the
bearing (89). Lubricate gear casing.
Lubricate ‘O’rings (69) and ‘U’ cup seal (84) and install in
brake cover (73). The lip of ‘U’ cup seal (84) must be
toward the planet assembly. Add Silicone seal to gear
casing surface and install brake cover (73) so pins (81)
line up. Exercise caution during this operation to ensure
'O'rings (69) remain in position. Secure brake cover (73)
in position with capscrews (115).
Lubricate and install ‘O’rings (74) and (75) on piston
(76). Install piston (76) in brake cover (73).
Install brake friction disc (83) and brake disc (79).
Install springs (SO) on brake disc (79) starting with a
dished surface toward the brake disc. Alternate springs
(80) (dished up/dished down).
Align pin (82) in brake disc (79) with hole in cover (77)
then install cover (77) and pull down evenly with
capscrews (78).
Position hoist vertically with the brake end down. Set
screen (58) in motor side of gear casing (61) and loosely
secure with capscrews (6). Install tubes (57) through
screen (58) until they are fully seated. Tighten capscrews
(6). Install coupling (110) on pinion (112).
Install motor assembly and secure with capscrews (33).
Install silencer (68) in gear casing (61) with capscrew
(67).
Motor
If the motor assembly has been removed for disassembly,
inspection or repair it is necessary that it be reassembled into
casing (61) using a good quality silicone seal between the
casing (6 1) and motor mounting flange. The silicone seal
meust be allowed to cure for 3 hours before attempting to
pressurize the motor.
6

Air Gear Motor Assembly
(Ref. Dwg. D6340003)
1. Lubricate bearings (4) with grade 2 grease then install
bearings in motor flange (1). Ensure markings on bearing
cage are still visible after installation
2. Install screw (6) with washer (5).
3. Install motor rotors (45-7) and retainer ring (39) with the
part of the bearing (41).
4. Immobilize the motor rotors with a rod between the teeth
and install nuts (3). Lightly coat nut threads with Loctite
®234.
5. Install motor housing (46) with ‘O'ring (2) on motor
flange (1).
6. Install slide valve (44) springs (9), slide valve (10) with
quad-ring (48) quad-rings (42) and ‘O’ring (38) in motor
housing (46) and stop in cover (11).
7. Install bearing (41) and stop (36) in motor cover (11).
Install motor cover on motor housing (46). Ensure pins
(43) are fully aligned and engaged. Secure with
capscrews (8). Lightly coat capscrew threads with Loctite
® 234.
Air Gear Motor with emergency stop valve
(Ref. Dwg. D6340002)
Refer to air gear motor assembly instructions to begin
For mounting emergency stop valve:
1. Install the valve cone (30) with the joint (26) the washer
(27) and the distance ring (28) on the screw (29), put the
assembly in the cover (11).
2. Install and immobilize the valve cone (25) by its hole
with arod inaorifice ofthecover (ll)and secure the
screw (29).
3. Install the diaphragm (24).
4. Install the cover (22) and secure with screws (33-37-40)
5. Install the cover (50) with the ‘O’ring (5 1) and the spring
(52). Secure with screws (31).
Air Gear Motor with overload and emergency stop valve.
(Ref. Dwg. D6340001)
Refer to air gear motor assembly instructions to begin
For mounting overload and emergency stop valve:
1. Install the valve cone (30) with the joint (26) the washer
(27) and the distance ring (28) on the screw (29) put the
assembly in the cover (11).
2. Install and immobilize the valve cone (25) by its hole
with arod inaorifice ofthecover (ll)and secure the
screw (29).
3. Install the diaphragm (24).
4. Install the ball (14) the rececer spring (15) and the spring
(23).
5. Install valve cone assembly (18-21-16-17-2)
6. Install the cover (22) and secure with screws (33-37-40).
7. Install the joint (19) and the screw (20) in the cover (22).
8. Install thecover (50) with the’O’ring (51) and thespring
(52). Secure with screws (31).
9. Install the screw (47) the Usit-ring (13) and the nut stop
(12).
PHS2 Pendant Control Assembly
(Ref. Dwg. D6090018)
1. Install levers (163) in pendant handle with pin (165).
Stake pm in pendant handle at both ends to secure.
2. Install setscrews (164).
3. Check that 'O'ring is undamaged and securely crimped in
valve cone. Install valve cone assemblies (166).
4. Install springs (167).
5. Check that ‘O’ring is undamaged and securely crimped in
slide valves. Install quad ring (168) and slide valve ass’y
(169).
6. InstaIl springs (170).
7. Lubricate and install 'O'ring (171) on rear cover (172).
Install rear cover in pendant handle.
8. InstaIl retainer ring (173).
PHS2U Pendant Control With Emergency Stop Assembly
(Ref. Dwg. D6340012)
Refer to PHS2 control assembly to begin PHS2U assembly.
9. Install ‘O’ring (182) on shultle valve stop (183) and spool
(187).
10. Install that shultle valve stop (183) with ball (184); those
spool (187) in the pendant handle (18 1) and secuse with
setcrews (185).
11. Install the emergency bottom (188).
12. Install the eyebolt (162) and the fitting (32).
Pendant Control Adjustment :
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Connect the inlet of the pendant to 100 psi (7 bar) air
supply.
Connect a manometer at the outlet of the lever to be
adjusted.
Apply a small amount of Loctite ® 243 on the adjustment
setscrew (164).
Tighten the adjustment setscrew to obtain a pressure of
15 psi (1 bar) without actionning the lever.
Release the adjustment setscrew by a halfturn (pressure
must fall to zero).
Push the lever. Check that pressure reaches 93 +/- 7 psi
(6.5 +/- 0.5 bar). Check that there is no leak at the
exhaust.
Release the lever, exhaust must occur and result in rapid
pressure reduction
Repeat operations “6 and 7” from 2 to 3 times
Disconnect the manometer. Check to ensure that there are
no leaks when the lever is not activated.
Repeat the operations from 2 to 9 with each lever.
Hook Assemblies
If the hook assemblies have been disassembled for inspection
or repair attention is required on reassembly to ensure that all
ten balls (131) are installed and retained with washer (132)
and hook ring (129) for single fall bottom hook, or retainer
wire (130) for double fall bottom hook.

2
(Dwg :D6340003)
8

ITEM DESCRIPTION
QTY
PART
NO. OF PART TOTAL NO.
1 Motor Flange 1 9609-0008
2 5700-0002
4 Ball Bearing 2 5060-0002
5 Washer 1 9609-0032
6 Screw 1 4130-6706
I
7 Driving Gear 9609-0031
I
8 Screw 4 4130-0806
9 Spring 2 9424-0224
10 SlideValve 2 9424-0212
I
11 Motor Cover
1
9609-0079
I
32 Fitting 3 6165-2632
33 Screw 4 413l-2206
34 Screw 1 4200-7707
36 Stop 2 9609-0042
39 RetainerRing 2 4780-1339
43 Pin 6 4600-0416
44 SlideValve 2 9412-0030
45 Idle Gear 1 9609-0030
46 Motor Housing 1 9609-0007
9

‘/I/
(Dwg: D6340002)
10

ITEM DESCRIPTION
QTY
PART
NO. OF PART TOTAL NO.
1 Motor Flange 1 9609-0008
2 5700-0002
4 Ball Bearing 2 5060-0002
I I
5 Washer 1 9609-0032
6 Screw 1 4130-6706
7 Driving Gear 1 9609-0031
8 Screw 4 4130-0806
9 Spring 2 9424-0224
10 SlideValve 2 9424-0212
11 Motor Cover 1 9609-0270
22 Cover 1 9609-0271
28 Spacer 1 9617-0055
29 Screw 1 4130-8206
30 C1apet 1 9617-0053
31 Screw 3 4132-6306
32 Fitting 5 6165-2632
33 Screw 6 4132-2206
34 Screw 1 4200-8307
36 Stop 2 9609-0042
I
37 I Screw 4 4132-2306
39 RetainerRing 2 4780-1339
40 Screw 2 4132-4306
I
44 SlideValve 2 9412-0030
45 Idle Gear 1 9609-0030
46 Motor Housing 1 9609-0007
Cover 9617-0059
52
55 Spring 1 6915-8732
Motor with emergencystop
valveass’y 1 7609-0430
(incl’s item 1through52)
RecommendedSpare.
11

I-z-
(Dwg D6340001)
12

lTEM DESCRIPTION
QTY
PART ITEM DESCRIPTION
QTY
PART
NO. OF PART TOTAL NO. NO. OF PART TOTAL NO.
1 Motor Flange
3 Locknut
1 9609-0008
2 5700-0002
4 Ball Bearing 2 5060-0002
5 Washer 1 9609-0032
6 Screw 1 4130-6706
7 Driving Gear 1 9609-0031
8 Screw 4 4130-0806
9 Spring 2 9424-0224
10 SlideValve 2 9424-0212
11 Motor Cover 1 9609-0266
12 Nut Stop 1 4370-7611
13 Usit-ring 1 5840-4531
14 Ball 1 6940-0125
15 SpringReceiver 1 9636-0023
16 Washer 1 9636-0019
17 Nut 1 4300-1111
21 Diaphram 1 9636-0020
22 Cover 1 9609-0267
23 Spring 1 6915-9432
1 9617-0054
27 Washer 2 4570-0005
39 RetainerRing 2 4780-1339
40 Screw 2 4132-4306
41 NeedleBearing 3
5646-1912
43 Pin 6 4600-0416
44 SlideValve 2 9412-0030
45 Idle Gear 1 9609-0030
46 Motor Housing 1 9609-0007
47 Screw 1 4200-7107
50 Cover 1 9617-0059
52 Spring 1 6915-8732
55 motorwith overloadand 1 7609-0429
* emergencystopvalve ass’y
*
incl’s item (1) through (52)
13

(Dwg D6090001)
14

ITEM DESCRIPTION
QTY
PART
NO. OF PART TOTAL NO.
valve
56 Idle gear I 2 9609-0040
57 Tube 2 9609-0055
59 Chain guide 1 9609-0019
60 Ring 2 9609-0076
61 Casing 1 9609-0002
62 Bearing 1 5080-0005
63 Ring gear (standard) 1 9609-0094
I -- .
Ring gear (high Precision) 9609-0037
64 Planet Support 1 9609-0014
65 Screw 2 4131-9606
66 Nut 2 4370-23 11
67 Screw 1 4130-0106
70 Shultle valve stop 1 9609-0223
73 Brakecover I 1 9609-0226
76 Piston 9609-0113
77 Cover 1 9609-0005
78 Screw 5 4130-0206
80 Spring washer 7 6916-0532
81 Pin 1 4600-1716
82 Pin 1 4640-6118
85 Retainer Ring I 1 4770-0015
Hoist Assembly with Option “R”.
Substitute or addthefollowing parts onhoist with option “R”
65 Screw I 2 4132-7206
66 Screw
I
3 4370-7011
67 Screw 1 4132-1406
78 Screw 5 4132-2606
97 Chain Holder 1 9609-0145
99 Washer 2 4520-1004
88 Spring washer 1 6916-0432
89 Ball Bearing 1 5080-0009
90 Gasket 1 9609-0041
91 Ring gear 1 9609-0038
92 Bearing (Standard) 4 5650-1513
Bearing (High Precision) 4 5650-1613
93 Planet Pin 2 9609-0039
I
94 Spacer (Standard) 2 9609-0095
Spacer (High Precision) 2 9609-0026
96 Planet gear (Standard) 1 set 3609-0129
Planet gear (High Precision) 1 set 3609-0130
97 Chain Holder 1 9609-0013
98
Chain guide stop 1 9609-0020
99 Washer 2 4520-0004
100 Screw 2 4131-3606
101 Pin 2 9609-0027
102 Limit switch 2 9609-0051
15
104 Spring 2 6916-0332
105 Retainer ring 2 4770-3067
106 Bearing 2 5005-0007
107 Sprocket 1 9609-0009
109 Bearing 1 5632-15 12
110 coupling 1 9609-0034
111 Bearing 1 5636-2432
112 Pinion 1 9609-0035
113 Pin 1 4640-4618
114 Washer 1 4500-0106
115 Screw 4 413l-4906
116 Washer 1 4520-0008
117 Screw 1 9609-0098
118 Setscrew 2 4200-7007
100 Screw 1 4131-6506
114 Washer 1 4500-1108
115 Screw 4 4132-7406
116 Washer 1 4520-1008
117 Screw 1 9609-0138
Recommended Spare.

PAL250K to PAL1000K
Top Hook Assembly
138
PAL630 / PAL980K & PAL1000K
Bottom Hook Assembly PAL250K / PAL310K & PAL500K Bottom Hook Assembly
(Dwg. D6090002) 16

REAR VIEW OF PALAIR PLUS HOIST
Dwg. D6090018)
18

ITEM DESCRIPTION
QTY
PART
NO. OF PART TOTAL NO.
34 Setscrew 1 4200-7707
32 Fitting 3 6165-2632
160 Pendant Assembly (incl’s item 32 and 161 through 173) 1 7579-0038
161 Pendant Handle 1 9579-0034
162 Lifting Eye 1 6422-2332
163 Lever 2 9579-0038
164 Setscrew 2 4200-7407
165 Pin
1 9579-0040
--_ --
166 Valve Assembly (with ‘O’Ring crimped) 2 9579-0036
167 Spring 2 6915-8632
169 Spool (with ‘0’ Ring crimped) 2 9579-0035
170 2 6915-8732
172 Rear Cover 2 9579-0037
173 Retainer Ring 2 4770-3028
200 Meter of Control (incl’s item 201 through 203) (*) 3387-003 1
201 Hose
202 Hose Tie
203 Strain Relief Wire
3
2/m
1
204 Sleeve Clamp 1 6112-5032
205 Thimble 1 6932-5332
Recommended Spare. (*) Specify length of control when ordering
19