Ingersoll-Rand ML250K Installation guide

Form P6554
PARTS, OPERATION AND MAINTENANCE MANUAL
for
AIR CHAIN HOIST MODELS*
ML250K ML5OOK ML1OOOK
250 kg (1/4 ton) 500 kg (1/2 ton) 1000 kg (1 ton)
ML250KR ML500KR
250 kg (1/4 ton) 500 kg (1/2 ton)
Spark Resistant Spark Resistant
ML250KS
250 kg (1/4 ton)
Slow Speed
ML500KS
500 kg (1/2 ton)
Slow Speed
(Dwg. MHTPA0456)
ML1OOOKS
1000 kg (1 ton)
Slow Speed
* Capacities of hoists are in metric tons (1 metric ton = 2200 Ibs.)
READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual
contains important safety, installation, operation and maintenance infor-
mation. Make this manual available to all persons responsible for the
operation, installation and maintenance of these products.
Do not use this hoist for lifting, supporting, or transporting people or lifting or supporting
loads over people.
Always operate, inspect and maintain this hoist in accordance with American National
Standards Institute Safety Code ( ASME B30.16) and any other applicable safety codes and
regulations.
Refer all communications to the nearest Ingersoll-Rand Material Handling Office or
Distributor.
Form P6554
Edition 9
June 1994
03531324
© 1994 Ingersoll-Rand Company
MATERIAL HANDLING

This manual provides important information for all
personnel involved with the safe installation, operation and
proper maintenance of this product. Even if you feel you
arc familiar with this or similar equipment, you should read
and understand this manual before operating the product.
Danger, Warning, Caution and Notice
Throughout this manual there are stepsand procedures
which, if not followed, may result in a injury. The follow-
ing signal words are used to identify the level of potential
hazard.
Safety Summary
Danger is used to indicate the
presence of a hazard which will
causesevere injury, death, or
substantial property damage if the
warning is ignored.
Warning is used to indicate the
presence of a hazard which can
causesevere injury, death, or
substantial property damage if the
warning is ignored.
Caution is used to indicate the
presence of a hazard which will or
can causeminor injury or property
damage if the warning is ignored.
Notice is used to notify people of
installation, operation, or mainte-
nance information which is impor-
tant but not hazard-related.
l Do not use this hoist or attached equipment for lifting,
supporting, or transporting people or lifting or support-
ing loads over people.
l Powered hoists are designed to provide a 5 to 1 safety
factor. The supporting structures and load-attaching
devices used in conjunction with this hoist must provide
adequate support to handle all hoist operations plus the
weight of the hoist and attached equipment. This is the
customer’s responsibility. If in doubt, consult a
registered structural engineer.
l Lifting equipment is subject to different regulations in
each country. These regulations may not be specified in
this manual.
The National Safety Council, Accident Prevention Manual
for Industrial Operations, Eighth Edition and other recog-
nized safety sources make a common point: Employees
who work near cranes or assist in hooking on or arranging
a load should be instructed to keep out from under the load.
From a safety standpoint, one factor is paramount: conduct
all lifting operations in such a manner that if there were an
equipment failure, no personnel would be injured. This
means keep out from under a raised load and keep out of
the intended path of any load.
Ingersoll-Rand Material Handling hoists are manufactured
in accordance with the latest ASME B30.16 standards.
The Occupational Safety and Health Act of 1970 generally
places the burden of compliance with the owner/employer,
not the manufacturer. Many OSHA requirements are not
concerned or connected with the manufactured product but
are, rather, connected with the final installation. It is the
owner’s responsibility and user’s responsibility to deter-
mine the suitability of a product for any particular use. It is
recommended that all applicable industry, trade associa-
tion, federal, state and local regulations be checked. Read
all operating instructions and warnings before operation.
Rigging: It is the responsibility of the operator to exercise
caution, usecommon senseand be familiar with proper
rigging techniques. SeeASME B30.9 for rigging informa-
tion, American National Standards Institute, 1430 Broad-
way, New York, NY 10018.
This manual has been produced by Ingersoll-Rand to
provide dealers, mechanics, operators and company
personnel with the information required to install, operate,
maintain and repair the products described herein.
It is extremely important that mechanics and operators be
familiar with the servicing procedures of these products, or
like or similar products, and are physically capable of
conducting the procedures. These personnel shall have a
general working knowledge that includes:
1. Proper and safe use and application of mechanics
common hand tools aswell as special
Ingersoll-Rand or recommended tools,
2. Safety procedures, precautions and work habits
established by accepted industry standards.
Ingersoll-Rand can not know of, nor 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.
2

The following warnings and operating instructions have
been adapted in part from American National (Safety)
Standard ASME B30.16 and are intended to avoid unsafe
operating practices which might lead to personal injury or
property damage.
Ingersoll-Rand recognizes that most companies who use
hoists have a safety program in force in their plants. In the
event you are aware that some conflict exists between a
rule setforth in this publication and a similar rule already
setby an individual company, the more stringent of the two
should take precedence.
Safe Operating Instructions are provided to make an
operator aware of dangerous practices to avoid and are not
necessarily limited to the following list. Refer to specific
sections in the manual for additional safety information.
1. Read the manufacturer’s operating instructions before
operating the hoist.
2. Never lift a load greater than the rated capacity of the
hoist (unless for test purposes).
3. Never use the load chain as a sling.
4. Never operate the hoist with twisted, kinked or
damaged chain.
5. Be certain the load is properly seatedin the saddle of
the hook.
6. Do not use load chains asa ground for welding. Do
not attach a welding electrode to a hoist or sling chain.
7. Do not use the up and down stops asa means of
stopping a hoist. The up and down stops are emer-
gency devices only. Keep hands and clothing free from
the throttle lever.
8. Do not leave a load suspended for extended periods.
9. Always stand clear of the load path.
IO. Never use the hoist for lifting or lowering people, and
never stand on a suspended load.
11. Never carry loads over people.
12. Before each shift, check the hoist for wear or damage.
Check brakes, limit stops, etc.
13. Periodically, inspect the hoist thoroughly and replace
worn or damaged parts.
14. Follow the lubrication instructions.
1.5. Do not attempt to repair load chain or hooks. Replace
them when they become worn or damaged.
16. Never operate a hoist when the load chain is not
centered under the hook. Do not “side pull” or “yard”.
17. Always rig the hoist properly and carefully.
18. Easethe slack out of the load chain when starting a
lift. Do not jerk the hoist load.
19. Keep the load chain clean and well lubricated. Do not
20. Be certain there are no objects in the way of a moving
load.
21. Be certain the air supply is shut off before performing
maintenance on the hoist.
22. Do not swing a suspended load.
23. Keep the load block overhead when not in use.
24. Properly secure hoist before leaving it unattended.
25. Only allow personnel trained in safety and operation
on this product to operate the hoist.
26. Avoid collision or bumping of hoists.
27. Do not operate a hoist if you arc not physically fit to
do so.
28. Pay attention to the load at all times when operating a
hoist.
29. Never splice a hoist chain by inserting a bolt between
links or by any other means.
30. Do not force a chain or hook into place by hammering,
and never insert the point of the hook into a chain link.
31. Do not allow the chain to be exposed to extremely
cold weather. Do not apply loads to a cold chain.
drag the load chain or hook on the floor.

Each hoist is supplied from the factory with the warning
tag and label shown. If the tag or label are not attached to
your hoist, order a new tag or label and install it. Seeparts
list in parts section. Read and obey all warnings and other
safety information attached to this hoist. Tag and label may
not be shown actual size.
DO NOT USE
LOWERING PEOPLE
Table 1
Speed with Rated Load Speed with Half Load Speed with No Load
Hoist Model Rated No.
No. Capacity Chain fpm m/m fpm m/m m/m
(kg) fpm
Falls UP down up down up down up down up down up down
ML250KS 40 90 12.2 27.4 53 71 16.1 21.6
ML250K 250 1 101 117 30.8 35.7 145 III 44.2 33.8 171 99 52.1 30.1
ML250KR 26 38 7.9 11.6 34 36
ML500KS 22 66 6.7 20.1 30 44
I
ML500K 500 55 97 16.8 29.6 80 72 24.4 22.0 1O6
ML500KR 2 13 20 4.0 6.1 17 18
ML1000KS 11 33 3.4 10.0 15 22 4.6 6.7 22
I000 2
ML1000K 28 49 8.5 14.9 40 36 12.2 11.0
Performancefiguresbasedon 70CFM (45 CFM for MLKS andMLKR Hoists) at 90 psi (620 kPa) air supply at hoist inlet. Pendant
control models use approximately 4 SCFM more air.
4

Model Code Explanation
Series
=M Example: ML500 KR-2C 10-5 BZ
Link Chain Type = L
Hoist Capacity
250K = 2.50kg - l/4 metric ton (550 lb)
500K = 500 kg - l/2 metric ton (1100 lb)
lOOOK = 1000 kg - 1metric ton (2200 lb)
Spark Resistant
R = Spark Resistant (ML250K and ML500K only)
S = Slow Speed Spotting
1 = Pull Chain
2 = Pendant
3 = 2 Motor Pendant
4 = 3 Motor Pendant
Suspension
A = Fixed Lug
C = Swivel Top Hook
D = Plain Rigid Trolley (Tapered Wheels for I-Beam)
DT = Plain Rigid Trolley (Flat Tread Wheels)
F = Hand Chain Geared Trolley (Tapered Wheels for I-Beam)
FT = Hand Chain Geared Trolley (Flat Tread Wheels)
M = Plain Hook-on Trolley (Tapered Wheels for I-Beam)
MT = Plain Hook-on Trolley (Flat Tread Wheels)
H = Vane Motor Driven Trolley, Pendant Control,
(2) Wheel Drive (Tapered Wheels for I-Beam)
HT = Vane Motor Driven Trolley, Pendant Control,
(2) Wheel Drive (Flat Tread Wheels)
Length of Lift
10
xx = 10 ft. (3 m)
= Specify Length
Pendant Drop
5 = 5 ft. (1.5 m)
xx = Specify Length
BZ = Zinc Plated Chain
BB = Bullard Burnham Hook(s)
BR = Bronze Hook(s)

Prior to installing the hoist, carefully inspect it for possible
shipping damage.
Hoists are supplied fully lubricated from the factory.
Lubrication of the load chain is recommended before initial
hoist operation.
l Owners and users are advised to examine specific,
local or other regulations, including American
National Standards Institute and/or OSHA Regulations
which may apply to a particular type of use of this
product before installing or putting hoist to use.
l A falling load can cause injury or death. Before
installing, read “SAFETY INFORMATION”.
Hoist
Make certain your hoist is properly installed. A little extra
time and effort in so doing can contribute a lot toward
preventing accidents and helping you get the best service
possible.
Always make certain the supporting member from which
the hoist is suspended is strong enough to support the
weight of the hoist plus the weight of a maximum rated
load plus a generous factor of at least 500% of the com-
bined weights.
If the hoist is suspended by a top hook, the supporting
member should rest completely within the saddle of the
hook and be centered directly above the hook shank. Do
not use a supporting member that tilts the hoist to one side
or the other.
Hook Mounted Hoist Installation
Place hook over mounting structure. Make sure hook latch
is engaged.
Trolley Mounted Hoist Installation
(Refer to Dwg. TPA825-2)
When installing a trolley on a beam, measure the beam
flange and temporarily install the trolley on the hoist to
determine the exact distribution and arrangement of the
spacers.The distance between the wheel flanges should be
3/16 in. to l/4 in. (4.76 mm to 6.35 mm) greater than the
width of the beam flange. The number of spacers(257)
between the trolley side plate (250) and the mounting lug
on the hoist must be the samein all four locations in order
to keep the hoist centered under the I-beam. The remaining
spacersmust be equally distributed on the outside of the
side plates. (For additional information refer to Installation
and Maintenance Manual Form P6609 for Vane Motor
Driven Trolleys.)
I
I SPACER MINIMUM
REQU I RED
(SEE INSTRUCTIONS)
MLK Hoist Plain Rigid Trolley
(Dwg. TPD909)
l At least one Mounting Spacer (257) must he used
between the head of each Trolley Bracket Bolt (255)
and the Trolley Bracket (250) and between each Trolley
Bolt Nut (256) and the Trolley Bracket. Failure to do
this could cause the hoist to fall when used improperly.
Torque the Trolley Bolt Nuts (256) to 150 ft-lb (203 N.m).
When installing the hoist and trolley on the beam, make
certain the side plates are parallel and vertical. After
installation, operate the trolley over the entire length of the
beam with a capacity load suspended4 to 6 inches (I 0 to
15cms) off the floor.
l To avoid an unbalanced load which may damage the
trolley, the hoist must be centered under the trolley.
l Trolley wheels ride on the top of the lower flange of
the beam.

Chain Container
When installing a fabric chain container on an MLK hoist,
refer to drawings TPB605-2 and TPD580 in the parts
section.
AIR OUT
l Make certain to adjust the balance chain so that the
chain container does not contact the load chain.
l Allow chain to pile naturally in the chain container.
Piling the chain carelessly into the container by hand
may lead to kinking or twisting that will jam the hoist.
1. Check the chain container size to make sure the length
of load chain is within the capacity of the chain
container. Replace with a larger chain container, if
required.
2. Attach the chain container to the hoist.
3. Run bottom block to lowest point and run hoist in up
direction to feed the chain back into the container.
Air System
The supply air must be clean, lubricated and free from
water or moisture. A minimum of 90 psi (6.2 bar/620 Kpa)
at the hoist motor is required to provide rated hoist
capacity.
Air Lines
The inside diameter of the hoist air supply lines must not
be smaller than l/2 in. (13 mm) basedon a maximum of 50
ft. (15 m) between the air supply and the hoist. Contact the
factory for recommended air line sizes for distances greater
than 50 ft. (15 m). Before making final connections, all air
supply lines should be purged before connecting to unit
inlet. Supply lines should be asshort and straight as
installation conditions will permit. Long transmission lines
and excessive useof fittings, elbows, tees,globe valves etc.
cause a reduction in pressure due to restrictions and surface
friction in the lines. If quick-disconnect fittings are used at
the inlet of the hoist, they must have at least a 3/8 in. (9.5
mm) air passage.Use of smaller fittings will reduce
performance.
l Always use an air line filter and lubricator with an
MLK hoist.
REGULATOR
LUBRICATOR FILTER
IN
(Dwg. MHTPA0191)
Air Line Lubricator
(Ref. Dwg. MHTPA0191)
Always use an air line lubricator with these hoists. Use a
lubricator having an inlet and outlet at least aslarge asthe
inlet on the hoist motor. Install the air line lubricator as
close to the air inlet on the hoist motor aspossible. Refer to
“ACCESSORIES” in the parts section for the recom-
mended Filter-Lubricator-Regulator.
l Lubricator must be located no more than 10 ft. (3 m)
from the motor.
The air line lubricator should be replenished daily and set
to provide lubrication at a minimum rate of 1to 3 drops per
minute adjusted at maximum hoist speed,of SAE 10W oil
or a good grade of hydraulic oil. A fine mist will be
exhausted from the throttle control valve when the air line
lubricator is functioning properly.
l Do not use automotive type detergent oil. Detergents
will delaminate the motor vanes and cause premature
failure.
Air Line Filter
(Ref. Dwg. MHTPA0191)
It is recommended that an air line strainer/filter be installed
asclose aspractical to the motor air inlet port to prevent
dirt from entering the motor. The strainer/filter should
provide 10micron filtration and include a moisture trap.
Clean the strainer/filter monthly to maintain its operating
efficiency.

Moisture in Air Lines
Moisture that reachesthe air motor through the supply
lines is the chief factor in determining the length of time
between service overhauls. Moisture traps can help to
eliminate moisture. Other methods, such asan air receiver
which collects moisture before it reaches the motor or an
aftercooler at the compressor that cools the air prior to
distribution through the supply lines, are also helpful.
l Shut off air supply before filling air line lubricator.
The Inlet Strainer (42 or 344) must be installed on the
hoist. Failure to do so may result in a hoist malfunction.
The Bleed Adjustment Screws (35 or 336) used on hoists
with a pendent control are factory adjusted to provide
optimum control at 90 psig (6.2 bar/620 kPa) air pressure.
If the hoist is used with other air supply pressures, the
Bleed Adjustment Screws may require readjustment.
Adjustment of Bleed Screws on Pendent
Control Models
For maximum performance and control, adjust the bleed
screws (35 or 336) asfollows:
1.
2.
3.
4.
Loosen the Adjustment Screw Locknut (36 or 337).
Back out the Adjustment Screw (35 or 336) approxi-
mately one third (l/3) of a turn.
While fully depressing the Pendent Throttle Lever
(205) and holding it in that position, turn in the
Adjustment Screw until the Piston Rod fully retracts.
This adjustment will provide a good balance of
spotting control and maximum hoist speed.If better
spotting control is desired, slowly back out the
Adjustment Screw a little at a time until the spotting
control is suitable.
Tighten the Adjustment Screw Locknut (36 or 337).
Storing the Hoist
1. Always store the hoist in a no load condition.
2. Wipe off all dirt and water.
3. Oil the load chain, hook pins and hook latch.
4. Place in a dry location.
5. Plug hoist air inlet port.
6. Before returning hoist to service follow instructions
for Hoists not in Regular Service in the “INSPEC-
TION’ section.
8

The four most important aspectsof hoist operation are:
1. Follow all safety instructions when operating hoist.
2. Allow only people trained in safety and operation on
this product to operate hoist.
3. Subject each hoist to a regular inspection and mainte-
nance asoutlined in ASME B30.16.
4. Be aware of the hoist capacity and weight of load at all
times.
Operators must be physically competent. Operators must
have no health condition which might affect their ability to
act, and they must have good hearing, vision and depth
perception. The hoist operator must be carefully instructed
in his duties and must understand the operation of the hoist,
including a study of the manufacturer’s literature. The
operator must thoroughly understand proper methods of
hitching loads and should have a good attitude regarding
safety. It is the operator’s responsibility to refuse to operate
the hoist under unsafe conditions.
Initial Operating Checks
Hoists are tested for proper operation prior to leaving the
factory. Before the hoist is placed into service the follow-
ing initial operating checks should be performed.
1.
2.
3.
4.
5.
6.
7.
8.
After installation of trolley mounted hoists, check to
ensure the hoist is centered below the trolley.
Check for air leaks in the supply hose and fittings to
pendant, and from pendant to manifold.
When first running the hoist or trolley motors some
light oil should be injected into the inlet connection to
allow good lubrication.
When first operating the hoist and trolley it is recom-
mended that the motors be driven slowly in both
directions for a few minutes.
Operate the trolley along the entire length of the beam.
Inspect hoist and trolley performance when raising,
moving and lowering test load(s). Hoist and trolley
must operate smoothly and at rated specifications prior
to being placed in service.
Check that trolley (if equipped) and hook movement is
the samedirection asarrows or information on the
pendant control.
Raise and lower a light load to check operation of the
hoist brake.
9. Check hoist operation by raising and lowering a load
equal to the rated capacity of the hoist a few inches
(cm) off the floor.
10. Check operation of limit devices.
11. Check to seethat the hoist is directly over the load. Do
not lift the load at an angle (side pull or “yard”).
9
12. Check to seethat the hoist is securely connected to the
overhead crane, monorail, trolley or supporting
member.
13. Check to seethat the load is securely inserted in the
hook, and that the hook latch is engaged.
l Only allow personnel trained in safety and operation
of this product to operate the hoist and trolley.
l The hoist is not designed or suitable for lifting,
lowering or moving persons. Never lift loads over
people.
Hoist Controls
MLK Two Lever Pendant
Two lever pendants provide operation of the hoist only. For
units with powered trolleys a four lever pendant is re-
quired.
RAISE
LOAD
(Dwg. MHTPA0427)
l The hook latch is intended to retain loose slings or
devices under slack conditions. Hook latches are not
intended to be an anti-fouling device, so caution must
be used to prevent the latch from supporting any of the
load.
Refer to Form P6778 for information on Pendant Throttle
Handle Assemblies for two and three motor functions.

There are two types of inspection, the frequent inspection
performed by the operator and periodic inspections
performed by personnel trained in the operation and repair
of this hoist.
Careful inspection on a regular basis will reveal potentially
dangerous conditions while still in the early stages,
allowing corrective actions to be taken before the condition
becomes dangerous.
Any deficiency revealed through inspection must be
reported to an appointed person. A determination must be
made asto whether a deficiency constitutes a safety hazard
before resuming operation of the hoist.
Records and Reports
Some form of inspection record should be maintained for
each hoist, listing all points requiring periodic inspection.
A written report should be made monthly on the condition
of the critical parts of each hoist. These reports should be
dated, signed by each person who performed the inspec-
tion, and kept on file where they are readily available to
authorized personnel.
Frequent Inspection
On hoists in continuous service, frequent inspection should
be made at the beginning of each shift. In addition, visual
inspections should be conducted during regular service for
any damage or evidence of malfunction.
1. OPERATION. Check for visual signs or abnormal
noises (grinding etc.) which could indicate a potential
problem. Make sure all controls function properly and
return to neutral when released. Check chain feed
through the hoist and bottom block. If chain binds,
jumps, is excessively noisy or “clicks”, clean and
lubricate the chain. If problem persists, replace the
chain. Do not operate the hoist until all problems have
been corrected.
2. HOOKS. Check for wear or damage, increased throat
width, bent shank or twisting of hook. Replace hooks
which exceed the throat opening discard width
specified in Table 2 (see Dwg. MHTPA0040) or
exceed a IO” twist (seeDwg. MHTPAOlll). If the
hook latch snapspast the tip of the hook, the hook is
sprung and must be replaced. Refer to the latest
edition of ASME B30.10 “HOOKS” for additional
information. Check hook support bearings for
lubrication or damage. Ensure they swivel easily and
smoothly.
3. UPPER AND LOWER LIMIT DEVICE. Test
operation with no load slowly to both extremes of
travel. Upward travel must stop when the bottom
block or stop buffer on chain hits hoist limit arm.
Downward travel must stop when the loop at the
unloaded end of the chain decreasesand activates the
limit arm.
. Throat Width
4
(Dwg. MHTPA0040)
Table 2
ML 1000K and ML I000KS l-1/4 31.8 I-7/32 31.0
ML250KR and ML500KR I-7/32 31.0 l-5/16 33.4
Twisted
DO NOT USE Normal
Can Be Used
(Dwg. MHTPAO111)
4. AIR SYSTEM. Visually inspect all connections,
fittings, hoses and components for indication of air
leaks. Repair any leaks found. Check and clean the
filter in the Inlet Nipple, if equipped, and the strainer
in the Inlet Strainer (42).
IO

5. CONTROLS. During operation of hoist, verify
response to pendant is quick and smooth. Seethat the
controls return to neutral when released. If hoist
responds slowly or movement is unsatisfactory, do not
operate hoist until all deficiencies have been corrected.
6. HOOK LATCH. Make sure the hook latch is present
and operating. Replace if necessary.
l Do not use hoist if hook latch is missing or damaged.
7. LOAD CHAIN. Examine each of the links for
bending, cracks in weld areasor shoulders, traverse
nicks and gouges, weld splatter, corrosion pits,
striation (minute parallel lines) and chain wear,
including bearing surfaces between chain links (see
Dwg. MHTPA0102). Replace a chain that fails any of
the inspections. Check chain lubrication and lubricate
if necessary. Refer to “Load Chain” in “LUBRICA-
TION” section.
Diameter Welded Area
Wear in
these areas
(Dwg. MHTPA0102)
l The full extent of load chain wear cannot be deter-
mined by visual inspection. At any indication of load
chain wear inspect chain and chain wheel in accordance
with instructions in “Periodic Inspection”.
8. LOAD CHAIN REEVING. Ensure welds on standing
links are away from the powered chain wheel. Rein-
stall chain if necessary. Make sure chain is not
capsized, twisted or kinked. Adjust asrequired.
Periodic Inspection
According to ASME B30.16, frequency of periodic
inspection depends on the severity of usage:
NORMAL HEAVY SEVERE
yearly semi-annually quarterly
Disassembly may be required for HEAVY or SEVERE
usage. Keep accumulative written records of periodic
inspections to provide a basis for continuing evaluation.
Inspect all the items in “Frequent Inspection”. Also inspect
the following:
1.
2.
3.
4.
5.
6.
7.
8.
9.
FASTENERS. Check all rivets, split pins, capscrews
and nuts. Replace if missing or tighten if loose.
ALL COMPONENTS. Inspect for wear, damage,
distortion, deformation and cleanliness. If external
evidence indicates the need, disassemble. Check
gears, shafts, bearings, sheaves,chain guides, springs
and covers. Replace worn or damaged parts. Clean,
lubricate and reassemble.
HOOKS. Inspect hooks carefully for cracks using
magnetic particle or other suitable non-destructive
method. Inspect hook retaining parts. Tighten or
repair, if necessary.
LOAD CHAIN WHEELS. Check for damage or
excessive wear. Replace if necessary. Observe the
action of the load chain feeding through the hoist. Do
not operate a hoist unless the load chain feeds through
the hoist and hook block smoothly and without audible
clicking or other evidence of binding or malfunction-
ing.
MOTOR. If performance is poor, disassemble the
motor and check for wear or damage to bearings and
shafts. The parts should be cleaned, lubricated and
reassembled. Replace worn or damaged parts.
BRAKE. Raise a load equal to the rated capacity of
the hoist a few inches (cms) off the floor. Verify hoist
holds the load without drift. If drift occurs, disas-
semble. Remove brake discs asdescribed in the
“MAINTENANCE” section. Check and clean the
brake parts each time the hoist is disassembled.
Replace the brake discs if the thickness is less than
.090 in. (2.29 mm).
SUPPORTING STRUCTURE. Check for distortion,
wear and continued ability to support load.
TROLLEY. (if equipped) Check that the trolley
wheels track the beam properly and clearance between
side rollers and beam is correct, l/l 6 to 3/l6 in. (1.6to
4.7 mm). Check and that wheels and rail are not
excessively worn and inspect side plates for spreading
due to bending. Do not operate the hoist until the
problem has been determined and corrected.
LABELS AND TAGS. Check for presence and
legibility. Replace if necessary.
10. LOAD CHAIN END ANCHORS. Ensure both ends of
load chain are securely attached. Secure if loose, repair
if damaged, replace if missing. Check chain stopper is
correctly installed and functional.
11. LOAD CHAIN. Measure the chain for stretching by
suspending a 50 to 100 Ibs. (23 to 4.5kg) load from the
hoist. Measure the load chain over the outside of seven
link sections all along the chain paying particular
attention to the most frequently reeved links. When
any seven links in the working length reachesor
exceeds the discard length shown in Table 3, replace
the entire chain (seeDwg. MHTPA0041). Always use
a genuine INGERSOLL-RAND Material Handling
replacement chain.
11

Table 3
Dimensions Of Link - Inches Discard
‘N’
Zinc plated load chain is available for standard hoists.
Always use stainless steel load chain on Spark Resistant
Hoists.
Gauge Length over ‘N’ links with
light load suspended from hook
(Dwg. MHTPA0455)
12. CHAIN CONTAINER. Check for damage or exces-
sive wear and that chain container is securely attached
to the hoist. Secure or replace if necessary.
13. LIMIT ASSEMBLY. Check limit arm moves freely.
Hoists Not in Regular Use
1. A hoist which has been idle for a period of one month
or more, but less than one year, should be given an
inspection conforming with the requirements of
“Frequent Inspection” prior to being placed into
service.
2. A hoist which has been idle for a period of more than
one year should be given an inspection conforming
with the requirements of “Periodic Inspection” prior to
being placed into service.
3. Standby hoists should be inspected at least semi-
annually in accordance with the requirements of
“Frequent Inspection”. In abnormal operating condi-
tions hoists should be inspected at shorter intervals.
12

To ensure continued satisfactory operation of the hoist, all
points requiring lubrication must be serviced with the
correct lubricant at the proper time interval as indicated for
each assembly. Correct lubrication is one of the most
important factors in maintaining efficient operation.
The lubrication intervals recommended in this manual are
basedon intermittent operation of the hoist eight hours
each day, five days per week. If the hoist is operated almost
continuously or more than the eight hours each day, more
frequent lubrication will be required. Also, the lubricant
types and change intervals are basedon operation in an
environment relatively free of dust, moisture, and corrosive
fumes. Use only those lubricants recommended. Other
lubricants may affect the performance of the hoist. Ap-
proval for the useof other lubricants must be obtained from
your Ingersoll-Rand Technical Support Department or
distributor. Failure to observe this precaution may result in
damage to the hoist and/or its associated components.
Whenever a Series MLK Hoist is disassembled for over-
haul or replacement of parts, lubricate asfollows:
I. Coat all motor parts with a light film of
Ingersoll-Rand Pneu-Lube@ Medium Oil No. 50 or a
good quality hydraulic oil before assembling.
l Do not use automotive type detergent oil. Detergents
will delaminate the motor vanes and cause premature
failure.
2. Apply a coating of Ingersoll-Rand No. 11Grease to
the Planet Gear Bearings (83), the Brake Driver
Bearing (87), and gearing before assembly.
3. The top and bottom hooks arc supported by thrust
bearings. These bearings must be packed with
Ingersoll-Rand No. 68 greaseor a standard No. 2
multi-purpose greaseat regular intervals. Neglect of
proper lubrication will lead to bearing failure.
Load Chain
l Failure to maintain clean and well lubricated load
chain will result in rapid load chain wear that can lead
to chain failure which can cause severe injury, death or
substantial property damage.
1.
2.
3
_.
4.
5.
6.
Lubricate load chain weekly, or more frequently,
depending on severity of service.
In a corrosive environment, lubricate more frequently
than normal.
Lubricate each link of the load chain and apply new
lubricant over existing layer.
Lubricate hook and hook latch pivot points.
If required, clean chain with acid free solvent to
remove rust or abrasive dust build-up and lubricate the
chain.
Use Ingersoll-Rand LUBRI-LINK@ or a SAE SOto
90 EP oil.
Hook Assemblies
1. Lubricate the hook and hook latch pivot points. Hook
and latch should swivel/pivot freely.
2. Use Ingersoll-Rand LUBRI-LINK@ or a SAE SOto
90 EP oil.
Trolley (if equipped)
Periodically, greasethe wheel bearings with
Ingersoll-Rand No. 68 greaseor a standard No.2 multi-
purpose grease.A greasefitting is provided on the end of
each wheel axle.
13

This section provides the information necessary for troubleshooting this hoist. The troubleshooting guide provides a general
outline of problems which could be experienced with normal use of this hoist. It lists the symptom, the possible cause, and the
possible remedy for the trouble being experienced.
SYMPTOM CAUSE REMEDY
Hoist will not No air supply to hoist, or too Check PSI (bar) at valve inlet. Refer to “SPECIFICATIONS”
operate. little CFM or PSI. section for correct CFM (cu.m/min) and PSI (bar).
Valve or throttle lever sticking. Check throttle lever for free movement.
Pendant malfunction. Check PSI (bar) at pendant. Minimum operating pressure in
pendant line is 55 PSI (3.8 bar).
Hoist is overloaded. Reduce load to within rated capacity.
Motor is damaged. Repair or replace. See“MAINTENANCE” section.
Lubricator is low on oil. Fill lubricator.
Brake is not releasing. Check brake release circuit and PSI (bar) at the brake inlet.
(55 PSI (3.8 bar) minimum)
Load continues to Valve or throttle lever sticking. Check throttle lever for free movement.
move when hoist is
stopped. “UP” Dump valves not releasing. Check pendant hose dump valves.
direction. Pendant lever sticking. Check lever and restore free movement.
Load continues to Valve or throttle lever sticking. Check throttle lever for free movement.
move when hoist is
stopped. “DOWN” Dump valves not releasing. Check pendant hose dump valves.
direction. Brake is slipping. Check brake springs and brake disc linings for wear. See
“MAINTENANCE” section.
Hoist is overloaded. Reduce load to within rated capacity.
Pendant lever sticking. Check lever and restore free movement.
Hoist will not lift Hoist is overloaded. Reduce load to within rated capacity.
rated capacity. No air supply to hoist, or too Check PSI (bar) at valve inlet. Refer to “SPECIFICATIONS”
little CFM or PSI. section for correct CFM (cu.m/min) and PSI (bar).
Main air valve travel is restricted. Check throttle lever and linkage for free movement.
Exhaust restricted. Inspect vents and replace mufflers.
Motor is damaged. Check for worn motor bearings, vanes or vane springs.
Reduced speedand/ Old style hoists have filter in Install new style inlet nipple with no filter screen.
or capacity. inlet nipple which may be
plugged restricting air flow.
14

SYMPTOM
Hook lowers, but
will not raise.
Hook can be raised
but not lowered.
CAUSE
No air supply to hoist, or too
little CFM (cu.m/min).
Hoist is overloaded.
Pendant malfunction.
Brake piston seals leaking.
Low air pressure.
REMEDY
Check power supply and connections, in power supply line.
Reduce load to within rated capacity.
Check PSI (bar) at air inlet connection on pendant.
Install new sealsrefer to “MAINTENANCE” section.
Check PSI (bar) at valve inlet. Raise pressure to rated
capacity.
Load chain jumps
on sheave or is
making a snapping
sound.
Trolley
Trolley won’t stop
or trolley wheels
slip.
Pendant malfunction.
No oil on load chain.
Worn or rusted chain.
Worn load sheave.
Capsized Hook.
Hoist not in-line with load.
Incorrectly reeved load chain.
Damaged beam.
Too much oil, greaseor paint on
track of beam.
Trolley not spacedfor beam
clearance.
Check PSI (bar) at fitting connection on pendant,
Lubricate load chain. See“LUBRICATION” section.
See“INSPECTION” to determine wear limit. Replace if
necessary and lubricate frequently.
Replace worn parts.
Correct asdescribed in “MAINTENANCE” section.
Align hoist with load. Do not “yard” or side pull.
Check load chain is correctly reeved.
Repair or replace beam.
Clean off oil, greaseor paint.
Check trolley spacing. Refer to “INSTALLATION” section.
Air powered trolley
doesnot operate. Pendant lever sticking.
No air supply to trolley, or too
little CFM (cu.m/min) or PSI
(bar).
Check lever and restore free movement.
Check PSI (bar) at trolley valve.
Control valve is sticking. See“MAINTENANCE” section.
15

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 personnel trained in the operation and
service of this hoist to perform maintenance.
l After performing any maintenance on the hoist,
dynamically test 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 may be required to comply with
standards and regulations set forth in areas outside of
the USA.
l Shut off air system and depressurize air lines before
performing any maintenance.
Load Chain Care
Keep the chain well lubricated asinstructed in the “LU-
BRICATION” section. Never operate a hoist when the load
chain does not flow freely and smoothly into and out of the
Chain Wheel, or when it makes noises indicative of
binding or other malfunctions.
Chain Replacement
Refer to “INSPECTION” section for information on load
chain inspection.
Excessive chain wear cannot be detected by casual obser-
vation. The chain is casehardened to a depth of 0.010 in. to
0.0 12in. (25 to 30 mm) and once this caseis 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 Wheel properly, greatly increasing the chance
of malfunction and chain breakage.
One Chain Wheel will outlast several chains if the chain is
replaced asrecommended. The use of a worn chain will
causethe Chain Wheel to wear rapidly.
If the chain is visibly damaged, examine the Chain Wheel
and Chain Guard. Install a new Chain Wheel if the old one
is visibly worn. Install a new Guard if the old one is broken
or distorted.
For Single Line (fall) Hoists, Method 1
1. Remove the Brake Spring and Piston Housing, Brake
Discs and Brake Plates to expose the Brake Driver.
2. At the side of the Chain Wheel opposite the Chain
Anchor Bolt, engage the first link of Chain in a pocket
of the Chain Wheel FLAT SIDE DOWN (Dwg.
TPD571-1). The weld on the second link must face
away from the powered Chain Wheel. (Ref. Dwg.
MHTPA0472).
3. Rotate the Brake Driver by hand to thread the Chain
through the hoist.
4. Keep the Chain straight and do not twist it. Attach the
free end of the Chain using the Chain Anchor Bolt,
Washers and Spacer (Dwg. TPD572). Clean the brake
parts and inspect them for excessive wear before
assembling.
wheel pocket “Flat
Chain outside of top drive
(Dwg. TPDS7 1-1)
Top Hook-
Attach Unloaded
Chain End Chain Wheel
to Hoist
Check Chain is /
not Twisted
(Dwg. TPD572)
16

For Double Line Hoists, Method I
l The replacement chain for a series MLK double line
hoist must have an EVEN number of links.
Install the Chain through the Chain Wheel asin Steps
1through 4 of the instructions for single line Hoist,
and attach the end of the Chain to the Hoist using the
Anchor Bolt and fasteners. Keep the Chain straight.
Make certain the Chain is straight and feed the end
through the bottom hook pocket wheel with the first
link ON EDGE WITH THE WELD TO THE INSIDE
OF THE IDLER SHEAVE WHEEL.
Keep the Chain straight and attach the free end to the
chain anchor bracket.
Top Hook
Chain Wheel 7
Attach Unloaded
Chain End
to Hoist ,
Bottom Hook
Pocket Wheel
(Dwg. TPD574)
Capsized Hook
Make certain the bottom block has
NOT been flipped through the chain falls
(Dwg. MHTPA0043)
Appearance of
chain that is
Not Twisted
(Dwg. MHTPA0020)
Appearance of
chain that
Is Twisted
For Single or Double Line Hoists, Method 2
1. On ML250K and MLSOOK single line Hoists, discon-
nect the load end of the Chain from the Bottom Hook
Block. On MLSOOKR and MLlOOOK double line
Hoists, disconnect the load end of the Chain from the
Chain Anchor Bracket and withdraw it from the
Bottom Hook Sheave Block. Do not remove the Chain
from the Hoist.
2. Using an abrasive wheel, cut a section from the last
standing link as shown in Dwg. MHTPA0471.
l Do not distort the link in any manner. It must be able
to pass over the Chain Wheel without binding. The last
complete link of old chain must be a flat link unless two
cut links are used to make the first link of the new chain
a flat link.
17

Load Chain
Standing
Link
ChainChain
WheelWheel
Chain WeldChain Weld
To Outside OnTo Outside On
Powered ChainPowered Chain
WheelsWheels
(Dwg. MHTPA0472)
r-- 3/8
in. (9.6 mm)
“C” Link
5.
(Dwg. MHTPA0471)
Connect old Chain by hooking the end of the new
Chain onto the cutaway link. Make certain the welds
on the standing links (links that are perpendicular to
the Chain Wheel) face away from the powered Chain
Wheel.
Slowly run the Hoist in the raise direction, running off
the old Chain and reeving the new Chain over the
Chain Wheel. The first link of new Chain over the
Chain Wheel must be a flat link.
After the new Chain is installed, secure the unloaded
end of the Chain to the side of the Hoist. Make certain
there is no twist in the unloaded end of the Chain
between the Chain Wheel and the end link.
l A twisted Chain can jam as it passesover the Chain
Wheel, which can result in damage to the Hoist or even
breaking the Chain causing severe injury, death or
substantial property damage.
6. On single line Hoists, install the Stop Ring (1 15) and
Spring (114) and then attach the Bottom Hook Block
Assembly.
7. On double line Hoists, reeve the load end of the new
Chain around the Pocket Wheel in the Sheave Block
Assembly, making certain the Chain is not twisted
between the Hoist and Sheave Block.
l The new chain must have an EVEN number of links
when the hoist has two chain falls and uses a bottom
sheave block.
8. Keeping the load end of the Chain straight, attach the
end link to the Chain Anchor Bracket.
9. Lubricate the Chain asinstructed in the “LUBRICA-
TION” section.
10. Run the hook up and down several times under power
with no load to make certain the Chain is running
smoothly over the Chain Wheel. There must be no
apparent binding or evidence of malfunctioning.
Servicing the Filter and Strainer
1.
2.
3.
4.
6.
7.
8.
9.
Disconnect the air supply from the Hoist.
Unscrew the air hose from the Inlet Strainer (42) or
(344 old style).
Unscrew the Inlet Strainer from the Inlet Body (38 or
340).
Wash the screen inside the Inlet Strainer clean with a
quality, non-toxic, nonflammable commercial solvent
in a well ventilated area. If the screen is damaged or
cannot be cleaned, replace the Inlet Strainer.
Unscrew the Inlet Nipple (39 or 341) from the Valve
Chest and remove the Inlet Nipple and Inlet Body
from the Valve Chest.
Push the Inlet Nipple out of the Inlet Body.
Remove the two Swivel Inlet Seals (40 or 342) from
the Inlet Nipple.
If the Swivel Inlet Gasket (41 or 343) is damaged,
replace it.
If hoist is equipped with a filter inside the Inlet Nipple,
clean by washing with a quality, non-toxic, nonflam-
mable commercial solvent in a well ventilated area. If
the filter cannot be cleaned, replace the Inlet Nipple.
(New style Inlet Nipples do not have filters)
10. Moisten the new Swivel Inlet Seals with O-ring
lubricant and install them in the grooves around the
body of the Inlet Nipple.
11. Push the Inlet Nipple into the Inlet Body until the hex
of the Nipple is flush against the face of the Inlet
Body.
12. Keep the threaded hole of the Inlet Body facing away
from the Hoist and screw the Inlet Nipple into the
Valve Chest.
13. Screw the Inlet Strainer into the Inlet Body.
14. Screw the air hose into the Inlet Strainer.
15. Reconnect the air supply to the Hoist.
Disassembly
l Disconnect the air supply hose before performing any
maintenance or repairs on this Hoist.
General Instructions
1. The MLK Hoist is constructed of
various modules, and
during the process of disassembly it is not always
necessary to disassemble a particular module just
because it is removed from the Hoist. For example, it
is necessary to remove the Valve Chest Assembly in
order to disassemble the motor. However, the Valve
18

2.
3.
4.
5.
Chest need not be disassembled unless parts within the
Valve Chest require replacement. Do not disassemble
the Hoist any further than necessary to replace or
repair damaged parts.
Whenever grasping a part in a vise, always use leather-
covered or copper-covered vise jaws to protect the
surface of the part and help prevent distortion. This is
particularly true of threaded members and housings.
Do not remove any part which is a press fit in or on a
sub-assembly unless the removal of that part is
necessary to complete the repair or replacement of the
part.
Do not disassemble this Hoist unless you have a
complete set of new gaskets, O-rings and sealson hand
for replacement. These are available in Overhaul
Gasket Kit MLK-K445.
Do not attempt to wash sealed bearings.
Disassembly of the Valve Chest used on Hoists
with second letter of the Serial Number other
than A through G or with second and third
letters of the Serial Number other than HA,
HB or HC.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10
11.
If the Hoist has a pendent control, disconnect the three
Pendent Hoses (211) from the Elbow and Adapters
(221 and 222).
Remove the Pendent Links (223).
Unscrew the Valve Chest Screws (44 and 45) and
remove the Valve Chest (14) and Valve Chest Gaskets
(43).
Unscrew and remove the Swivel Inlet Assembly. Push
the Inlet Nipple (39) out of the Inlet Body (38) to
expose the Swivel Inlet Seals (40).
Unscrew the Valve Chest Cover Screws (37) and
remove the Valve Chest Cover (33) and Valve Chest
Cover Gasket (31).
Remove the Piston and Piston Shaft Assemblies (26
and 28) and Piston Springs (25).
Remove the Valve SeatLock Screws (23).
While exerting pressure against the Valve Seats(20),
use retaining ring pliers to remove the Valve Seat
Retainers (24).
Using a hooked tool, pull the Valve Seatsfrom the
Valve Chest or tap the bottom of the Valve Chest on a
block of wood.
Remove the two Valve Assemblies (15 and 17) and
Valve Springs (19) from the Valve Chest.
If the Piston Shaft Seals (29) require replacement,
press the Piston Retaining Pins (30) from each Piston
and Shaft and slide the Pistons off the Shafts.
Disassembly of the Valve Chest used on Hoists
with second letter of the Serial Number A
through G or with second and third letters of
the Serial Number HA, HB, or HC.
l Parts for this style valve chest may no longer be
available. To replace with current style valve chest
order kit no. MLK-K545B (03835519).
1.
2.
3.
4.
5.
If the hoist has a pendent control, disconnect the three
Pendent Hoses (211) at the Elbows (221 and 222).
Unscrew the Valve Chest Screws (44 and 45) and
remove the assembled Valve and Valve Chest Gaskets
(43).
Unscrew and remove the Swivel Inlet Assembly (340).
Slide the inlet sleeve off the swivel body to expose the
Swivel Inlet Seals (342).
Unscrew the Valve Chest Cover Capscrews (339), and
remove the Valve Chest Cover (334) along with the
Piston Rods (328 and 329), Pistons (330) and Piston
Springs (333). Remove the Valve Chest Cover Gasket
(338).
Withdraw the two Valves (325) and the two Valve
Springs (327).
l Do not mix the Valves (325). They are a lap fit in
their respective sleeve.
Disassembly of the Brake Mechanism
1. Unscrew the four Shoulder Bolts (105) and remove the
assembled Spring and Piston Housing (96).
2. If you are going to disassemble the Spring and Piston
Housing, proceed asfollows:
a.
b.
C.
d.
e.
Remove the Plate Screws (104) and the Plate
(103).
Place the assembly, Pressure Plate (98) down-
ward, on an arbor press or place the assembly
vertically in a vise.
While holding the Housing against the compres-
sion of the Springs (97), hold the Pressure Plate
Screw (98A) with a wrench and unscrew the
Piston Nut (98B).
Ease up on the arbor press slowly and carefully.
Pull off the Pressure Plate and push the Piston
(99) from the Housing.
3. Withdraw the Brake Plates (94) and Brake Discs (95).
Disassembly of the Motor
1. Remove the entire brake mechanism. Refer to Disas-
sembly of the Brake Mechanism.
2. Remove the Brake Driver Retainer (93) and withdraw
the Brake Driver (92).
9

3. Remove the assembled Valve Chest (14). Refer to
Disassembly of the Valve Chest.
4. Remove the Limit Actuator Retaining Pin (52) and
withdraw the Limit Actuator (51).
5. Unscrew the Valve Chest Plate Screws (48) and
remove the Valve Chest Plate (46).
6. Grasp the Rear End Plate (67) and pull the entire
assembled motor from the Hoist. If the motor is a little
“sticky”, tap on the brake end of the Motor Shaft (64)
with a soft drift.
l If the Cylinder Dowel (71) separates from the as-
sembled motor, insert a long pin in the dowel pin hole
to align the Front End Plate (72) during removal.
7. Grasp the Motor Shaft vertically in copper-covered
vise jaws.
8. Remove the Motor Shaft Rear Retaining Ring (65).
9. Lift off the Rear End Plate (67) and Bearing (66),
Cylinder (70) Cylinder Dowel (71), Vanes (69), Rotor
(68), Front End Plate (72) and Bearing (73).
Disassembly of the Gearing
1.
2.
3
4.
5.
6.
7.
8.
9.
10.
Remove the entire brake mechanism. Refer to Disas-
sembly of the Brake Mechanism.
Remove the Brake Driver Retainer (93) and withdraw
the Brake Driver (92).
Withdraw the Brake Tube (57).
Grasp the Brake Housing (90) and pull it away from
the Housing (1) just far enough to expose the two
cutout areasat the rear of the Housing. Rotate the
Brake Housing until the large diameter of each Planet
Gear (82) is aligned with a cutout area.Withdraw the
Brake Housing, Ring Gear (88) and Planet Gear Frame
Assembly asa unit.
Remove the Ring Gear Gasket (89).
Pull the Brake Housing (90) from the Gear Frame
Bearing (86). If it is a little “sticky”, lightly tap on the
rear of the Planet Gear Frame (81) with a plastic
hammer to loosen it.
Pull the Ring Gear (88) from the Brake Housing, if
required.
Using a bearing puller, remove the Gear Frame
Bearing (86).
Remove the Planet Gear Shafts (85) by pressing them
toward the short hub end of the Planet Gear Frame
(81).
Do not remove the needle bearings (83 or 87) from the
Planet Gears (82) or Planet Gear Frame unless you
have new bearings on hand for installation. A needle
bearing is always damaged during the removal
process.
Disassembly of the Throttle Lever and Chain Guide
I. Drive out the Limit Actuator Retaining Pin (52) and
remove the Limit Actuator (51).
2. Drive out the Throttle Lever Retaining Pin (54).
3. Grasp the square end of the Throttle Shaft (50) and
withdraw it from the Hoist.
4. Unscrew the Chain Guide Screws (11) and remove the
Chain Guide (10).
Disassembly of the Chain Wheel and Chain Guard
1.
2.
3.
4.
5.
6.
7.
8.
Remove the brake mechanism. Refer to Disassembly
of the Brake Mechanism.
Remove the Valve Chest. Refer to Disassembly of the
Valve Chest.
Remove the Motor. Refer to Disassembly of the
Motor.
Remove the Gearing. Refer to Disassembly of the
Gearing.
Remove the Throttle Lever and Chain Guide. Refer to
Disassembly of the Throttle Lever and Chain Guide.
Using a soft drift, lightly tap the motor end of the
Chain Wheel (76) to drive it out through the brake end
of the Housing.
Use a bearing puller to remove the Chain Wheel
Bearings (77 and 79).
Remove the Chain Guard Retaining Screws (13A) and
remove the Chain Guard (13).
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 housing
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 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
necessary to carefully scrapeold Loctite® from the bearing
bores. Dry each part using low pressure, filtered com-
pressed 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.
20