Lodestar AIR XL User manual

OPERATING,
MAINTENANCE
& PARTS
M A N U A
AIR
CHAIN HOIST
Manual No. A652-D
Before installing hoist, fill in
the information below. Refer
to the hoist identification
plate.
Model No. __________________
Serial No. __________________
Purchase Date ______________
Rated Capacity______________
53031
AAIIRR XXLL CCHHAAIINN
HHOOIISSTT
Rated capacities 2 through 7½ tons/
2000 through 7500 kg
Follow all instructions and warnings for
inspecting, maintaining and operating this hoist.
The use of any hoist presents some risk of personal
injury or property damage. That risk is greatly
increased if proper instructions and warnings are not
followed. Before using this hoist, each operator
should become thoroughly familiar with all warnings,
instructions and recommendations in this manual.
Retain this manual for future reference and use.
Forward this manual to operator.
Failure to operate equipment as directed
in manual may cause injury.
®

X AIR HOIST PARTS AND SERVICES ARE AVAI AB E IN THE UNITED STATES AND IN CANADA
As a XL Air Hoist user, you are assured of reliable repair and parts services through a network of Master Parts Depots and
Service Centers that are strategically located in the United States and Canada. These facilities have been selected on the
basis of their demonstrated ability to handle all parts and repair requirements promptly and efficiently.
Below is a list of the Master Parts Depots in the United States and Canada. To quickly obtain the name of the U.S. Service
Center located nearest you, call 314-869-7200. Fax: [phone]. In the following list, the Canadian Service Centers are
indicated.
i
UNITED STATES MASTER PARTS DEPOT CANADIAN SERVICE CENTERS
MISSOURI
Distributed by Tri-State Equipment Company Inc.
[email protected]
www.tsoverheadcrane.com
Tel: [phone]
A BERTA
**COLUMBUS McKINNON, LTD.
10311-174th Street Edmonton,
Alberta T5S 1H1


!WARNING
Usage of hoists that do not involve lifting of the load
on the lower hook or using hoists in the inverted posi-
tion without special precaution may cause an accident
resulting in injury and/or property damage.
TO AVOID INJURY:
Consult Factory for information concerning using hoists in
these applications.
SAFETY PRECAUTIONS
Each XL Air Hoist is built in accordance with the specifications contained herein and at the time of manufacture com-
plied with our interpretation of applicable sections of the *American Society of Mechanical Engineers Performance
Standard for Air Chain Hoist HST-5M, “Overhead Hoists B30.16,” and the Occupational Safety and Health Act. Check
each installation for compliance with the application, operation and maintenance sections of these articles.
The safety laws for elevators, lifting of people and for dumbwaiters specify construction details that are not incorporated in
XL hoists. For such applications, refer to the requirements of applicable state and local codes, and the American
National Safety Code for elevators, dumbwaiters, escalators and moving walks (ASME A17.1). Columbus McKinnon
Corporation cannot be responsible for applications other than those for which CM equipment is intended.
* Copies of this Standard can be obtained from ASME Order Department, 22 Law Drive, Box 2300, Fairfield, NJ 07007-2300, U.S.A.
ii
19. Not allow the load chain or hook to be used as an electrical or
welding ground.
20. Not allow the load chain or hook to be touched by a live
welding electrode.
21. Not remove or obscure the warnings on the hoist.
22. Not operate a hoist on which the safety placards or decals are
missing or illegible.
23. Not operate a hoist unless it has been securely attached to a
suitable support.
24. Not operate a hoist unless load slings or other approved single
attachments are properly sized and seated in the hook saddle.
25. Take up slack carefully - make sure load is balanced and load
holding action is secure before continuing.
26. Shut down a hoist that malfunctions or performs unusually and
report such malfunction.
27. Warn personnel of an approaching load.
1. Not operate a damaged, malfunctioning or unusually
performing hoist.
2. Not operate the hoist until you have thoroughly read
and understood this Operating, Maintenance and Parts
Manual.
3. Not operate a hoist which has been modified.
4. Not lift more than the rated load for the hoist.
5. Not use hoist with twisted, kinked, damaged or worn
load chain.
6. Not use the hoist to lift, support, or transport people.
7. Not lift loads over people.
8. Not operate a hoist unless all persons are and
remain clear of the supported load.
9. Not operate unless load is centered under hoist.
10. Not attempt to lengthen the load chain or repair dam-
aged load chain.
11. Protect the hoist’s load chain from weld splatter or
other damaging contaminants.
12. Not operate hoist when it is restricted from forming a
straight line from hook to hook in the direction of loading.
13. Not use load chain as a sling, or wrap load or chain
around load.
14. Not apply the load to the tip of the hook or to the
hook latch.
15. Not apply load unless load chain is properly seated in
the chain wheel(s) or sproket(s).
16. Not apply load if bearing prevents equal loading on all
load chains.
17. Not operate beyond the limits of the load chain travel.
18. Not leave load supported by the hoist unattended
unless specific precautions have been taken.
!WARNING
Improper operation of a hoist can create a potentially
hazardous situation which, if not avoided, could
result in death or serious injury. To avoid such a
potentially hazardous situation, the operator shall: 
!CAUTION
Improper operation of a hoist can create a potentially haz-
ardous situation which, if not avoided, could result in
minor or moderate injury. To avoid such a potentially haz-
ardous situation, the operator shall:
1. Maintain a firm footing or be otherwise secured when operating
the hoist.
2. Check brake function by tensioning the hoist prior to each lift
operation.
3. Use hook latches. Latches are to retain slings, chains, etc. under
slackconditions only.
4. Make sure the hook latches are closed and not supporting any
parts of the load.
5. Make sure the load is free to move and will clear all obstructions.
6. Avoid swinging the load or hook.
7. Make sure hook travel is in the same direction as shown on the
controls.
8. Inspect the hoist regularly, replace damaged or worn parts, and
keep appropriate records of maintenance.
9. Use the hoist manufacturer’s recommended parts when repairing
the unit.
10. Lubricate load chain per instructions in this manual.
11. Not use the hoist load limiting or warning device to measure load.
12. Not use limit stops as routine operating stops unless allowed by
manufacturer. They are emergency devices only.
13. Not allow your attention to be diverted when operating hoist.
14. Not allow the hoist to be subjected to sharp contact with other
hoists, structures, or objects through misuse.
15. Not adjust or repair the hoist unless qualified to perform such
adjustments or repairs.
 !
THIS SYMBO POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH IF NOT FO OWED
COU D ENDANGER THE PERSONA SAFETY AND/OR PROPERTY OF YOURSE F AND OTHERS.
READ AND FO OW A INSTRUCTIONS IN THIS MANUA AND ANY PROVIDED WITH THE
EQUIPMENT BEFORE ATTEMPTING TO OPERATE YOUR X HOIST.
 !

iii

1
ITEM PAGE NO.
MASTER PARTS DEPOTS AND SERVICE CENTERS. . . . .i
SAFETY PRECAUTIONS .. . . . . . . . . . . . . . . .ii
HOIST SAFETY IS UP TO YOU . . . . . . . . . . . .iii
GENERA INFORMATION
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 2
REPAIR/REP ACEMENT PO ICY . . . . . . . . . 3
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . ..3
INSTA ATION
UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTA ING THE SUSPENSION
HOOK SUSPENSIONS . . . . . . . . . . . . . . . . . . . 4
LU SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . 6
MOUNTING TRO EY ON HOIST . . . . . . . . . 6
INSTA ING TRO EY SUSPENDED
HOIST ON BEAM . . . . . . . . . . . . . . . . . . . . . 7
INSTA ING BREATHER . . . . . . . . . . . . . . . . . . 8
INSTA ING MUFF ER. . . . . . . . . . . . . . . . . . . 8
AIR SUPP Y SYSTEM . . . . . . . . . . . . . . . . . . . . . 8
CHECKING FOR TWIST IN OAD CHAIN . . . . 9
CHAIN CONTAINER . . . . . . . . . . . . . . . . . . . . . 9
CONTRO CORD . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATING INSTRUCTIONS
GENERA . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
A HOISTS . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HOIST WITH P AIN TRO EY . . . . . . . . . . . 10
HOIST WITH GEARED TRO EY . . . . . . . . . . . 10
HOIST WITH MOTOR DRIVEN TRO EY . . . 10
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . 10
ITEM PAGE NO.
MAINTENANCE
INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FREQUENT INSPECTIONS . . . . . . . . . . 10,11
PERIODIC INSPECTIONS. . . . . . . . . . . . . 11,12
HOOK INSPECTION . . . . . . . . . . . . . . . . . . . 11
LOAD CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . 11
PROTECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 11
UBRICATION
HOIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LOAD CHAIN . . . . . . . . . . . . . . . . . . . . . . 14
AIR LUBRICATOR . . . . . . . . . . . . . . . . . . . 14
TROLLEY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ADJUSTMENTS
HOIST BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 14
TROLLEY BRAKE . . . . . . . . . . . . . . . . . . . 15
RECOMMENDED SPARE PARTS . . . . . . . 15
PREVENTIVE MAINTENANCE . . . . . . . . . 15
TROUB E SHOOTING
HOISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
MOTOR DRIVEN TROLLEY. . . . . . . . . . . . 16
AIR DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HOIST DISASSEMB Y/REASSEMB Y . . 17
VA VE DISASSEMB Y/REASSEMB Y . 18
AIR MOTOR DISASSEMB Y/REASSEMB Y .
19,20
REMOVA AND REP ACEMENT OF OAD CHAIN
20
REEVING OAD CHAIN
3 AND 5 TON DOUBLE REEVED UNITS . . . 21
6 AND 71/2 TON TRIPLE REEVED UNITS . . 21
CUTTING CHAINS. . . . . . . . . . . . . . . . . . . . . . 22
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REPAIR PARTS
ORDERING INSTRUCTIONS. . . . . . . . . . . . 22
EXP ODED VIEWS AND PARTS ISTS . . . 24-39
FOREWORD
This manual contains important information to help you properly install, operate and maintain your hoist for maximum
performance, economy and safety.
Please study its contents thoroughly before putting your hoist into operation. By practicing correct operating proce-
dures and by carrying out the recommended preventative maintenance suggestions, you will experience long, depend-
able and safe service. After you have completely familiarized yourself with the contents of this manual, we recommend
that you carefully file it for future reference.
The information herein is directed to the proper use, care and maintenance of the hoist and does not comprise a hand-
book on the broad subject of rigging. Rigging can be defined as the process of lifting or moving heavy loads using
hoist and other mechanical equipment. Skill acquired through specialized experience and study is essential to safe rig-
ging operations. For rigging information, we recommend consulting a standard textbook on the subject.
TAB E OF CONTENTS

SPECIFICATIONS
The XL Air Chain Hoist is a highly versatile material han-
dling device that can be used to lift loads that are within
its rated load capacity. Variable speed units with rated
loads up to 7½ tons (7500 kg.) are available. The hoist can
be supplied with a single hook suspension up to 6 ton
(6000 kg.) capacity or suspended from a plain, geared or
motor driven trolley. The standard lift is 10 feet and
longer lifts can be provided on a per order basis.
This hoist’s variable speed is obtained by varying the pres-
sure of the pilot control lines through the pendant. This
variable pilot pressure is used to modulate the main con-
trol valve for both direction and speed.
The standard features of the XL Air Chain Hoist include:
Hardened, alloy steel, oblique lay liftwheel pro-
vides constant chain speed and reduces chain wear.
Hoistaloy®load chain for long and dependable
service.
Lightweight cast aluminum frame and covers.
Surface hardened, alloy steel, helical gears run-
ning in an oil bath provide smooth and quiet
operation.
Protector that prevents lifting an excessive overload.
Variable speed hoist motor.
Hardened, forged steel hooks equipped with latch.
Double disc spring return brake.
2
TAB E 1-SPECIFICATIONS
X AIR CHAIN HOISTS
GENERA INFORMATION
X Hoist with
Motor Driven
Trolley
*Lifting speeds are based on 90 PSI air supply.
Shielded, lifetime lubricated ball bearings at all
rotating points. Open bearings are used in gear case.
Three stage gear reduction.
TO S
RATED LOAD kg. 2 2000
Plain and Geared
Trolley
2
2000
Motor Driven
Trolley
3
3000 5 5000 6 6000 7 1/2 7500
*VARIABLE SPEEDS UP TO:
FPM
MPM
31
9.4
21
6.4
13
3.9
10
3.0
8.5
2.6
FEET
MAXIMUM LIFT METERS
100
30.5
100
30.5
100
30.5
100
30.5
100
30.5
REEVI G OF LOAD CHAI SI GLE DOUBLE TRIPLE
MI IMUM HEADROOM
HOOK SUSPE DED - I . (mm)
TROLLEY SUSPE DED - I (mm) 25 (635) 28.69 (729) 35.31 (897)
33 (838) 34.25 (870) 36.18 (919) 34.25 (870) /A
RA GE OF TROLLEY ADJUSTABILITY
“S” BEAMS
I .
FLA GE WIDTH mm
6X12.5’ TO 15 X 42.9’
3.33 TO 5.50
84.5 TO 139.7
8 x 18.4 to 20 x 66.0’
4.00 TO 6.250
101.6 TO 158.8
VARIABLE MOTOR DRIVE TROLLEY
TRAVEL SPEED - FPM (MPM) /A 50 (15.2)
APPROX. ET WEIGHT -LBS. (Kg.)
HOOK SUSPE DED
WITH PLAI TROLLEY
WITH GEARED TROLLEY
WITH MOTOR DRIVE TROLLEY
347 (157)
407 (184)
452 (205)
----
----
----
----
505 (229)
421 (191)
476 (216)
491 (222)
569 (258)
421 (191)
576 (261)
586 (266)
611 (277)
453 (205) /A
608 (275)
618 (280)
643 (291)

REPAIR/REP ACEMENT PO ICY
All XL Air Chain Hoists are thoroughly inspected and perfor-
mance tested prior to shipment. If any properly maintained
hoist develops a performance problem due to a material or
workmanship defect, as verified by factory, repair or
replacement of the unit will be made to the original pur-
chaser without charge. This repair/replacement policy
applies only to XL Hoists installed, maintained and operated
as outlined in this manual, and specifically excludes parts sub-
ject to normal wear, abuse, improper installation, improper
or inadequate maintenance, hostile environmental effects
and unauthorized repairs/modifications.
We reserve the right to change materials or design if, in our
opinion, such changes will improve our product. Abuse,
repair by an unauthorized person, or use of non-factory
replacement parts voids the guarantee and could lead to
dangerous operation. For full Terms of Sale, see Sales Order
Acknowledgement. Also, refer to the back cover for
Limitations of Warranties, Remedies and Damages, and
Indemnification and Safe Operation.
ACCESSORIES
HOOK SUSPENSIONS
Hook suspensions are available for suspending 2 through 6
ton hoist from a trolley with a single load bar or for sus-
pending the hoist from a fixed structure.
3
UG SUSPENSIONS
Lug suspensions are required to suspend the XL Air Hoist
from plain, geared or motor driven trolleys described
below. When the hoist is to be suspended from a plain,
geared or motor driven trolley, the lug suspension is
attached to the hoist prior to shipment.
UG SUSPENSION
P AIN TRO EYS
These are manual push type trolleys designed for use with
the XL Air Hoist. The trolley is adjustable to operate on a
range of American Standard ‘S’ beams and flat flanged
beams. The plain trolley is mounted on the hoist prior to
shipment.
P AIN TRO EY
GEARED TRO EYS
The geared trolley is similar to the plain trolley except it is
moved by the means of a hand chain. The hand chain
rotates a pinion that drives gears attached to trolley
wheels and moves trolley along the beam. The geared trol-
ley is mounted on the hoist prior to shipment.
MOTOR DRIVEN TRO EYS
The motor driven trolley is similar to the geared trolley
except the hand chain wheel is replaced with a gear
reducer and an air motor. The motor is controlled by a
bidirectional valve mounted to the motor and it is con-
trolled by levers located on the pendant control station.
A variable speed motor driven trolley is mounted on the
hoist prior to shipment.
2 ton 3-6 ton
HOOK SUSPENSION

CHAIN CONTAINER
This accessory is used to hold the slack chain and is sup-
plied complete with mounting hardware and instruc-
tions. The chain container is recommended for those
applications where the slack chain will interfere with
the load or drag on the floor as may be the case with
double and triple reeved units. Chain containers are
shipped separately and can be furnished for units
already in use.
4
ATCH OK®HOOKS
Latchlok hooks are available to replace the standard
upper or lower latch type hooks (2-6 ton only). The
unique design of the Latchlok hook assures that it will
stay locked until the operator releases it by depressing
the release button. It will not open accidentally—even if the
load chain goes slack. Once opened, it can be shut with
one hand or the weight of the load when it is lifted.
Latchlok hooks can be supplied with the hoist or can be
provided in kit form for hoists already in service.
ATCH OK®HOOK
INSTA ATION
UNPACKING
After opening the carton, carefully inspect the hoist,
control line, pendant, suspension, trolley and chain con-
tainer for damage that may have occurred during ship-
ment. If there is damage, refer to instructions on the
packing slip envelope.
INSTA ING SUSPENSION
A. HOOK SUSPENSIONS
For hook suspended 2 through 6 ton units, the suspension is
shipped separately and must be attached to the hoist as
follows:
1. 2 Ton Single Reeved Units. As shipped from the facto
ry, the hook is rigid with the plane of the hook parallel
to the long axis of the hoist. The hook can be changed
to swivel type or the plane of the hook can be changed
to perpendicular to the long axis of the hoist as follows:
a. If a swivel type hook is required, use a 1/4 inch
(6.4 mm) drift, and working through the hole
in the side of the suspension adapter, drive the
hook nut pin into the nut so that it is flush
with the side of the nut. Discard the loose pin
packed with the suspension.

!WARNING
Operating a unit with obvious external damage may
cause load to drop and may result in personal injury
and/or property damage.
TO AVOID INJURY:
Carefully check unit for external damage prior to
installation.
INSPECT FOR SHIPPIN
DAMA E
MOTOR DRIVEN TRO EY
TO CONVERT
TO SWIVEL
TYPE HOOK
DRIFT

a. If a swivel type hook is required, remove and discard
the keeper plate screw and keeper plate. Then
using ahammer, drive the hook nut pin into nut so
that the end of the pin is flush with side of the
nut.
b. If it is necessary to position the hook so that the
plane of the hook is perpendicular to the long axis
of the hoist, first convert to a swivel type hook as
described above but do not discard the keeper
plate and screw. Turn hook 90 degrees and insert
the loose pin (packed with the suspension) into a
hole in the hook nut. Loosely reassemble keeper
plate to the suspension adapter so that the hook is
free to swivel approximately 45 degrees in either
direction. The hook will be made rigid after suspension
is attached to the hoist.
c. Slide the suspension adapter into the cavity on
top of hoist. Install the dead end bolt and
thread it by hand to engage the dead end block
(3 and 5 ton double reeved units) or idler
sheave hanger (6 ton units). Then tighten the
dead end bolt to a seating torque of 120 pound
feet (160NM).
If the hook is to be perpendicular to long axis of hoist
per step b above, rotate the hook to that position and
firmly tighten the keeper plate screw while making sure
the loose pin engages the slot in keeper plate.
NOTE: INSTA BREATHER IN MAIN HOUSING
AFTER HOOK SUSPENSION IS ASSEMB ED TO
HOIST. SEE PAGE 8.
b. If it is necessary to position the hook so that the
plane of the hook is perpendicular to the long
axis of hoist, first convert to a swivel type hook as
described above. Rotate the hook 90 degrees and
slide the loose pin (packed with the suspension)
through the hole in the side of the suspension
adapter and engage the hole in the hook nut.
c. After the hook is in the desired position, slide the
suspension adapter into cavity on top of hoist and
secure it using the suspension adapter screw from
the kit. Tighten screw to a seating torque of 16 pound
feet (22 NM).
NOTE: INSTA BREATHER IN MAIN HOUSING AFTER
HOOK SUSPENSION IS ASSEMB ED TO HOIST. SEE
PAGE 8.
2. 3 and 5 Ton Double Reeved and 6 Ton Triple
Reeved Units. As shipped from the factory, the hook is
rigid with the plane of the hook parallel to long axis of
hoist. The hook can be changed to swivel type or the
plane of the hook can be changed to perpendicular to the
long axis of the hoist as follows:
5
CHAN IN
POSITION OF
HOOK
TO CONVERT TO
SWIVEL TYPE
HOOK
INSTALLIN
HOOK
SUSPENSION
3, 5, & 6 TON
UNIT
CHAN IN
POSITION OF
HOOK

B. UG SUSPENSIONS
The following instructions are provided to cover
installing the lug suspension after the hoist has been
reassembled following inspection and/or repair. On
hoists shipped from factory, the lug suspension is
installed prior to mounting the trolley.
1. 2 Ton Single Reeved Units. Slide the suspension
adapter into the cavity on top of hoist and secure it
using the suspension adapter screw. Tighten the
screw to a seating torqueof16 pound feet (22 NM).
2. 3 And 5 Ton Double Reeved And 6 And 7½
Ton Triple Reeved Units. Slide the suspension
adapter into cavity on top of hoist. Install the dead
end bolt and thread it by hand to engage the dead
end block (3 and 5 ton double reeved units) or idler
sheave hanger ( 6 and 7 1/2 ton triple reeved
units). Then tighten the dead end bolt to a seating
torque of 120 pound feet (160 NM).
6
INSTALLIN LU SUS-
PENSION—2 TON UNITS
INSTALLIN LU
SUSPENSION—3, 5, 6
AND 7 1/2 TON
MOUNTING TRO EY ON HOIST
The following instructions are provided to cover mount-
ing plain, geared and motor driven trolleys after the hoist
has been reassembled following inspection and/or repair.
On units shipped from factory, these trolleys are mounted
on the hoists.
1. Measure the actual width of the beam flange on
which the trolley is to operate. To determine proper
trolley side frame spacing to assure that adequate
wheel clearance is provided, the distance between the
beam flange and the inside face of the trackwheel
flange (approximately 1/8 to 3/16 inch on straight
runway beams, 3/16 to 1/4 inch on curved beams for
2 ton units. See Figure 2 -page 7 and 1/4 inch for
straight runway beams, 3/8 inch on curved beams for
3 thru 7 1/2 ton units. See Figure 1 - page 7).
2. Use Table 2 (page 7) to determine proper spacing for 2
ton plain and geared units. On 2 ton motor driven
trolleys and, 3 thru 7 1/2 ton capacity units, proper
spacing is obtained by varying the number of spacer
washers (furnished with trolley) that are installed on
the suspension pins.
3. For 2 ton units, assemble a slotted nut to one
end of each suspension bolt and secure it using a
cotter pin. Spread legs of cotter pin to keep it in
place. Using Table 2 (page 7) as a reference for washer
spacing, assemble side frames and bolts and
washers together as shown below. Do not install
remaining cotter pins at this time. These are to
be installed after the trolley is mounted on the
beam.
For 3 thru 7½ ton units, temporarily assemble trolley to
hoist using 3 or 4 washers at each end of suspension pins,
between side plates and suspension lug. Tighten pin nuts
for accurate check of spacing. Measure the distance
between the inside faces of the trackwheel flanges and
compare to the dimension required. Remove trolley side
plates and add or remove an equal number of inside spac-
er washers as required to obtain proper distance between
wheels. When spacing is correct, install all remaining spac-
er washers on the outside ends of each suspension pin
and secure the pins with lockwashers and hex nut (See
Note Below). The nuts should not be completely tight-
ened until after hoist and trolley are mounted onto
beam.
NOTE: It is very important that all spacer washers
that come with the trolley be used. Install
remaining spacer washers equally on out
side ends of each suspension pin.

!WARNING
Using other than factory supplied suspension adapter
screw or dead end bolt to attach suspension adapter
to hoist may cause the screw or bolt to break and
allow the hoist and load to fall.
TO AVOID INJURY:
Use only the factory supplied suspension adapter
screw or dead end bolt and tighten these to the seat-
ing torque specified above.
MOUNTIN
TROLLEY ON
HOIST
HANDWHEEL OR TROLLEY
MOTOR EARED OR MOTOR
DRIVEN TROLLEY ONLY
Dead End Bolt

7
4. On geared trolleys, make sure the handwheel
is on the loose end/chain container side of the hoist.
On motor driven trolleys make sure the motor is
located on the loose end/chain container side of the
hoist.
INSTA ING TRO EY SUSPENDED HOIST ON BEAM
Stops must be positioned to contact the trolley side
frames and not exert impact force on the hoist.
Trolleys are mounted on the hoist prior to shipment
and side frames are positioned for the nominal beam
flange specified on the order. However, due to varia-
tions in beam flange widths, actual beam flange width
should be measured to determine the exact distribu-
tion of the spacer washers. See Mounting Trolley On
Hoist Section.

!WARNING
TO AVOID INJURY:
Install rail stops at each end of the beam on which
the trolley is to operate.

!WARNING
If washer spacing recommendations are not followed,
trolley may fall from beam.
TO AVOID INJURY:
Measure the actual beam flange on which the trolley
is to operate and use Table 2 to determine the
arrangement of the spacer washers for that flange
width.
NOTE: USE OF OTHER THAN SUPP IED SPACER WASHERS
MAY CAUSE IMPROPER TRACKWHEE SPACING.
Table 2. Trolley Spacer Washer Arrangement
Plain and Geared
Figure 2.
Figure 1.
QUANTITY OF
OUTSIDE WASHERS
SHOULD BE EQUAL
-BOTH SIDES
QUANTITY OF
INSIDE WASHERS
SHOULD BE EQUAL
-BOTH SIDES
Operating the trolley on a beam that has no rail
stops may allow the trolley to fall off the end of the
beam.
Before installing geared or motor driven trolleys (2 ton
only) on the beam, lubricate the trackwheel gears and
pinion with Texaco Novatex #2 or equivalent heavy cup
grease.
On open end beams, remove rail stops, lift hoist/trolley
into position and slide the hoist/trolley assembly onto
beam flange. Reinstall the rail stops.
On closed end beams, loosen the suspension bolt nuts
on one side of trolley and slide one side frame out far
enough to clear the beam flange. Lift hoist/trolley
assembly up so that trackwheels are riding on beam
flange. Draw side frames together by tightening the
suspension bolt nuts snugly.
Be sure to install cotter pins through slotted nuts and
hole in suspension bolts and spread legs of cotter pins
to secure on 2 ton plain and geared units. For 2 ton
motor driven trolley and 3 thru 7 1/2 ton units, be sure
lockwashers are positioned properly on the suspension
pins and completely tightened.
FLANGE
WIDTH
IN.(mm)
2 Ton
No. of Washers
A B C D
Standard
Trolleys
3 3/8 (82.7) 13 0 0 13
3 5/8 (92.0) 11 2 2 11
3 7/8 (98.4) 10 3 4 9
4 (101.6) 9 4 4 9
4 1/8 (104.7) 8 5 5 8
4 5/8 (117.4) 5 8 8 5
5 (127.0) 3 10 10 3
5 1/8 (130.1) 3 10 11 2
5 1/4 (133.3) 2 11 12 1
5 1/2 (139.7) 0 13 13 0
Special
Trolleys
5 5/8 (142.9) 12 1 1 12
6 (1252.4) 10 3 3 10
6 1/4 (158.7) 9 4 5 8
6 3/8 (161.9) 8 5 6 7
7 (177.8) 4 9 9 4
7 1/8 (181.0) 3 10 10 3
7 1/4 (184.1) 3 10 11 2
7 3/8 (187.3) 2 11 12 1
7 1/2 (190.5 1 12 12 1
7 5/8 (193.7) 0 13 13 0
* inimum Beam
Radius ft. ( ) 4’-0” (1.22)
*Dimension applies to minimum S-beam and will
vary with larger s-beams.

8
Units with anti-tipping rollers should be adjusted to pro-
vide 1/8” maximum gap between the bottom of the
beam and the roller. Run the trolley the length of the
beam to check for tight places. Readjust if needed.
On geared trolleys, the bottom of the hand chain loop is
normally located two feet (0.6M) above the floor. If it is
desired to change this, find the unwelded link and open
it by spreading with a chisel or twist one end with a
wrench while holding the other end in a vise or another
wrench. Remove an even number of links (2,4,6, etc.) as
necessary to shorten the chain or add an even number of
links to lengthen the chain (when lengthening the chain,
another open link will be required and this can be made
from a welded link by cutting through weld with a hack-
saw). Make certain that the chain is not twisted–then re-
install and close open links.
NOTE: AFTER THE UNIT IS CONNECTED TO THE
AIR SUPP Y SYSTEM (SEE BE OW), SUS
PEND ACAPACITY OAD FROM THE HOIST
AND OPERATE THE TRO EY OVER THE
ENTIRE ENGTH OF THE RUNWAY OR MONO
RAI SYSTEM TO BE SURE THAT THE ADJUST
MENTS AND OPERATION IS SATISFACTORY.
ON SYSTEMS WITH CURVES,THE EDGES OF
THE RAI AT THE CURVED SECTIONS SHOU D
BE KEPT IGHT Y UBRICATED WITH GREASE.
INSTA ING MUFF ER
Install the 3” long 1 1/4” NPT pipe nipple through the
hole in the motor end cover and thread it into the valve
exhaust port. Install the 1 1/4” NPT pipe elbow onto the
end of the pipe nipple. Tighten the elbow until it faces
downward. Install the muffler into the elbow and tight-
en.

!WARNING
An excessively worn beam flange may fail and allow
the trolley to fall from the beam.
TO AVOID INJURY:
Periodically inspect the beam flange for wear. Replace
beam if flange is worn.
INSTA ING BREATHER
After the hook suspension is assembled to the hoist or after the
hoist and trolley are mounted on the beam, remove the upper
plug from the main housing (652-110) and install the breather
(inside information envelope). Failure to install the breather
could damage oil seals and thus cause oil leaks.
AIR SUPP Y SYSTEM
Connect the hoist to a filtered and lubricated air source
using a 1” (25.4 mm.) I.D. hose (see Figure 3). Do not use
smaller diameter hose, since it will restrict air flow and
reduce hoist performance. If the hoist is suspended from a
trolley, provide sufficient hose to reach from the source to
the farthest point of trolley travel. Hose Trolleys are rec-
ommended to keep the hose up and out of the way.
A filter and lubricator (see Figure 3) must be installed
between the air source and the air hose leading to the
hoist. These keep the air flowing free from dirt and add
lubricant to the air so internal parts of the motor are con-
stantly lubricated. Use a good grade of air powered tool
oil or SAE 10W machine oil. Such oil can be obtained from
CM®, Coffing, or Budgit.
The recommended operating air pressure for the hoist is
90 psig. When line pressure exceeds 100 psig (at the hoist
when it is lifting rated load), it is recommended that a
pressure regulator be provided in the air supply line to
keep the pressure at 90 psig. Although there is a wide
range of pressures within which the hoist will operate,
motor efficiency decreases as the air pressure drops.
Excessive moisture in the air line may cause rust or ice to
form in the muffler when air expands as it passes through
the motor. Install a moisture separator in the air line and
an after cooler between compressor and air receiver to
help prevent moisture problems.
INSTALL
BREATHER
Figure 3. Filter and Lubricator Unit

!WARNING
Operating hoist without muffler can cause hearing
loss.
TO AVOID INJURY:
To avoid injury, only operate hoist with muffler
securely attached.





OPERATING INSTRUCTIONS
GENERA
1. The Protector is designed to allow the first reduction gear
to slip on an excessive overload. An overload is indicated
when the hoist will not raise the load. Also, some clutching
noise may be heard if the hoist is loaded beyond rated
capacity. Should this occur, immediately release the (Up)
control to stop operation of the hoist. At this point, the
load should be reduced to the rated hoist capacity or the
hoist should be replaced with one of the proper capacity.
When the excessive load is removed, normal hoist opera-
tion is automatically restored.
CAUTION: THE PROTECTOR IS SUSCEPTIB E TO OVER
HEATING AND WEAR WHEN S IPPED FOR EXTENDED
PERIODS. UNDER NO CIRCUMSTANCE SHOU D THE
PROTECTOR BE A OWED TO S IP FOR MORE THAN A
FEW SECONDS.
Due to the above, a hoist equipped with a Protector is not
recommended for use in any application where there is a
possibility of adding to an already suspended load to the
point of overload. This includes *dumbwaiter installations,
containers that are loaded in mid-air, etc.
*Refer to limitations on Page ii concerning dumb-
waiter applications.
Also, if a XL Hoist with a Protector is used at unusual
extremes of ambient temperatures, above 150°F (65°C) or
below 15° F (-9°C) changes in lubricant properties may
permit the hoist to raise larger loads than under normal
operating conditions and presents possibility of damage
or injury.
2. Hoist operation is controlled by depressing the pendant
throttle control levers. Depressing the UP ( )lever will
move the lower hook towards the hoist and depressing the
DOWN ( ) lever will move the lower hook away from the
hoist. The speed of lifting and lowering can be varied by the
distance the lever is depressed. To stop lifting and lowering,
release the lever. The up and down levers are momentary
type and the hoist will operate in the selected direction as
long as the lever is held in the depressed direction. Release
the lever and the hoist will stop.
3. If material being handled must be immersed in
water, pickling baths, any liquid, dusty or loose
solids, use a sling chain of ample length so that the
hook is always above the surface. Bearings in the
hook block are shielded only against ordinary atmos-
pheric conditions.
4. Read the operation section of American National
Standard ASME B30.16.
A HOISTS
1. Before picking up a load, check to see that the hoist
is directly overhead.
2. When applying a load, it should be directly under
the hoist or trolley. Avoid off-center loading of any
kind.
9
CHECKING FOR TWIST IN OAD CHAIN
3 And 5 Ton Double Reeved Units
The best way to check for this condition is to run the
lower hook, without a load, to within 2 feet (0.6M) of
the hoist. If the dead end of chain has been properly
installed, a twist can occur only if the lower hook block
has been capsized between the strands of chain.
Reverse capsize to remove twist.
6 And 7 1/2 Ton Triple Reeved Units
On these models, the load chain is dead ended on top
of the lower hook block. If chain has been properly
installed, the only way a twist can occur is if the lower
hook block has been capsized between the strands of
chain. If this has occurred, two strands of chain will be
wrapped around each other and to remove twist,
reverse the capsize.
CHAIN CONTAINER
If a chain container is to be used, attach it to the hoist
frame and place chain in container per instructions
provided with the chain container kit.
UNDER NO CIRCUMSTANCES SHOU D THE HOOK
B OCK OR OAD BE PERMITTED TO COME IN CON-
TACT WITH THE CHAIN CONTAINER. IF CONTACT IS
MADE, THE FUNCTION OF THE CHAIN CONTAINER
CAN BE INTERFERED WITH, THE CONTAINER MAY
BE DAMAGED AND IT COU D FA OFF OF THE
HOIST.
PENDANT HOSE
Unless ordered on a special basis, the hoist is supplied
with a pendant hose that will position the pendant
approximately 4 feet (1.2M) above the lower hook
when it is at the lower limit of lift. If this places the
pendant too close to the floor, the pilot hoses and
strain cable can be shortened with diagonal cutters.

! WARNING
TO AVOID INJURY:
Do not allow the hook block or dead end stop to
contact the bottom of the hoist.
Allowing the hook block to run into the bottom of
the hoist when raising a load or allowing the dead
end stop to run into the frame when lowering a
load may break the chain and allow the load to
drop.

! WARNING
Tying knots or loops to shorten the drop of the
pendant will make the strain relief ineffective and
the pilot hoses may break or collapse restricting air
flow.

10
3. Take up a slack load chain carefully and start the load
easily to avoid shock and jerking of the hoist load
chain. If there is any evidence of overloading,
immediately lower the load and remove the excess
load.
4. Do not allow the load to swing or twist while hoisting.
5. Do not allow the load to bear against the hook latch.
HOIST WITH P AIN TRO EY
This unit should be moved by pushing on the suspended load or
by pulling the empty hook.
HOIST WITH GEARED TRO EY
This unit should be moved by means of the trolley hand
chain. Pull on the chain farthest from end toward which
the unit is to travel.
HOIST WITH MOTOR DRIVEN TRO EY
This unit should be moved by operating the controls
located on the upper block of the pendant. Anticipate
the stopping point and allow trolley to coast to a smooth
stop. Reversing or “plugging” to stop the trolley causes sway-
ing of load.
SAFETY PROCEDURES
For safety precautions and a list of Do’s and Do Not’s for
safe operation of hoists, refer to page ii.
1. When preparing to lift a load, be sure that attach-
ments to the hook are firmly seated in the hook sad-
dle. Avoid off center loading of any kind, especially
loading on the tip of the hook.
2. When lifting, raise load only enough to clear the
floor or support and check to be sure that the
attachments to the hook and load are firmly seated.
Continue lift only after you are assured the load is
free of all obstructions.
3. Do not load hoist beyond the rated load shown on
hoist identification plate and capacity labels.
Overload can cause immediate failure of some load-
carrying part or create a defect causing subsequent
failure at less than rated load. When in doubt, use
the next larger capacity of XL Hoist.
4. Do not use this or any other overhead materials han-
dling equipment for lifting persons.
5. Stand clear of all loads and avoid moving a load over
the heads of other personnel. Warn personnel of
your intention to move a load in their area.
6. Do not leave load suspended in air unattended.
7. Permit only qualified personnel to operate unit.
8. Do not wrap the load chain around the load and
hook onto itself as a choker chain.
Doing this will result in:
a. The loss of the swivel effect of the hook which
could mean twisted chain and a jammed lift
wheel.
b. The chain could be damaged at the hook.
9. On double and triple reeved hoists, check for twists
in the load chain. A twist can occur if the lower
hook block has been capsized between the strands
of chain. Reverse the capsize to remove the twist.
10. Do not allow the load to bear against the hook
latch. The latch is to help maintain the hook in posi-
tion while the chain is slack before taking up slack chain.
11. Take up a slack load chain carefully and start load eas-
ily to avoid shock and jerking of hoist load chain. If
there is any evidence of overloading, immediately
lower the load and remove the excess load.
12. Do not allow the load to swing or twist while hoisting.
13. STAY ALERT! Watch what you are doing and use
common sense. Do not use the hoist when you are
tired, distracted or under the influence of drugs,
alcohol or medication causing diminished control.
INSPECTION
To maintain continuous and satisfactory operation, a reg-
ular inspection procedure must be initiated to replace
worn or damaged parts before they become unsafe.
Inspection intervals must be determined by the individ-
ual application and are based on the type of service to
which the hoist will be subjected and degree of exposure
to wear, deterioration or malfunction of the critical com-
ponents.
The type of service to which the hoist is subjected can be
classified as “Normal,” “Heavy,” or “Severe.”
Normal Service: Involves operation with randomly distrib-
uted loads within rated load limit, or uniform loads less
than 65 percent of rated load for not more than 25 per-
cent of the time.
Heavy Service: Involves operating the hoist within rated
load limit which exceeds normal service.
Severe Service: Normal or heavy service with abnormal
operating conditions.
Two classes of inspection—Frequent and Periodic—
must be performed.
FREQUENT INSPECTIONS: These inspections are visual
examinations by the operator or other designated person-
nel. Records of such inspections are not required. The fre-
quent inspections are to be performed monthly for normal
service, weekly to monthly for heavy service, and daily to
weekly for severe service, and they should include those
items listed in Table 3.
PERIODIC INSPECTIONS: These inspections are visual
inspections of external conditions by an appointed person.

!WARNING
Allowing the load to bear against the hook latch
and/or hook tip can result in loss of load.
TO AVOID INJURY:
Do not allow the load to bear against the hook latch
and/or hook tip. Apply load to hook bowl or saddle only.
MAINTENANCE

Replace Hook
When Opening
Is reater
Than
1 1/2 IN.
38.1 mm
2 3/8 IN.
60.3 mm
CAPACITY
(TONS)
2
3, 5, 6 AND 7 ½
LATCH TYPE HOOK
(Upper and Lower)
TO MEASURE OPENIN ,
DEPRESS LATCH A AINST
HOOK BODY AS SHOWN.
*UPPER HOOK NOT AVAIL ABLE
FOR 7 1/2 TON
Replace Hook
When Opening
Or Seat are:
CAPACITY
(TONS)
2
3, 5, and 6
LATCHLOCK® TYPE HOOK
(UPPER AND LOWER)
“A” Max.
2 1/2 IN.
63.5 mm
2 15/16 IN.
74.6 mm
“B” Mn.
1 1/8 IN.
28.5mm
113/32 IN.
35.7mm
Hook Inspection
MEASURE
OPENIN
“A”
“B” Max.
OAD CHAIN
Cleaning and Inspection
First clean the load chain with a non-acid or non-caustic
type solvent. Then slack the chain and make a link-by-
link inspection for nicks, gouges, twisted links and exces-
sive wear or stretching. Chain exhibiting wear should be
checked throughout its entire length and replaced if
worn beyond serviceable limits.
Checking For oad Chain Wear
Slack the portion of the chain that normally passes over
the liftwheel. Examine the interlink area for the point of
maximum wear (polishing). Measure and record the stock
diameter at this point of the link. Then measure stock
diameter in the same area on a link that does not pass
over the liftwheel (use the link adjacent to the loose end
link for this purpose). Compare these two measurements.
If the stock diameter of the worn link is 0.010 inches
(0.254mm), or greater, less than the stock diameter of
the unworn link, the chain must be replaced.
Note that worn chain can be an indication of worn hoist
components. For this reason, the hoist’s chain guides,
hook blocks and liftwheel should be examined for wear
and replaced as necessary when replacing worn chain.
Also, these chains are specially heat treated and hard-
ened and should never be repaired.

!WARNING
Using other than factory supplied load chain may
cause the chain to jam in the hoist and/or allow the
chain to break and the load to drop.
TO AVOID INJURY:
Due to size requirements and physical properties, use
only Hoistaloy®load chain in the XL Air Hoists.
IMPORTANT:
DO NOT USE REP ACED CHAIN FOR OTHER PURPOS-
ES SUCH AS IFTING OR PU ING. OAD CHAIN MAY
BREAK SUDDEN Y WITHOUT VISUA DEFORMATION.
FOR THIS REASON, CUT REP ACED CHAIN INTO
SHORT ENGTHS TO PREVENT USE AFTER DISPOSA .
PROTECTOR™
The Protector should operate for the normal life of
hoist without service. The device has been calibrated
at the factory for a specific capacity/gear ratio of the
XL Air Hoist. It is not adjustable and it is not inter-
changeable with other capacities/gear ratios.
RATED L AD *LIFT SPEED C L R C DE
T NS (Kg.) FPM (MPM)
2 (2000) 31 (14.0) Blue
3 (3000) 21 (9.5) Orange
5 (5000) 13 (5.9) reen
6 (6000) 10(4.5) Blue
7 1/2 (7500) 8.5 (3.8) reen
11
Records of periodic inspections are to be kept for continuing
evaluation of the condition of the hoist. Periodic inspections
are to be performed yearly for normal service, semi-annually
for heavy service and quarterly for severe service, and they
are to include those items listed in Table 3.
CAUTION: ANY DEFICIENCIES ARE TO BE CORRECTED
BEFORE THE HOIST IS RETURNED TO SERVICE. A SO,
THE EXTERNA CONDITIONS MAY SHOW THE NEED
FOR DISASSEMB Y TO PERMIT A MORE DETAI ED
INSPECTION, WHICH, IN TURN, MAY REQUIRE THE USE
OF NONDESTRUCTIVE TYPE TESTING.
HOOK INSPECTION
Hooks damaged from chemicals, deformations or cracks, or
that have more than a 10° twist from the hook’s unbent
plane, excessive opening or seat wear must be replaced. Also,
hooks that are opened and allow the latch to not engage the
tip must be replaced. Any hook that is twisted or has exces-
sive throat opening indicates abuse or overloading of the
unit. Inspect other load sustaining parts for damage.
On latch type hooks, check to make sure that the latch is not
damaged or bent and that it operates properly with sufficient
spring pressure to keep the latch tightly against the tip of the
hook and allow latch to spring back to tip when released. If
latch does not operate properly, it should be replaced. See
below to determine when the hook must be replaced.

12
Table 3. Minimum Frequent Inspections
TYPE OF SERVICE ITEM
Normal Heavy Severe
a) Brake for evidence of slippage.
b) Control functions for proper operation.
c) Hooks for damage, cracks, twists, excessive throat opening. latch engagement
and latch operation–see page 13.
d) Load chain for adequate lubrication, as well as for signs of wear, damaged links
or foreign matter–see page 15.
e) Load chain for proper reeving and twists.
Daily
to Weekly
Weekly
to Monthly
Monthly
Table 4. Minimum Periodic Inspections
ITEM
Normal Heavy Severe
TYPE OF SERVICE
a) All items listed in Table 3 for frequent inspections.
b) External evidence of loose screws, bolts or nuts.
c) External evidence of worn, corroded, cracked or distorted hook block, gears,
bearings, dead end block, dead end pin, dead end bolt and suspension components.
d) External evidence of damage to hook retaining nut and pin. Also check the
upper suspension adapter making sure it is fully seated in the hoist frame and
that suspension adapter screw or dead end bolt is tight.
e) External evidence of damage or excessive wear of the liftwheel and hook block
sheave chain pockets. Widening and deepening of the pockets may cause the
chain to lift-up in the pocket and result in binding between liftwheel and chain
guide or between the sheave and hook block. Also, check the chain guide for
wear or burring where the chain enters the hoist. Severely worn or damaged
parts should be replaced.
f) External evidence of excessive wear of brake parts, and brake adjustment—see
page 14.
g) Check the operation of the control station making sure the paddles operate
freely and do not stick in either position.
h) Check air supply hose and control hose for kinks, cuts, leaks and damage
i) Inspect trolley trackwheels for external wear on tread and flange and for wear
on internal bearing surfaces as evidenced by a looseness on the stud.
Suspension components for damage, cracks, wear and operation. Also check sus-
pension adapter screw or dead end bolt for proper tightness—(see pages 4,
5,and 6).
j) Inspect the loose end link, loose end screw, dead end block on double reeved
units and dead end plate on triple reeved units. Replace worn or distorted parts.
k) Inspect the hook for excess free play or rotation. Replace worn parts as evidenced
by excess free play or rotation.
l) Inspect for oil leaks at the gasket on either side of intermediate plate. Tighten
the screws used to attach the main housing and brake housing to intermediate
plate. If leak persists, disassemble hoist (see page 17) and replace gaskets.
m) Inspect inside of motor and brake housings for presence of oil. Oil in motor
housing may be excess chain lubricant or a leaking seal. Wipe out oil and moni-
tor. If leak persists, replace seal (652-122 or 652-132). Oil in brake housing is due
to leaking seal. Replace seal (652-122 or 652-134).
n) Inspect all splines for signs of wear and deterioration. Replace splined parts if
worn or damaged.
Yearly
Every 6 Months
Every 3 Months

13
Notes

14
UBRICATION
NOTE: TO ASSURE ONG IFE AND TOP PERFORMANCE,
BE SURE TO UBRICATE THE VARIOUS PARTS OF
THE X AIR HOIST USING THE UBRICANTS
SPECIFIED BE OW. IF DESIRED, THESE UBRCANTS
MAY BE PURCHASED FROM THE FACTORY.
HOIST UBRICATION
Gears. Check the oil level in gear housing at least once a
month, maintaining it at the bottom of oil level hole in
the main housing (652-110).
Drain the housing every 2-3 years and refill with one gal-
lon (3.86 liters) of gear oil Hulbest EP ISO V 68 thru 460
(H-2 Classification).
CAUTION: THE PROTECTOR IS DESIGNED TO OPERATE
IN THE ABOVE MENTIONED OI . DO NOT
USE ANY OTHER TYPE OF UBRICANT OR
THE PROTECTOR WI NOT OPERATE PROP
ER Y AND PARTS COU D BE DAMAGED.
Chain Guides, iftwheel & Sheave Wheels.
When the hoist is disassembled for inspection and/or
repair, the chain guides, sheave wheels (on multi-reeved
units) and liftwheel must be lubricated with Lubriplate Bar
and Chain Oil 10-R (Fiske Bros. Refining Co.) prior to
reassembly. Apply sufficient lubricant to obtain natural
runoff and full coverage.
oad Chain. Keep chain lubricated with a small amount
of lubricant. This will greatly increase the life of load
chain. Do not allow the chain to run dry.
Keep it clean and lubricate at regular intervals with
Lubriplate Bar and Chain Oil 10-R (Fiske Bros. Refining
Co.) or equal lubricant. Normally, weekly lubrication and
cleaning is satisfactory, but under hot and dirty conditions,
it may be necessary to clean the chain at least once a day
and lubricate it several times between cleanings. When
lubricating the chain, apply sufficient lubricant to obtain
natural runoff and full coverage.
Bearings. All bearings except the lower hook thrust bear-
ings are pre-lubricated or are in an oil bath and need no
lubrication. The lower hook thrust bearing should be lubri-
cated at least once a month with heavy duty machine oil.

!WARNING
The lubricants used in and recommended for the XL Air Hoist
may contain hazardous materials that mandate specific han-
dling and disposal procedures.
TO AVOID CONTACT AND CONTAMINATION:
Handle and dispose of lubricants only as directed in applicable
material safety data sheets and in accordance with applicable
local, state and federal regulations.

!WARNING
Used motor oils contain known carcinogenic materials.
TO AVOID HEA TH PROB EMS:
Never use used motor oils as a chain lubricant. Only
use Lubriplate Bar and Chain Oil 10-R or equal as a
lubricant for the load chain.
Service Air ine ubricator. The air line filter and
lubricator is the only source of lubrication for control
valves and air motor. Fill lubricator with a good grade
air tool oil or 10W machine oil Feed one drop of oil for
every 50 to 75 cubic feet of air going through the air
motor.
Miscellaneous. If the unit is disassembled, splines
inside the coupling (652-103) should be coated with an
EP type grease (such as Evans Products Co. Anti-Scoring
Extreme Pressure Lub. No. 3) before reassembly.
TRO EY UBRICATION
Trackwheel bearings are pre-lubricated and require no
lubrication.
Geared Trolley. Once a month lubricate trackwheel
gears with Texaco Novatex No. 2 or an equivalent heavy
cup grease or graphite grease.
Every six months lubricate handwheel shaft bearings in
3-in-1 machine oil.
Motor Driven Trolley. Once a month lubricate track-
wheel gears with Texaco Novatex No. 2 or an equivalent
heavy cup grease or graphite grease.
For 2-7 1/2 ton trolleys, the right angle worm gear reducer oil
should be changed after the first 100 hours of operation, then
after every 2500 hours of normal service. When replacing oil
due to repairs or service, use Mobil SHC-626 or equal, for
each oil change.
ADJUSTMENTS
HOIST BRAKE
The correct air gap between spacer tube and field plate when
brake is not activated, is 0.025 inch (.63 mm) and need not be
adjusted until the gap reaches 0.045 inch (1.14 mm).
To adjust the brake, proceed as follows:
1. Turn off air supply and bleed stored air by depressing
pendant paddles.
2. Remove brake end cover.
3. Before adjusting the gap, back off the brake nuts
and examine friction linings and friction surfaces for
wear, scoring or warpage (min.thk. .188). Any of
these symptoms indicate the need for replacement
of parts.
4. Turn brake nuts clockwise gaging the air gap on
all three posts..
5. Replace cover, turn on air supply and check operation.

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




15
RECOMMENDED SPARE PARTS
To insure continued service of the XL Air Hoist, the
following is a list of parts that are recommended to
be kept on hand at all times to replace parts that
have worn. Parts applicable to your unit should be
stocked.
Refer to page 22 thru 39 for ordering instructions
and the parts list for part numbers.
PREVENTIVE MAINTENANCE
In addition to the inspection procedure on page 12,
a preventive maintenance program should be estab-
lished to prolong the useful life of the hoist and
maintain its reliability and continued safe use. The
program should include the periodic and frequent
inspections with particular attention being paid to
the lubrication of the various components using the
recommended lubricants (see page 14).
Key No. Part Name Qty for Each
Hoist in Service
652-131 Brake Friction Disc 2
652-307 Valve O-Ring Kit 1
652-308 Motor Repair Kit 1
TRO EY BRAKE (2 THRU 7½ TON UNITS)
(Optional Accessory)
Horton/Nexen Brake Information:
The brake can be ordered with the trolley or it is avail-
able in kit form for installation on a unit in the field.
To order a brake kit for an existing unit, contact sales
and indicate the serial number of the trolley on which
it is to be installed.
 !WARNING
Components such as motors, valves, lines, fil-
ter/lubricators located after a closed shut-off
value can contain pressurized air.
Disassembly in this state can cause injury.
Bleed the stored air by repeatedly depressing
the pendant paddles.

16
TROUB E SHOOTING
TROUB E PROBAB E CAUSE REMEDY
1. Hoist does not operate. a. Insufficient air pressure at source.
b. Insufficient air supply at hoist
c. Clogged air intake filter or muffler.
d. Excessive overload
e.. Clogged spool value.
f. Clogged pendant throttle control.
g. Motor failure.
h. Lack of lubrication.
i. Brake not operating
a. Check and adjust air pressure.
b. Use correct size air supply hose.
c. Shut off air supply, disconnect air
supply hose and clean air filter and
muffler.
d. Reduce load to the rated capacity
of the hoist.
e. Disassemble and check for free
movement of spool and condition of
o-rings. (see page 18, 19)
f. Disassemble and check parts
g. Disassemble motor and check rotor
vanes (see page 19 ,20)
h. Make sure there is oil in the lubri-
cator.
i. Make sure the air tubing to the
brake is not kinked or pinched.
Disassemble brake and check for worn
or damaged parts. Check brake
adjustment as described on page 14.
2. Hoist will not hold suspended load. a. Brake not holding.
b. Broken brake spring.
c. Excessive overload.
a. See item 1 (i)
b. Replace spring.
c. See item 1 (d)
3. Hook will raise but will not lower
or hook will lower but not raise
a. Clogged pendant throttle control.
b. Clogged spool value
c. Excessive load.
d. Clogged brake shuttle value.
a. See item 1 (f)
b. See item 1 (e)
c. See item 1 (d)
d. Clean shuttle valve
4. Hoist loses power. a. Insufficient air pressure.
b. Clogged spool value.
c. Clogged muffler.
d. Worn or broken rotor vanes.
a. See item 1 (a)
b. See item 1 (e)
c. Clean or replace muffler.
d. Replace worn or damaged rotor
vanes (see page 19, 20)
5. Pendant throttle control levers do
not return to off position.
a. Foreign material, rust or corrosion
in pendant throttle control, levers
bent or lever pivot pin bent.
a. Clean pendant throttle control and
replace worn or damaged parts.
6. Cannot regulate speed using the
pendant throttle control levers.
a. Brake not operating properly.
b. Pendant throttle control not oper-
ating properly.
a. See item 1(i)
b. See item 5.
7. Lifting and lowering speeds differ
from rated speeds.
a. Incorrect air pressure or inadequate
air supply.
b. Loss of power.
a. Check air pressure at hoist when
hoist is operating.
b. See item 1 (b)
8. Hook does not stop promptly. a. Brake slipping.
b. Excessive load.
c. Protector slipping.
d. Clogged quick release value.
a. Check brake adjustment as
described on page 15. Check for worn
parts.
b. Reduce loading to the capacity limit
of hoist as indicated on the identification
plate.
c. If protector is not functioning properly,
it should be replaced.
d. Check for air blast from value when
NOTE: The operation of the trolley motor, valve, and pendant is the same as for the hoist. Items
1,3,4,5,and 7 also refer to trolley maintenance.