Lodestar XL 2 ton, XL 3 ton, XL 5 ton, XL 6 ton, XL 7 1/2 ton Air Chain Hoist User manual

O P E R AT I N G ,
MAINTENANCE
& PA R T S
MANUAL
AIR
CHAIN HOIST
AIR XL CHAIN
HOIST
®
Rated capacities 2 through 7½ tons/
2000 through 7500 kg
Before installing hoist, fill in
the information below. Refer
to the hoist identification
plate.
Model No. __________________
Serial No. __________________
Purchase Date ______________
Rated Capacity______________
53031
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.
Manual No. A652-D
XL AIR HOIST PARTS AND SERVICES ARE AVAILABLE 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 (800) 888-0985. Fax: (716) 689-5644. In the following list, the Canadian Service Centers
are indicated.
UNITED STATES MASTER PARTS DEPOT
CALIFORNIA
OTTO SYSTEMS, INC.
12010 Bloomfield Ave.
Sante Fe Springs, CA 90670
562/462-1612 or 800/596-7392
Fax 562/462-1617
or
7656 Las Positas Road
Livemore, CA 94551
925/245-8800 or 800/508-68860
Fax 925/245-8804
GEORGIA
ACE INDUSTRIES, INC.
6295 McDonough Drive
Norcross, GA 30093
770/441-0898 or 800/733-2231
Fax 800/628-3648
ILLINOIS
JOHN SAKASH COMPANY, INC.
700 Walnut Street
Elmhurst, IL 60126
630/833-3940
Fax 630-833-9830
INDIANA
HORNER ELECTRIC COMPANY, INC.
1521 East Washington Street
Indianapolis, IN 46201
317/639-4261
Fax 317/639-4342
IOWA
VM HOIST & CRANE SERVICES
PO Box 440
Walford, IA 52351
319/846-6040
Fax 319/846-6045
KANSAS
INDEPENDENT ELECTRIC MACHINERY
4425 Oliver Street
Kansas City, KS 66106
913/362-1155 or 800/833-2610
Fax 913/904-3330
LOUISIANA
BEERMAN PRECISION, INC.
PO Box 6018
Metairie, LA 70009
504/207-6000
Fax 504/207-6044
MASSACHUSETTS
ABEL DISTRIBUTORS, INC.
50 Parker Street, Unit 2
Newburyport, MA 01950
978/463-0700
Fax 978/463-5200
NEW JERSEY
SHUPPER-BRICKLE EQUIPMENT CO.
PO Box 803
2394 Route 130, Suite C
Dayton, NJ 08810
732/438-3888
Fax 732/438-3889
CANADIAN SERVICE CENTERS
NEW YORK
VOLLAND ELECTRIC EQUIPMENT CO.
75 Innsbruck Drive
Buffalo, NY 14227
716/656-9900
Fax 716/656-8899
ALBERTA
BENNETT & EMMOTT, LTD.
18131 118th Avenue
Edmonton, Alberta T5S 1M8
403/454-9000
Fax 403/454-8990
NORTH CAROLINA
TEAM SESCO
2225 Freedom Drive
Charlotte, NC 28208
704/372-4832 or 800/487-3726
Fax 704/358-1098
**COLUMBUS McKINNON, LTD.
10311-174th Street
Edmonton, Alberta T5S 1H1
800/263-1997
Fax 403/486-6160
OHIO
MAZZELLA LIFTING TECHNOLOGIES
21000 Aerospace Parkway
Cleveland, OH 44142-1072
440/239-7000 or 800/362-4601
Fax 440/239-7010
PENNSYLVANIA
AMICK ASSOCIATES, INC.
11 Sycamore Street
PO Box 529
Carnegie, PA 15106-0529
412/429-1212 or 800/445-9456
Fax 412/429-0191
RAM MOTORS & CONTROLS, INC.
5460-B Pottsville Pike, Docks 8-11
PO Box 748
Leesport, PA 19533
610/916-8000 Ext. 1011
Fax 610/916-7957
SOUTH CAROLINA
ENGINEERED SYSTEMS, INC.
1121 Duncan-Reidville Road
Duncan, SC 29334
864/879-7438 or 800/879-7438
Fax 864/879-6428
TEXAS
ABEL EQUIPMENT CO., INC.
3710 Cavalier Drive
Garland, TX 75042
972/272-7706
Fax 972/272-6955
HYDRAULIC EQUIPMENT SERVICES, INC.
1021 North San Jacinto Street
Houston, TX 77002
713/228-9601
Fax 713/228-0931
WISCONSIN
TRESTER HOIST & EQUIPMENT, INC.
W136 N4863 Campbell Drive
Suite #4
Menomonee Falls, WI 53051
262/790-0700 or 800/234-6098
Fax 262/790-1009
BRITISH COLUMBIA
FLECK BROTHERS, LTD.
4084 McConnel Court
Burnaby, British Columbia V5A 3N7
MANITOBA
KING’S ELECTRIC MOTORS, INC.
633 Tyne Avenue
Winnipeg, Manitoba R2L 1J5
204/663-5332
Fax 204/663-4059
NOVA SCOTIA
*W & A MOIR
95 Ilsley Ave.
Burnside Park, Nova Scotia B3B 1L5
902/468-7720
Fax 902/468-3777
ONTARIO
*R & W HOIST REPAIR, LTD.
790 Redwood Square
Units 5, 6, & 7
Oakville, Ontario L6L 6N3
905/825-5500
Fax 905/825-5315
*TORONTO ELECTRIC HOIST
SALES & SERVICE
9 CoDeco Court
North York, Ontario M3A 1A1
416/386-0820
Fax 416/386-0821
*MASLACK SUPPLY, LTD.
488 Falconbridge Road
Sudbury, Ontario P3A 4S4
705/566-1270
Fax 705/566-4208
*COLUMBUS McKINNON, LTD.
P.O. Box 1106
10 Brook Road, North
Cobourg, Ontario K9A 4W5
905/372-0153
Fax 905/372-3078
QUEBEC
*HERCULES SLING & CABLE
3800 TransCanada Highway
Pointe-Claire, Quebec H9R 1B1
514/428-5511514/48631-5511
Fax 514/428-5555
*LEGER PALANS ET OUTILLAGES, INC.
7995-17th Ave.
Montreal, Quebec H1Z 3R2
514/376-3050
Fax 514/376-0657
**ARE ALSO MASTER PARTS DEPOTS
**MASTER PARTS DEPOT ONLY
i
SAFETY PRECAUTIONS
Each XL Air Hoist is built in accordance with the specifications contained herein and at the time of manufacture complied 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.
THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH IF NOT FOLLOWED
COULD ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY OF YOURSELF AND OTHERS.
READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL AND ANY PROVIDED WITH THE
EQUIPMENT BEFORE ATTEMPTING TO OPERATE YOUR XL HOIST.
! WARNING
Usage of hoists that do not involve lifting of the load
on the lower hook or using hoists in the inverted position 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.
! 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:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Not operate a damaged, malfunctioning or unusually
performing hoist.
Not operate the hoist until you have thoroughly read
and understood this Operating, Maintenance and Parts
Manual.
Not operate a hoist which has been modified.
Not lift more than the rated load for the hoist.
Not use hoist with twisted, kinked, damaged or worn
load chain.
Not use the hoist to lift, support, or transport people.
Not lift loads over people.
Not operate a hoist unless all persons are and
remain clear of the supported load.
Not operate unless load is centered under hoist.
Not attempt to lengthen the load chain or repair damaged load chain.
Protect the hoist’s load chain from weld splatter or
other damaging contaminants.
Not operate hoist when it is restricted from forming a
straight line from hook to hook in the direction of loading.
Not use load chain as a sling, or wrap load or chain
around load.
Not apply the load to the tip of the hook or to the
hook latch.
Not apply load unless load chain is properly seated in
the chain wheel(s) or sproket(s).
Not apply load if bearing prevents equal loading on all
load chains.
Not operate beyond the limits of the load chain travel.
Not leave load supported by the hoist unattended
unless specific precautions have been taken.
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.
! CAUTION
Improper operation of a hoist can create a potentially hazardous situation which, if not avoided, could result in
minor or moderate injury. To avoid such a potentially hazardous situation, the operator shall:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Maintain a firm footing or be otherwise secured when operating
the hoist.
Check brake function by tensioning the hoist prior to each lift
operation.
Use hook latches. Latches are to retain slings, chains, etc. under
slackconditions only.
Make sure the hook latches are closed and not supporting any
parts of the load.
Make sure the load is free to move and will clear all obstructions.
Avoid swinging the load or hook.
Make sure hook travel is in the same direction as shown on the
controls.
Inspect the hoist regularly, replace damaged or worn parts, and
keep appropriate records of maintenance.
Use the hoist manufacturer’s recommended parts when repairing
the unit.
Lubricate load chain per instructions in this manual.
Not use the hoist load limiting or warning device to measure load.
Not use limit stops as routine operating stops unless allowed by
manufacturer. They are emergency devices only.
Not allow your attention to be diverted when operating hoist.
Not allow the hoist to be subjected to sharp contact with other
hoists, structures, or objects through misuse.
Not adjust or repair the hoist unless qualified to perform such
adjustments or repairs.
ii
iii
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 procedures and by carrying out the recommended preventative maintenance suggestions, you will experience long, dependable 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 handbook 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 rigging operations. For rigging information, we recommend consulting a standard textbook on the subject.
TABLE OF CONTENTS
ITEM
PAGE NO.
MASTER PARTS DEPOTS AND SERVICE CENTERS. . . . .i MAINTENANCE
ITEM
PAGE NO.
INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . .ii
HOIST SAFETY IS UP TO YOU . . . . . . . . . . . .iii
GENERAL INFORMATION
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 2
REPAIR/REPLACEMENT POLICY . . . . . . . . . 3
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . ..3
INSTALLATION
UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLING THE SUSPENSION
HOOK SUSPENSIONS . . . . . . . . . . . . . . . . . . . 4
LUG SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . 6
MOUNTING TROLLEY ON HOIST . . . . . . . . . 6
INSTALLING TROLLEY SUSPENDED
HOIST ON BEAM . . . . . . . . . . . . . . . . . . . . . 7
INSTALLING BREATHER . . . . . . . . . . . . . . . . . . 8
INSTALLING MUFFLER. . . . . . . . . . . . . . . . . . . 8
AIR SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . . 8
CHECKING FOR TWIST IN LOAD CHAIN . . . . 9
CHAIN CONTAINER . . . . . . . . . . . . . . . . . . . . . 9
CONTROL CORD . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATING INSTRUCTIONS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ALL HOISTS . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HOIST WITH PLAIN TROLLEY . . . . . . . . . . . 10
HOIST WITH GEARED TROLLEY . . . . . . . . . . . 10
HOIST WITH MOTOR DRIVEN TROLLEY . . . 10
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . 10
FREQUENT INSPECTIONS . . . . . . . . . . 10,11
PERIODIC INSPECTIONS . . . . . . . . . . . . . 11,12
HOOK INSPECTION . . . . . . . . . . . . . . . . . . . 11
LOAD CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . 11
PROTECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LUBRICATION
HOIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LOAD CHAIN . . . . . . . . . . . . . . . . . . . . . . 14
AIR LUBRICATOR . . . . . . . . . . . . . . . . . . . 14
TROLLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ADJUSTMENTS
HOIST BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 14
TROLLEY BRAKE . . . . . . . . . . . . . . . . . . . 15
RECOMMENDED SPARE PARTS . . . . . . . 15
PREVENTIVE MAINTENANCE . . . . . . . . . 15
TROUBLE SHOOTING
HOISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
MOTOR DRIVEN TROLLEY. . . . . . . . . . . . 16
AIR DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HOIST DISASSEMBLY/REASSEMBLY . . 17
VALVE DISASSEMBLY/REASSEMBLY . 18
AIR MOTOR DISASSEMBLY/REASSEMBLY .
19,20
REMOVAL AND REPLACEMENT OF LOAD CHAIN
20
REEVING LOAD 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
EXPLODED VIEWS AND PARTS LISTS . . . 24-39
1
GENERAL INFORMATION
SPECIFICATIONS
The XL Air Chain Hoist is a highly versatile material handling 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.
Shielded, lifetime lubricated ball bearings at all
rotating points. Open bearings are used in gear case.
Three stage gear reduction.
This hoist’s variable speed is obtained by varying the pressure of the pilot control lines through the pendant. This
variable pilot pressure is used to modulate the main control valve for both direction and speed.
The standard features of the XL Air Chain Hoist include:
Hardened, alloy steel, oblique lay liftwheel provides 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 running 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.
XL Hoist with
Motor Driven
Trolley
TABLE 1-SPECIFICATIONS
XL AIR CHAIN HOISTS
TONS
kg.
RATED LOAD
*VARIABLE SPEEDS UP TO:
FPM
MAXIMUM LIFT
FEET
2
2000
Plain and Geared
Trolley
31
MPM
9.4
100
METERS
MINIMUM HEADROOM
HOOK SUSPENDED - IN. (mm)
TROLLEY SUSPENDED - IN (mm)
RANGE OF TROLLEY ADJUSTABILITY
“S” BEAMS
IN.
mm
VARIABLE MOTOR DRIVEN TROLLEY
TRAVEL SPEED - FPM (MPM)
APPROX. NET WEIGHT -LBS. (Kg.)
HOOK SUSPENDED
WITH PLAIN TROLLEY
WITH GEARED TROLLEY
WITH MOTOR DRIVEN TROLLEY
*Lifting speeds are based on 90 PSI air supply.
2
3
3000
5
5000
6
6000
7 1/2
7500
21
13
10
8.5
6.4
100
30.5
REEVING OF LOAD CHAIN
FLANGE WIDTH
2
2000
Motor Driven
Trolley
30.5
SINGLE
3.9
100
30.5
DOUBLE
35.31 (897)
33 (838) 34.25 (870)
25 (635)
28.69 (729)
3.0
100
30.5
8 x 18.4 to 20 x 66.0’
84.5 TO 139.7
101.6 TO 158.8
N/A
347 (157)
407 (184)
452 (205)
----
TRIPLE
36.18 (919)
34.25 (870)
6X12.5’ TO 15 X 42.9’
3.33 TO 5.50
2.6
100
30.5
N/A
4.00 TO 6.250
---------505 (229)
421
476
491
569
(191)
(216)
(222)
(258)
50 (15.2)
421
576
586
611
(191)
(261)
(266)
(277)
453 (205)
608 (275)
618 (280)
643 (291)
N/A
REPAIR/REPLACEMENT POLICY
All XL Air Chain Hoists are thoroughly inspected and performance 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 purchaser without charge. This repair/replacement policy
applies only to XL Hoists installed, maintained and operated
as outlined in this manual, and specifically excludes parts subject 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 suspending the hoist from a fixed structure.
2 ton
LUG 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.
LUG SUSPENSION
PLAIN TROLLEYS
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.
3-6 ton
HOOK SUSPENSION
PLAIN TROLLEY
GEARED TROLLEYS
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 trolley is mounted on the hoist prior to shipment.
MOTOR DRIVEN TROLLEYS
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 controlled by levers located on the pendant control station.
A variable speed motor driven trolley is mounted on the
hoist prior to shipment.
3
INSTALLATION
UNPACKING
After opening the carton, carefully inspect the hoist,
control line, pendant, suspension, trolley and chain container for damage that may have occurred during shipment. If there is damage, refer to instructions on the
packing slip envelope.
INSPECT FOR SHIPPING
DAMAGE
MOTOR DRIVEN TROLLEY
CHAIN CONTAINER
This accessory is used to hold the slack chain and is supplied complete with mounting hardware and instructions. 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.
!
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.
INSTALLING 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
LATCHLOK® 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.
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.
DRIFT
LATCHLOK® HOOK
4
TO CONVERT
TO SWIVEL
TYPE HOOK
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.
CHANGING
POSITION OF
HOOK
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. 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).
CHANGING
POSITION OF
HOOK
NOTE: INSTALL BREATHER IN MAIN HOUSING AFTER
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).
HOOK SUSPENSION IS ASSEMBLED 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:
TO CONVERT TO
SWIVEL TYPE
HOOK
INSTALLING
HOOK
SUSPENSION
3, 5, & 6 TON
UNIT
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: INSTALL BREATHER IN MAIN HOUSING
AFTER HOOK SUSPENSION IS ASSEMBLED TO
HOIST. SEE PAGE 8.
5
MOUNTING TROLLEY ON HOIST
B. LUG 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 torque of 16 pound feet (22 NM).
INSTALLING LUG SUSPENSION—2 TON UNITS
The following instructions are provided to cover mounting 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.
MOUNTING
TROLLEY ON
HOIST
HANDWHEEL OR TROLLEY
MOTOR GEARED OR MOTOR
DRIVEN TROLLEY ONLY
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).
INSTALLING LUG
SUSPENSION—3, 5, 6
AND 7 1/2 TON
Dead End Bolt
! 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 seating torque specified above.
6
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 spacer washers as required to obtain proper distance between
wheels. When spacing is correct, install all remaining spacer 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 tightened 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.
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.
INSTALLING TROLLEY SUSPENDED HOIST ON BEAM
! WARNING
QUANTITY OF
INSIDE WASHERS
SHOULD BE EQUAL
-BOTH SIDES
QUANTITY OF
OUTSIDE 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.
TO AVOID INJURY:
Install rail stops at each end of the beam on which
the trolley is to operate.
Figure 1.
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 variations in beam flange widths, actual beam flange width
should be measured to determine the exact distribution of the spacer washers. See Mounting Trolley On
Hoist Section.
! 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.
Figure 2.
Table 2. Trolley Spacer Washer Arrangement
Plain and Geared
NOTE: USE OF OTHER THAN SUPPLIED SPACER WASHERS
MAY CAUSE IMPROPER TRACKWHEEL SPACING.
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.
Standard
Trolleys
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.
Special
Trolleys
2 Ton
FLANGE
WIDTH
IN.(mm)
A
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
5 5/8 (142.9)
12
1
1
12
No. of Washers
B
C
D
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
*Minimum Beam
Radius ft. (M)
4’-0” (1.22)
Dimension applies to minimum S-beam and will
*vary
with larger s-beams.
7
Units with anti-tipping rollers should be adjusted to pro- INSTALLING BREATHER
vide 1/8” maximum gap between the bottom of the
After the hook suspension is assembled to the hoist or after the
beam and the roller. Run the trolley the length of the
hoist and trolley are mounted on the beam, remove the upper
beam to check for tight places. Readjust if needed.
plug from the main housing (652-110) and install the breather
(inside information envelope). Failure to install the breather
On geared trolleys, the bottom of the hand chain loop is could damage oil seals and thus cause oil leaks.
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
INSTALL
wrench while holding the other end in a vise or another
BREATHER
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 hacksaw). Make certain that the chain is not twisted–then reinstall and close open links.
NOTE:
AFTER THE UNIT IS CONNECTED TO THE
AIR SUPPLY SYSTEM (SEE BELOW), SUS
PEND A CAPACITY LOAD FROM THE HOIST
AND OPERATE THE TROLLEY OVER THE
ENTIRE LENGTH OF THE RUNWAY OR MONO
RAIL SYSTEM TO BE SURE THAT THE ADJUST
MENTS AND OPERATION IS SATISFACTORY.
ON SYSTEMS WITH CURVES,THE EDGES OF
AIR SUPPLY SYSTEM
THE RAIL AT THE CURVED SECTIONS SHOULD Connect the hoist to a filtered and lubricated air source
BE KEPT LIGHTLY LUBRICATED WITH GREASE.
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
! WARNING
reduce hoist performance. If the hoist is suspended from a
trolley, provide sufficient hose to reach from the source to
An excessively worn beam flange may fail and allow
the farthest point of trolley travel. Hose Trolleys are recthe trolley to fall from the beam.
ommended to keep the hose up and out of the way.
TO AVOID INJURY:
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 conINSTALLING MUFFLER
stantly lubricated. Use a good grade of air powered tool
Install the 3” long 1 1/4” NPT pipe nipple through the
hole in the motor end cover and thread it into the valve oil or SAE 10W machine oil. Such oil can be obtained from
exhaust port. Install the 1 1/4” NPT pipe elbow onto the CM®, Coffing, or Budgit.
end of the pipe nipple. Tighten the elbow until it faces
downward. Install the muffler into the elbow and tighten.
Periodically inspect the beam flange for wear. Replace
beam if flange is worn.
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.
8
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.
! WARNING
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.
TO AVOID INJURY:
Do not allow the hook block or dead end stop to
contact the bottom of the hoist.
CHECKING FOR TWIST IN LOAD 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 SHOULD THE HOOK
BLOCK OR LOAD BE PERMITTED TO COME IN CONTACT 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 COULD FALL 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
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.
OPERATING INSTRUCTIONS
GENERAL
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 operation is automatically restored.
CAUTION: THE PROTECTOR IS SUSCEPTIBLE TO OVER
HEATING AND WEAR WHEN SLIPPED FOR EXTENDED
PERIODS. UNDER NO CIRCUMSTANCE SHOULD THE
PROTECTOR BE ALLOWED TO SLIP 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 dumbwaiter 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 atmospheric conditions.
4. Read the operation section of American National
Standard ASME B30.16.
ALL 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
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.
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 position while the chain is slack before taking up slack chain.
! WARNING
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 PLAIN TROLLEY
This unit should be moved by pushing on the suspended load or
by pulling the empty hook.
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.
HOIST WITH GEARED TROLLEY
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 TROLLEY
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 swaying of load.
11. Take up a slack load chain carefully and start load easily 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.
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 attachments to the hook are firmly seated in the hook saddle. 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 loadcarrying 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 handling 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.
INSPECTION
MAINTENANCE
To maintain continuous and satisfactory operation, a regular inspection procedure must be initiated to replace
worn or damaged parts before they become unsafe.
Inspection intervals must be determined by the individual 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 components.
The type of service to which the hoist is subjected can be
classified as “Normal,” “Heavy,” or “Severe.”
Normal Service: Involves operation with randomly distributed loads within rated load limit, or uniform loads less
than 65 percent of rated load for not more than 25 percent 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.
6. Do not leave load suspended in air unattended.
10
7. Permit only qualified personnel to operate unit.
Two classes of inspection—Frequent and Periodic—
must be performed.
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.
FREQUENT INSPECTIONS: These inspections are visual
examinations by the operator or other designated personnel. Records of such inspections are not required. The frequent 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.
9. On double and triple reeved hoists, check for twists
in the load chain. A twist can occur if the lower
PERIODIC INSPECTIONS: These inspections are visual
inspections of external conditions by an appointed person.
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. ALSO,
THE EXTERNAL CONDITIONS MAY SHOW THE NEED
FOR DISASSEMBLY TO PERMIT A MORE DETAILED
INSPECTION, WHICH, IN TURN, MAY REQUIRE THE USE
OF NONDESTRUCTIVE TYPE TESTING.
LOAD 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-bylink inspection for nicks, gouges, twisted links and excessive wear or stretching. Chain exhibiting wear should be
checked throughout its entire length and replaced if
worn beyond serviceable limits.
Checking For Load Chain Wear
Slack the portion of the chain that normally passes over
the liftwheel. Examine the interlink area for the point of
HOOK INSPECTION
maximum wear (polishing). Measure and record the stock
Hooks damaged from chemicals, deformations or cracks, or
diameter at this point of the link. Then measure stock
that have more than a 10° twist from the hook’s unbent
diameter in the same area on a link that does not pass
plane, excessive opening or seat wear must be replaced. Also, over the liftwheel (use the link adjacent to the loose end
hooks that are opened and allow the latch to not engage the link for this purpose). Compare these two measurements.
tip must be replaced. Any hook that is twisted or has excesIf the stock diameter of the worn link is 0.010 inches
sive throat opening indicates abuse or overloading of the
(0.254mm), or greater, less than the stock diameter of
unit. Inspect other load sustaining parts for damage.
the unworn link, the chain must be replaced.
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.
LATCH TYPE HOOK
(Upper and Lower)
TO MEASURE OPENING,
DEPRESS LATCH AGAINST
HOOK BODY AS SHOWN.
E
UR
AS ING
E
N
M PE
O
*UPPER HOOK NOT AVAIL ABLE
FOR 7 1/2 TON
CAPACITY
(TONS)
Replace Hook
When Opening
Is Greater
Than
2
1 1/2 IN.
38.1 mm
3, 5, 6 AND 7 ½
2 3/8 IN.
60.3 mm
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.
PROTECTOR™
“B” Max.
3, 5, and 6
!
IMPORTANT:
DO NOT USE REPLACED CHAIN FOR OTHER PURPOSES SUCH AS LIFTING OR PULLING. LOAD CHAIN MAY
BREAK SUDDENLY WITHOUT VISUAL DEFORMATION.
FOR THIS REASON, CUT REPLACED CHAIN INTO
SHORT LENGTHS TO PREVENT USE AFTER DISPOSAL.
“A”
2
Also, these chains are specially heat treated and hardened and should never be repaired.
TO AVOID INJURY:
Due to size requirements and physical properties, use
only Hoistaloy® load chain in the XL Air Hoists.
LATCHLOCK® TYPE HOOK
(UPPER AND LOWER)
CAPACITY
(TONS)
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.
Replace Hook
When Opening
Or Seat are:
“A” Max.
2 1/2 IN.
63.5 mm
“B” Mn.
1 1/8 IN.
28.5mm
2 15/16 IN.
74.6 mm
1 13/32 IN.
35.7mm
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 interchangeable with other capacities/gear ratios.
RATED LOAD
*LIFT SPEED
COLOR CODE
TONS (Kg.)
FPM (MPM)
2
3
5
6
7
(2000)
(3000)
(5000)
(6000)
1/2 (7500)
31 (14.0)
21 (9.5)
13 (5.9)
10(4.5)
8.5 (3.8)
Blue
Orange
Green
Blue
Green
Hook Inspection
11
Table 3. Minimum Frequent Inspections
ITEM
TYPE OF SERVICE
Monthly
a)
b)
c)
Daily
to Weekly
Heavy
Weekly
to Monthly
Normal
Severe
d)
e)
Brake for evidence of slippage.
Control functions for proper operation.
Hooks for damage, cracks, twists, excessive throat opening. latch engagement
and latch operation–see page 13.
Load chain for adequate lubrication, as well as for signs of wear, damaged links
or foreign matter–see page 15.
Load chain for proper reeving and twists.
Table 4. Minimum Periodic Inspections
TYPE OF SERVICE
Normal
Heavy
ITEM
Severe
a)
b)
c)
d)
e)
f)
Every 3 Months
Every 6 Months
Yearly
g)
h)
i)
j)
k)
l)
m)
n)
12
All items listed in Table 3 for frequent inspections.
External evidence of loose screws, bolts or nuts.
External evidence of worn, corroded, cracked or distorted hook block, gears,
bearings, dead end block, dead end pin, dead end bolt and suspension components.
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.
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.
External evidence of excessive wear of brake parts, and brake adjustment—see
page 14.
Check the operation of the control station making sure the paddles operate
freely and do not stick in either position.
Check air supply hose and control hose for kinks, cuts, leaks and damage
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 suspension adapter screw or dead end bolt for proper tightness—(see pages 4,
5,and 6).
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.
Inspect the hook for excess free play or rotation. Replace worn parts as evidenced
by excess free play or rotation.
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.
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 monitor. 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).
Inspect all splines for signs of wear and deterioration. Replace splined parts if
worn or damaged.
Notes
13
LUBRICATION
!
WARNING
The lubricants used in and recommended for the XL Air Hoist
may contain hazardous materials that mandate specific handling 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.
Service Air Line Lubricator. 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.
TROLLEY LUBRICATION
NOTE: TO ASSURE LONG LIFE AND TOP PERFORMANCE,
BE SURE TO LUBRICATE THE VARIOUS PARTS OF
THE XL AIR HOIST USING THE LUBRICANTS
SPECIFIED BELOW. IF DESIRED, THESE LUBRCANTS
MAY BE PURCHASED FROM THE FACTORY.
HOIST LUBRICATION
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 gallon (3.86 liters) of gear oil Hulbest EP ISO VG 68 thru 460
(H-2 Classification).
CAUTION: THE PROTECTOR IS DESIGNED TO OPERATE
IN THE ABOVE MENTIONED OIL. DO NOT
USE ANY OTHER TYPE OF LUBRICANT OR
THE PROTECTOR WILL NOT OPERATE PROP
ERLY AND PARTS COULD BE DAMAGED.
Chain Guides, Liftwheel & 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.
Load 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.
!
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 trackwheel 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.
WARNING
Used motor oils contain known carcinogenic materials.
TO AVOID HEALTH PROBLEMS:
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.
Bearings. All bearings except the lower hook thrust bearings are pre-lubricated or are in an oil bath and need no
lubrication. The lower hook thrust bearing should be lubricated at least once a month with heavy duty machine oil.
14
TROLLEY BRAKE (2 THRU 7½ TON UNITS)
RECOMMENDED SPARE PARTS
(Optional Accessory)
Horton/Nexen Brake Information:
The brake can be ordered with the trolley or it is available 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.
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.
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
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 established 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).
! WARNING
Components such as motors, valves, lines, filter/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.
15
TROUBLE SHOOTING
TROUBLE
1. Hoist does not operate.
PROBABLE CAUSE
REMEDY
a. Insufficient air pressure at source. a. Check and adjust air pressure.
b. Insufficient air supply at hoist
b. Use correct size air supply hose.
c. Clogged air intake filter or muffler. c. Shut off air supply, disconnect air
supply hose and clean air filter and
muffler.
d. Excessive overload
d. Reduce load to the rated capacity
of the hoist.
e.. Clogged spool value.
e. Disassemble and check for free
movement of spool and condition of
o-rings. (see page 18, 19)
f. Clogged pendant throttle control. f. Disassemble and check parts
g. Disassemble motor and check rotor
g. Motor failure.
vanes (see page 19 ,20)
h. Make sure there is oil in the lubricator.
h. Lack of lubrication.
i. Make sure the air tubing to the
i. Brake not operating
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.
b.
c.
d.
a.
b.
c.
d.
4. Hoist loses power.
a. Insufficient air pressure.
b. Clogged spool value.
c. Clogged muffler.
d. Worn or broken rotor vanes.
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.
6. Cannot regulate speed using the
pendant throttle control levers.
a. Brake not operating properly.
a. See item 1(i)
b. Pendant throttle control not oper- b. See item 5.
ating properly.
7. Lifting and lowering speeds differ
from rated speeds.
a. Incorrect air pressure or inadequate a. Check air pressure at hoist when
air supply.
hoist is operating.
b. Loss of power.
b. See item 1 (b)
8. Hook does not stop promptly.
a. Brake slipping.
Clogged pendant throttle control.
Clogged spool value
Excessive load.
Clogged brake shuttle value.
b. Excessive load.
c. Protector slipping.
d. Clogged quick release value.
See item 1 (f)
See item 1 (e)
See item 1 (d)
Clean shuttle valve
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)
a. Clean pendant throttle control and
replace worn or damaged parts.
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.
16
HOIST DISASSEMBLY
Refer to pages 24 through 39 for exploded views and
parts list. The following are general guide lines for disassembling the XL Air Hoist. Prior to disassembly:
1. Remove the dead end stop (652-304). Remove the
chain container.
2. Carefully run the chain out of the hoist. On 3 and 5
ton (double reeved) units, the chain will remain suspended from the dead end block (652-204).
3. Disconnect the hoist from the air supply system
and Lockout/Tagout disconnecting means.
! WARNING
Components such as motors, valves, lines, filter/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.
9. Remove the limit switch gear (652-149) from the
limit switch input shaft (652-104) and remove the
shaft from the intermediate plate.
10. Remove the second gear (652-159) from third reduction pinion and shaft (652-106) and remove the third
reduction pinion and shaft from the main housing
(652-110).
11. Remove the liftwheel gear (652-105) from the
liftwheel (652-111).
12. Remove the motor housing (652-107) from the main
housing (652-110).
13. Remove the chain stripper (652-114) and chain
guide (652-113).
14. On the 3, and 5 ton (Double Reeved) units,
remove the dead end block (652-204) and chain.
15. Remove the liftwheel (652-111) from the main housing.
*Slots are provided in the intermediate plate (652-109)
to aid in the removal.
4. Drain the oil from the hoist.
5. Remove the hoist from its support (hook suspended
units) or remove the hoist and trolley from the
beam. Remove the trolley from the hoist.
HOIST REASSEMBLY
These guide lines cover the disassembly of the major
mechanical components; not covered is the removal of
obvious items such as hardware and seals. While disassembling the hoist, care should be taken so as to not
damage the seals. Seals should be inspected for nicks or
damage that could cause oil leaks. Damaged seals
should be replaced prior to reassembly.
1.
If new seals are installed, make sure the lip of the
seal is on the oil side.
2.
Apply a light coat of gear oil to lips of all seals and
surfaces of shafts that pass thru the seals.
3.
Carefully slide the shafts through the seals.
4.
The frame screws used to attach the motor and gear
housings to the main frame should be tightened to
a seating torque of 21 pound feet (28 NM).
5.
Lubricate, especially the splines, as specified on page 14.
6.
Make sure that “this side out” embossed on the liftwheel gear is visible when the gear is assembled to
the liftwheel.
7.
Place the load chain (with welds down and towards
liftwheel. See illustration on page 20) over the liftwheel before attaching the motor housing to the
main frame. After assembly reeve the chain per page
20.
7. Remove the Protector (652-160).
8.
Follow the instructions starting on page 4 when reinstalling the unit.
8. *Remove the intermediate plate (652-109) from the
main housing (652-110) and remove gasket (652118).
9.
After installation, test the unit as indicated on page 22.
The reassembly of the hoist is, basically, the reverse of
the above disassembly sequence. However, during
reassembly:
1. Remove brake end cover (652-181).
2. Remove the brake assembly (652-161) and brake hub
(652-142).
3. Remove the motor end cover (652-182) and the complete motor (652-162). Coupling (652-103) should
remain on motor shaft.
4. On the 2, 3 and 5 ton units, remove chain plate
(652-178). On the 6 and 7 1/2 ton units,remove the
idler wheel housing (652-211) with idler wheel and
bearings.
5. *Remove the brake housing (652-108) and gasket (652-118).
6. Remove the drive shaft and pinion (652-112).
17
Down Pilot
Tube (Blue)
Up Pilot
Tube (Red)
Spool Body
Spool Body
Screws
Adapter Block
Quick Exhaust Valve
Quick Connect
Fitting Collar
Motor End View
VALVE DISASSEMBLY
1.
Turn off the air supply and bleed off the stored air by
repeatedly depressing the pendant paddles.
2.
Disconnect the five air lines (3/16” dia.) by pushing the
plastic collars toward the body of the quick connect fittings and pulling on the 3/16” diameter tube.
3.
Remove the (4) attaching bolts for the spool body.
4.
Remove the (4) attaching bolts for the adapter block.
5.
Remove the intake, exhaust, and spool end block by
removing the (4) socket head cap screws in each block.
Remove and discard the o-rings from under each block.
6.
Push the spool out of the spool body. Pull the (9) orings radially from the slots of the spool using a sharp
dental pick. DO NOT PRY AGAINST THE EDGE OF THE
SLOTS. Narrow faced diagonal cutters can be used to
cut the o-ring to aid in removal but do not contact the
edge of the slots.
7.
Remove the spool end caps using an arbor press and
snap ring pliers with right angle tips. CAUTION: The
end caps are under spring tension, therefore pressure
from the arbor press must be applied when removing
the retaining rings.
8.
18
Clean all parts in a mild solvent or detergent. Examine
the O.D. of the spool and the I.D. of the spool body. If
these surfaces have been scored by debris, the value
should be replaced because the o-ring will not seal
against a gouged surface.
VALVE REASSEMBLY
1.
Lubricate the return end caps, springs, and spool cavity
with a layer of EP grease as listed on page 14. Be sure
the vents on the end caps are exposed. Compress the
springs and caps with an arbor press and install the
retaining ring.
2.
Install the new spool o-rings from kit 653-307. Start
from either end and work inward. Apply a coating of
10W machine oil to the spool and slots for easier assembly. The 70 durometer (softer) o-rings are inserted into
the two end slots.
The 90 durometer (harder) o-rings are inserted into slots
2 thru 8. These slots are narrower at the top for retention of the o-rings and require special assembly. An oring has a flash line or lip at the I.D. and O.D. Roll an oring adjacent to the slot and align the outer lip. If the oring is twisted it will cause the spool to stick in the body
and give less slow speed control. Grab the o-ring on
opposite sides of the spool and slide into the slot. Roll
the spool on a clean hard surface to push the o-ring into
the slot. Again; oil the spool assembly and bore of the
spool body and assemble components.
3.
Insert new o-rings under the various blocks and assemble
to the spool body, motor, and adapter block. Tighten
the screws to 90 in-lbs. torque.
4.
Reassemble the (5) control lines as shown in the picture.
VALVE
Exhaust Block
Spool Body
Intake Block
Spool
Adapter Block
Spool End Block
70 Durometer o-rings
SPOOL
Vent
Spool
Spool
End Cap
MOTOR REBUILD
(see exploded view, page 39)
1
2
3
Remove the end cap.
Remove the dead end plate bolts
Remove the dead end plate. Do not use a screwdriver to
remove the end plate.
4 Remove the dowel pins from the body and push them
back into end plate until flush or just below the
machined surface of the dead end plate.
5 Remove the rotor using an arbor press.
6 Remove the vanes and ejection mechanisms. (Ejection
mechanism consists of vane springs and pins).
7 Remove the shaft seal and bearings from the drive end
plate. Remove the bearing from the dead end plate.
8. Do Not remove drive end plate bolts or drive end plate.
9 Clean parts. Check for scoring on the end plates and
rotor assembly. If scoring exists, contact factory.
10 Install the push pins.
11 Place the drive shaft of the rotor assembly through the
drive end plate. Press the drive bearing onto the drive
shaft.
12. Lightly tap on the inner race of the drive end bearing to
snug up the rotor to the drive end plate.
19
13. Install the vane spring lip into the notch at one end of
the vane and place in the rotor vane slot with the
spring facing the pushpin.
14. Place the proper end plate gasket on the body of the
dead end. If the original is damaged, replace with a
new one supplied in the service kit. If your air motor
uses O-rings, place the new O-rings in the body groove.
15. Place the dead end plate on the body.
16. Install the dead end bearing and press into place with
the bearing pusher tool from the tool kit.
17. Install the dowel pins.
18. Fully tighten the remaining bolts to 75-100 in-lbs.
19. Set the end clearance as required by model (.0060/.1524).
20. Apply a small amount of grease to the bearing seal and
nstall the drive end bearing seal by pressing it flush with
the bearing.
21. Reattach the end cap.
22. Apply a few drops of lubricant into ports and rotate the
shaft by hand for a few rotations.
REMOVAL AND REPLACEMENT OF LOAD CHAIN
USE ONLY CM LOAD CHAIN AND FACTORY
REPLACEMENT PARTS. USE OF OTHER CHAIN AND
PARTS MAY BE DANGEROUS AND VOIDS FACTORY
WARRANTY.
Star and 2-digit
year code
3 digit
trace code
! WARNING
USE OF COMMERICIAL OR OTHER MANUFACTURERS’
CHAIN AND PARTS TO REPAIR XL AIR HOISTS MAY CAUSE
LOAD LOSS
TO AVOID INJURY:
Use only factory supplied replacement load chain and
parts. Chain and parts may look alike, but factory
chain and parts are made of specific material or
processed to achieve specific properties.
Hoist load chain can be removed and installed using one
of the following methods. Method 1 is recommended if
only the load chain is replaced. Method 2 is recommended
when the entire hoist is disassembled for repair and /or
inspection.
METHOD 1
1. Remove the chain container or remove the loose
end of the chain from the hoist frame.
2. Using the procedures described on page 28 for cutting load chain, cut a portion out of the last loose
end link to form a coupling link. The portion
removed should be centered on the weld and be 1/2
inch (13mm) long. Remove burrs from cut edges.
3. Using the coupling link, attach the new chain to the
20
INSTALL LOAD
CHAIN PROPERLY
ON LIFTWHEEL
!
WARNING
Improper installation (reeving) of load chain can
result in dropped load.
TO AVOID INJURY:
Properly reeve load chain per the following instructions.
old chain. Carefully check the welds on the new
chain and make sure they are positioned the same
as the old chain. The new chain must enter the hoist
so that the welds are down and towards the lift
wheel. See illustration above. Failure to properly
position the chain will cause the chain to jam
between the liftwheel and chain guide.
4. Operate the hoist in the “down” direction until
approximately 6 feet (2 M) of the new chain is hang
ing free on the dead end side.
5. ON SINGLE REEVED UNITS, remove the hook block
from the old chain, remove the coupling link, discard the old chain and attach the hook block to the
new chain. ON DOUBLE REEVED UNITS, the hoist
must be removed from the trolley before reeving
the replacement load chain. For hook suspended
units, the hook must be positioned so that the dead
end bolt can be removed. If necessary, rotate hook
approximately 45 degrees following the instructions
on page 5. Now remove the chain plate and allow it
and the dead end block spacer (652-253) to slide
down the chain. Working through the cavity in
the bottom of the hoist, hold the dead end block
while loosening the dead end bolt. Remove the
dead end block and remove the dead end pin.
Remove the coupling link, pull the old chain out of
the hook block and discard the old chain. Reeve the
new load chain as described below. After reeving,
mount the trolley on the hoist or reposition the
hook, if necessary, per installation instructions start
ing on page 4. ON TRIPLE REEVED UNITS, remove the
dead end plate from the top of the hook block.
Remove the dead end pin and remove the old chain
from the dead end plate. Remove the coupling link,
pull the old chain out of the hook block and idler
sheave housing. Reeve the new load chain as
described below.
6. Remount the chain container or reattach the loose
end of the new chain to the hoist.
METHOD 2
1. Completely disassemble the hoist as described on
page 26.
2. Prior to reassembly, inspect the liftwheel, chain
guides and stripper for wear. If these parts are worn
or damaged, they could cause premature wear of
the chain. Replace worn or damaged parts.
3. Place chain on liftwheel with welds down and
towards liftwheel as shown below. Welds must
engage the relief machined in the bottom of the
4.
5.
6.
liftwheel pockets. If the chain is not properly placed
on the liftwheel, it will not be possible to install the
chain guide. After making sure the chain is correctly
installed on the liftwheel, continue to assemble the
hoist.
On single reeved units, remove the hook block from
the old chain and attach it to the new chain. On
double and triple reeved units, reeve the new chain
as described below.
Install the unit following the installation instructions
starting on page 4.
Remount the chain container or reattach the loose
end of the new chain to the hoist frame.
7.
8.
hoist frame. Turn the dead end bolt by hand to thread
it into the dead end block. Then tighten dead end bolt
to a seating torque of 120 pound feet (160 NM).
Slide the chain plate and spacer up the chain and
attach the chain plate to the hoist frame.
Retrace the chain and make sure there are no twists.
If there are twists, start over.
REEVING LOAD CHAIN
6 AND 7 1/2 TON HOISTS
REEVING LOAD CHAIN
3 AND 5 TON HOISTS
HOOK SUSPENSION SHOWN. LUG SUSPENSION SIMILAR
REEVING LOAD CHAIN
3, AND 5 TON DOUBLE REEVED UNITS
The following instructions assume that the trolley has
been removed from the hoist or the upper hook has
been positioned to provide access to the dead end bolt
and that there is 6 feet (2 m) of chain hanging free on
the dead end side of the hoist. Based on these, reeve the
load chain as follows:
1.
2.
3.
4.
5.
6.
Slide the suspension adapter into the hoist frame, if
has moved out of position or if it was removed.
Install the dead end bolt.
Attach a soft wire to the dead end of the chain. Feed
the wire around the hook block sheave. MAKING
SURE THERE ARE NO TWISTS, pull the chain thru the
hook block.
Feed the chain thru the square opening in the chain
plate and then thru the dead end block spacer.
Attach the last link of chain to dead end block using
the dead end pin.
MAKING SURE THERE ARE NO TWISTS IN THE
CHAIN, slide the dead end block into the cavity in
HOOK SUSPENSION SHOWN. LUG SUSPENSION SIMILAR
6 AND 7 1/2 TON TRIPLE REEVED UNITS
The following instructions assume that the idler wheel
housing assembly has been attached to the suspension
adapter and hoist frame, there is 6 feet (2 M) of chain
hanging free on the dead end side of the hoist and the
hoist is suspended from the trolley or permanent support..
Based on these, reeve the load chain as follows:
1. Attach a soft wire to the dead end of the chain. Feed
the wire around the lower hook block sheave. MAKING
SURE THERE ARE NO TWISTS IN THE CHAIN, pull the
chain thru the hook block.
2. Feed the soft wire into the outboard side of the idler
wheel housing and around the idler wheel. MAKING
SURE THERE ARE NO TWISTS IN THE CHAIN, pull the
chain over the idler wheel.
3. Remove the wire from the end of the chain and
route chain down to the hook block. MAKING SURE
THERE ARE NO TWISTS IN THE CHAIN, insert the last
link of the chain into the slot in the dead end plate.
Secure the chain using the dead end pin and attach
the dead end plate to top of hook block. Tighten the
dead end plate screws to a seating torque of 120
pound feet (160 NM).
4. Retrace chain and make sure there are no twists. If
there are twists, start over.
21
Hoistaloy load chain is hardened and it is difficult to
cut. The following methods are recommended when cutting a
length of new chain from stock or cutting off worn
chain. Always wear eye protection when cutting chain.
1. Use a grinder and nick the link on both sides (see
below), then secure the link in a vise and break off
with a hammer.
CUTTING CHAINS
GRINDER
NICKS
Cutting Chain by Nicking
2. Use a 7 inch ( 177 mm) minimum diameter by 1/8
inch ( 3.1 mm) thick abrasive wheel (or type recommended by wheel supplier) that will clear adjacent
links.
3. Use a bolt cutter (See below) similar to the H.K.
Porter No. 0590MTC with special cutter jaws for cutting
hardened chain. Jaws should be 1 inch (25.4 mm) long.
TESTING
Before using, all altered, repaired or used hoists that have
not been operated for the previous 12 months shall be
tested by the user for proper operation. First, test the unit
without a load and then with a light load of 50 pounds
(23 kg) times the number of load supporting parts of load
chain to be sure that the hoist operates properly and that
the brake holds the load when control is released. Next
test with a load of *125% of rated capacity. In addition
hoists in which load sustaining parts have been replaced
should be tested with *125% of rated capacity by or
under the direction of an appointed person and written
report prepared for record purposes. After this test, check
that the Protector functions. If the Protector permits lifting a load in excess of 200% of rated load, it should be
replaced.
NOTE: For additional information on inspection
and testing, refer to American National
Standard ASME B30.16 “Overhead Hoists”
obtainable from The American Society of
Mechanical Engineers, 345 East 47th Street,
New York, NY 10017 U.S.A.
*If the Protector prevents lifting of a load of 125% of
rated capacity, reduce load to rated capacity.
REPAIR PARTS
ORDERING INSTRUCTIONS
The following information must accompany all correspondence and orders for replacement parts:
Cutting Chain with a Bolt Cutter
!
WARNING
Cutting Chain Can Produce Flying Particles.
•
•
TO AVOID INJURY:
Wear Eye Protection
Provide A Shield Over Chain To Prevent Flying
Objects
1. Hoist rated load from identification plate.
2. Serial number of the hoist stamped below identification plate.
3. Length of lift.
4. Key number of part from the parts list.
5. Number of parts required.
6. Part name from the parts list.
7. Part number from the parts list.
If trolley replacement parts are ordered, also include the
type and capacity of the trolley.
NOTE: WHEN ORDERING REPLACEMENT PARTS, IT IS
RECOMMENDED THAT CONSIDERATION BE
GIVEN TO THE NEED FOR ALSO ORDERING
SUCH ITEMS AS GASKETS, FASTENERS, INSULATORS, SEALS, ETC. THESE ITEMS MAY BE
DAMAGED OR LOST DURING DISASSEMBLY
OR JUST UNFIT FOR FUTURE USE BECAUSE OF
DETERIORATION FROM AGE OR SERVICE.
!
WARNING
Using “commercial” or other manufacturer’s parts to
repair XL Air Hoists may cause load loss.
TO AVOID INJURY:
Use only factory supplied replacement parts. Parts may
look alike but factory original parts are made of specific materials or processed to achieve specific properties.
22
Repair Parts
Hoists that have been in service for a long period or under
adverse conditions may require disassembly for adjustment
and replacement of parts. The drawings on the following
pages are of the exploded type to indicate order of assembly
and relative position of parts. The parts list opposite each
drawing includes a key number for each part. These key
numbers appear on each drawing connected to the appropriate parts
Contents:
no.
1. Hoist Arrangement
2. Brake Components
3. Motor Components
4. Gearing Components
5. Liftwheel and Suspension components
6. Two Ton Plain and Geared Trolley
7. 2 Ton MDT, 3-7 1/2 Ton Trolley
8. 2 thru 7 1/2 Ton MDT Motor and Gearbox
9. Hoist Air Motor
Page
24-25
26-27
28-29
30-31
32-33
34-35
36-37
38
39
Important
When referring to your hoist in correspondence or
repair kit part orders, alway give the model number
from the hoist identification plate and the serial number
which is stamped on the motor housing directly below
Part Number for Packaged Lubricants Used in the XL Air Chain Hoist
(Refer to page 14 for Lubrication Instructions)
Lubricant Usage
Hoist Gears
Splines
Type of Lubricant
Hulbest EP ISO VG 68
thru 460 (H-2)
*Grease
EP Type Grease - Obtain Locally
Load Chain
Oil
Lower Hook Thrust Bearing
*Oil
Trolley Trackwheel Bearings and Gears Grease (Novatex #2)
Trolley Gears
Part Numbers and Packaged
Quantity of Lubricants
52776 for 1 Gal. Can
Grease (Novatex #1)
28608 for 1 Pint Can
28619 for 1 Gal. Can
Heavy Machine Oil
Obtain Locally
28632
28610
28613
28612
for
for
for
for
4
1
4
1
lb.
lb.
lb.
lb.
Can
Can
Can
Can
23
24
25
1
1
1
1
1
3
5
652-190
652-245
652-297
652-298
652-299
652-345
52714
52724
52726
52728
52757
Capacity Label
2 Ton
3 Ton
5 Ton
6 Ton
7 1/2 Ton
1
652-189
Warning Tube
Control Pendant Fittings (652-295)
Control Pendant Fittings
With Air Trolley.(652-295)
Control Cable
without MDT
with MDT
For 10’ Lift. For other lifts contact CM
Control Pendant
without MDT (2 paddle)
with MDT (4 paddle)
Warning Label
2 Ton
3 Ton
5 Ton
6 Ton
7 1/2 Ton
Lodestar XL Label
988271
I.D. Plate Drive Screw
4
652-185
687J6
53018
53018
53025
53037
53020
22825502
52715
52725
52726
52728
52785
52760
70728
Identification Plate
Lodestar XL
1
Part No.
652-183
Part Name
No.
Req’d
Key No.
26
27
652-195
652-196
652-197
652-232
652-244
652-261
652-273
652-274
652-275
652-276
652-277
652-278
652-279
652-295
652-339
652-340
652-194
1
1
3
1
4
1
1
1
3
1
1
5
1
1
1
1
Brake Intermediate Plate
Brake Armature Plate
Brake Nut
Drain Plug
Brake Attaching Screw
Control Grommet
Brake Retaining Plate
Air Cyclinder
Brake Spacer Tube
Breather, Brake
Screw, Brake
Screw, Brake Air Cyclinder Att’g
Nut Brake Piston
Fitting, Straight
Screw
Washer, Nylon
(3 springs total for brake assembly)
68820
53007
982448
989050
946801
27891
53004
53005
53006
53011
53029
53017
988230
53018
982688
982251
53044
70652
989074
53026
52028C
80409
52607
53008
Brake Friction Disc
Frame Plug (1”)
Air Brake Complete
Brake End Cover
Brake End Cover Screw
Brake Base Plate
Brake Field Plate
Brake Spring Kit
652-131
652-150
652-161
652-181
652-184
652-192
652-193
2
1
1
1
4
1
1
1
Part
No.
52632
Key No.
No.
Part Name
Req’d
652-108
1
Brake Housing Assembly
Brake Components
28
29
1
4
1
1
1
1
2
5
1
4
4
4
1
1
1
1
1
3
652-182
652-198
652-280
652-281
652-282
652-283
652-284
652-285
652-286
652-287
652-288
652-289
652-290
652-291
652-292
652-293
652-294
652-295
Fitting, Straight
Shuttle Valve
Strain Loop Lockwasher
Strain Loop Washer
Strain Loop Screw
Grommet
Motor Plate Lockwasher
Motor Plate Screw
Motor Screw
1 1/4 Pipe Nipple Galvanized
Fitting, Male 90 Deg. Elbow
Quick Exhaust Valve
Bi-Directional Valve
Muffler Connecting Elbow
Muffler
Motor Adapter Plate
Motor Cover Screw
Motor End Cover
Motor Housing Assembly (includes
652-128)
Air Motor
1
1
2
652-307
652-308
652-337
Warning Label, Spool Stop
Motor Repair Kit (See page 39)
Valve O-ring Repair Kit
A/R 3/16 Nylon Tubing
1
652-162
652-296
1
652-107
No.
Key
Part Name
Number Req’d
652-103
1
Motor Shaft Coupling
Motor Components
53043
53034
53033
53023
53018
53015
982226
927835
53017
53013
945851
987210
982597
53028
53021
53016
53003
53027
53014
53009
80409
53012C
53002
53019
Part
Number
52078
30
31
1
1
1
1
2
1
2
2
1
1
1
1
1
1
2
1
1
1
15
1
1
2
1
1
1
1
652-108
652-109
652-110
652-112
652-118
652-121
652-122
652-123
652-124
652-125
652-126
652-132
652-133
652-134
652-141
652-142
652-143
652-144
652-145
652-148
652-149
652-156
652-159
652-160
652-187
652-188
Intermediate Plate Assembly
Main Housing Assembly
Drive Shaft and Pinion
Main Housing Gasket
Breather
Drive Shaft Seal
Drive Shaft Bearing
2nd Reduction Pinion Bearing - Inboard
2nd Reduction Pinion Bearing- Outboard
3rd Reduction Pinion Bearing - Outboard
Liftwheel Seal - Inboard
Liftwheel Gear Snap Ring
Limit Switch Input Shaft Seal
Limit Switch Input Shaft Bearing
Brake Hub
Liftwheel Bearing-Gear End
3rd Reduction Pinion Bearing- Inboard
Frame Screw
Limit Switch Gear Pin
Limit Switch Gear
Frame Plug (3/4”)
2nd Gear
Protector Assembly
2 Ton, 6 Ton
3 Ton
5 ton, 7.5 Ton
Liftwheel Gear Bearing
2nd Reduction Pinion
Brake Housing Assembly
No.
Key
Part Name
Req’d
No.
652-100
2
Brake Hub Snap Ring
652-101
1
2nd Gear Snap Ring
652-102
1
2nd Pinion Snap Ring
652-104
1
Limit Switch Input Shaft
652-105
1
Liftwheel Gear
652-106
3rd Reduction Pinion and Shaft
1
Gearing Components
52614
52613
52616
80414
52023
52633
52630
52079
52709
70726
80401
80402
80403
88429
80408
80415
80416
80417
88437
68367
80413
88500
987289
983768
52713
989055
52024
52632
Part
Number
35764
36763
45766
52019
52021
52026
652-179
32
Double and Triple
Reeve Hook Block
652-216
652-201
652-203
652-213
652-206
652-210
652-215
652-217
652-207
652-220
652-218
652-222
652-175
652-202
652-200
652-177
652-227
Double and Triple
Reeve Upper Suspension
Complete
652-187
652-225
652-226
652-221
652-216
652-180
652-214
652-201
652-176
652-253
652-204
652-163
652-113
652-111
652-128
652-221
652-218
652-222
652-227
Single Reeve
Upper Suspension
Complete
652-114
652-205
Liftwheel and Suspension
652-211
652-212
652-256
652-257
652-258
652-129
652-127
652-110
652-220
652-216
652-224
652-217
652-175
652-216
652-202
652-200
652-177
652-179
652-163
652-180
652-178
652-337
Single Reeve
Lower Hook Block
652-305
652-304
652-306
652-338
652-107
33
Chain Plate::
1
652-178
4
4
2
2
1
1
1
1
1
1
1
2
652-180
652-187
652-200
652-201
652-202
652-203
652-204
652-205
652-206
652-179
Hook Block:
52057
80422
Dead End Pin
52051
88505
80421
52050
45946
80418
35369
52047
80414
982369
80423
80423
987288
1
1
652-257
652-258
1
1
652-338
1
1
652-337
652-306
652-305
53052
53053
Snubber Black Assembly
82638
982066
53030
45915
987898
982667
52064
5254
5255
982371
52708
987208
80419
80420
52624
52625
80418
52608
52651
52045
52047
52022
52035
45663
52701
52074
80425
52058
52054
52053C
52068
80424
Part
Number
Snubber Plate
Dead End Stop Screw Locking Nut
Dead End Stop Screw
Dead End Stop
Loose End Screw Washer
Loose End Screw Washer
1
652-256
1
Dead End Block Spacer
Loose End Screw
1
652-253
652-304
Upper Hook Suspension Latch Type Complete
2 Ton
3, 5, and 6 Ton
1
652-227
Anti-Rotation Plate Screw
Anti-Rotation Plate
Suspension Screw (2Ton Only)
Anti-Rotation Pin for:
2 Ton
3 , 5, and 6 Ton
Suspension Adapter for:
2 Ton
3,5, and 6 Ton
Upper Hook Nut for:
2 Ton
3,5, and 6 Ton
Upper Hook, Latch Type for:
2 Ton
3,5, 6 and 7 1/2 Ton
Upper Hook, Latchlok Type for:
2 Ton
3, 5, and 6 Ton
Hook Nut Pin
Latch Kit for:
2 Ton
3 5, 6 and 7 1/2 Ton
Dead End Plate Screw
Idler Wheel Bearing
Anchor Pin
Idler Wheel
Idler Wheel Housing
Dead End Plate
Dead End Bolt: 3, 5, 6 and 7 1/2 Ton
Part Name
1
1
1
1
1
1
1
1
1
6
2
1
1
1
1
1
No.
Req’d
652-226
652-225
652-224
652-222
652-221
652-220
652-218
36681
52625
5264
52017
52025
52049
52069
52046C
52048C
652-217
652-216
652-215
652-214
652-213
652-212
652-211
652-210
652-207
Key
No.
35612
52651
85885
Sheave Wheel Bearing
Dead End Block
Hook Nut or Collar for:
2 Ton
3,5,6 and 7 1/2 Ton
Hook Nut or Collar Pin for
2 Ton
3,5, 6 and 7 1/2 Ton
Lower Hook Thrust Bearing for:
2 Ton
3, 5, 6 and 7 1/2 Ton
Sheave Wheel
Liftwheel Gear Bearing
2 Tond
3 and 5 Ton
6 and 7 1/2 Ton
Chain Plate or Idler Housing Screw
Hook Block Screw:
2 Ton
3 and 5 Ton
6 and 7 1/2 Ton
2 Ton
3 and 4 Ton
Lower Hook with Latch: Latch Type:
2 Ton
3,5,6 and 7 1/2 Ton
Lower Hook - Loatchlok Type
2 Ton
3,5, and 6 Ton
3-6 Ton Lower Latchlok Kit
Half Link
Load Chain
80412
Liftwheel Seal - Gear End
2
652-129
80411
80410
52055
52041
52033
52630
53019
Part
Number
Liftwheel Bearing - Motor End
1
1
652-128
Chain Guide Pin
652-177
1
652-127
Chain Stripper
Chain Guide
652-176
3
652-114
1
1
652-113
Liftwheel
Main Housing Assembly
1
1
652-111
Part Name
Motor Housing Assembly (Includes 652-128)
652-163
1
652-110
652-175
1
1
652-107
No.
Req’d
Key
No.
Liftwheel and Suspension
34
35
No.
Req’d
1
1
2
4
4
-
4
8
8
4
4
4
4
2
4
1
1
1
Key No.
652-301
652-302
670-304
670-305
670-306
670-307
670-308
670-309
670-310
670-311
670-312
670-313
670-314
670-315
670-316
670-317
670-318
670-319
Geared Side Frame
Trackwheel Pinion Key
Trackwheel Gear Pinion
Trackwheel Gear Pin
Trackwheel Gear
Trackwheel Stud Nut
Trackwheel Stud Collar
Trackwheel Stud
Trackwheel Bearing Shield
Trackwheel Bearing Cone
Trackwheel Bearing Cup
Trackwheel wtih Bearing Cup
Spacer Washer-Specify No. Req’d
Suspension Bolt Nut Cotter Pin
Suspension Bolt Nut
Suspension Bolt
Suspension Adapter Screw/Dead End Bolt
Hoist Suspension Adapter
Part Name
59615
85546
58505
983503
982613
58484
58459
68918
88525
88525
88521
958726
988368
958818
58503
987208
52059
Part
Number
Handwheel
33143
59967
1
1
670-464
-
1
1
1
1
670-336
670-335
670-334
670-333
670-332
670-331
1
Anti-Tipping Roller Kit
Hand Chain Connecting Link
Hand Chain-Specify length req’d
Chain Guide Screw Nut
Chain Guide Screw L.W.
Chain Guide Screw Washer
Chain Guide Screw
Handchain Guide
52813
945491
619022
945822
945853
986224
987065
58152
1
670-327
Handwheel Key
59504
670-330
1
670-326
Handwheel Shaft
987061
988095
1
670-325
Handwheel Bracket Screw
945853
670-329 1 or 2 Trackwheel Pinion or Handwheel Shaft Nut
3
670-324
Handwheel Bracket Screw L.W.
58727
59616
59614
Part
Number
986270
3
670-323
Handwheel Bushing
Handwheel Bracket with Bushings
Plain Side Frame
Part Name
670-328 1 or 2 Trackwheel Pinion or Handwheel Shaft Nut L.W.
2
1
No.
Req’d
670-322
670-321
670-320
Key Nu.
2 Ton
Plain and Geared Trolleys Parts List
36
2 TON MOTOR DRIVEN TROLLEY,
3 THRU 7½ TON
PLAIN, GEARED AND MOTOR DRIVEN
TROLLEYS-EXPLODED VIEW
ANTI-TIPPING
BRACKET KIT
29
See page 38 for
Motor and Gear
Box assembly
REF.
NO.
NO.
REQ’D
1
2
2
3
8
4
4
2
5
2
6
7
8
9
10
11
12
13
14
4
1
1
2
4
4
4
4
40
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
***
PART DESCRIPTION
SIDE PLATE ASSEMBLY FOR:
4” TO 6 1/4” FLG. AND PATENTED TRACK
6 3/8” TO 8 5/8” FLG.
8 3/4” TO 11” FLG.
BALL BEARING
RETAINING RING
TRACKWHEEL-PLAIN
STANDARD
PATENTED TRACK
SPARK RESISTANT
TRACKWHEEL-GEARED
STANDARD
PATENTED TRACK
SPARK RESISTANT
RETAINING RING
PINION
PINION KEY
**RETAINING RING
3 TON
PLAIN
GEARED
700T-1400
700T-1402
700T-1404
700T-1406
700T-1407
700T-1700
700T-1701
700T-1702
700T-1703
700T-1704
PART NUMBER
2 & 3 TON
5 - 7 1/2 TON
MOTOR
PLAIN
GEARED
MOTOR
DRIVEN
DRIVEN
BET-2800
BET-2801
BET-2802
BET-2803
BET-2804
700T-1501
700T-1504
700T-1507
700T-1514
700T-1516
700T-1801
700T-1803
700T-1805
700T-1811
700T-1813
BET-3801
BET-3803
BET-3805
BET-3811
BET-3813
700T-1408 700T-1705
700T-1409 700T-1706
700T-1410 700T-1707
BET-2805 700T-1518 700T-1815 BET-3815
BET-2806 700T-1520
-----BET-3817
----700T-1521 700T-1818 -----
------------700T-1411
------------------700T-1412
700T-1414
700T-1416
BET-2807
BET-2808
---BET-2809
BET-2810
BET-2811
BET-2812
BET-2813
BET2814
BET-2815
BET-2816
BET-2817
700T-1708
700T-1709
700T-1710
700T-1711
700T-1719
700T-1720
700T-1718
700T-1721
700T-1725
700T-1712
700T-1713
700T-1714
------------700T-1523
------------------700T-1526
700T-1529
700T-1532
700T-1820
----700T-1823
700T-1825
700T1846
700T-1847
700T-1845
700T-1848
700T-1853
700T-1828
700T-1831
700T-1834
BET-3818
BET-3820
----BET-3821
BET-3823
BET-3824
BET-3825
BET-3826
BET-3828
BET-3830
BET-3833
BET-3836
HEX CAP SCREW
SELF LOCKING NUT
HEX JAM NUT
LOCKWASHER
SPACE WASHERS
SUSPENSION PIN FOR:
4” TO 6 1/4” FLG. AND PATENTED TRACK 700T-1418 700T-1715 BET-2818 700T-1535 700T-1837 BET-3839
2
6 3/8” TO 8 5/8” FLG.
700T-1420 700T-1716 BET-2819 700T-1537 700T-1839 BET-3841
8 3/4” TO 11” FLG
700T-1422 700T-1717 BET-2820 700T-1539 700T-1841 BET-3843
2
BUSHING
----700T-1723
------700T-1851 ---1
PLATE AND TUBE ASSEMBLY
---700T-1724
------700T-1852 ---2
RETAINING RING
---700T-1722
-------700T-1850 ---1
HANDWHEEL SHAFT
---700T-1726
------700T-1854 ---1
HANDWHEEL SHAFT KEY
---700T-1727
------700T-1856 ---2
WASHER
---700T-1728
------700T-1857 ---CHAIN GUIDE
8 5/8” O.D. HAND CHAIN WHEEL
---700T-1729
------------2
11 5/8” O.D. HAND CHAIN WHEEL
---700T-1730
------700T-1858 ---HAND CHAIN WHEEL
8 5/8” OUTSIDE DIAMETER
---700T-1731
-------------1
11 5/8” OUTSIDE DIAMETER
---700T-1732
------700T-1860 ---1
SUSPENSION ADAPTER
52784
52787
1
SUSPENSION ADAPTER SCREW
80430
80430
1
WARNING LABEL
---936986
---936986
1
TROLLEY CAPACITY LABEL
52764
52765
1
WARNING LABEL
936984
936984
1
ANTI-TIPPING ROLLER KIT
44927630
44927660
HAND CHAIN (NOT SHOWN)
STANDARD
---700T-1733
-------700T-1862
----AS
REQ’D
SPARK RESISTANT
---700T-1734
-------700T-1863
----OPEN LINK (1 REQUIRED)
---700T-1735
-------700T-1864
-----
* TOTAL QUANTITY OF 4 EACH REQUIRED FOR PLAIN TYPE TROLLEYS.
** TOTAL QUANTITY OF 1 EACH REQUIRED FOR 3 TON TROLLEYS.
*** SPECIFY LENGTH OF HAND CHAIN REQUIRED. STANDARD LENGTH EQUALS TWO TIMES HOIST LIFT PLUS 2’-6”.
37
3 THRU 7½ TON MOTOR AND GEAR BOX ASSEMBLY
2 THRU 7 1/2 TON MOTOR AND GEAR BOX ASSEMBLY
TROLLEY BRAKE
(OPTIONAL)
See
page 39
*SEE PAGE 39 FOR TROLLEY BRAKE ASSEMBLY
Ref. No.
No. Req’d
Part Description
Part Number
1
1
Gear Box Assembly
BET-3003
2
1
Air Brake
Contact Factory
3
1
Air Motor
22721301
4
1
Mounting Plate
22925703
5
1
Sandwich Plate
22925501
6
1
Valve
22746302
7
1
Muffler
227472-1
8
1
Air Hose Assembly
53042
9
1
Hex Bushing
53039
10
1
Reducing Tee
53040
11
1
Pipe Nipple
53041
*
13 *
1
Gasket
11443301
1
Gasket
22746801
12
* Not Shown
38
22
21
Air Motor Components
Ref.
No.
1
2
3
4
*
*
5
6
7
8
9
*
*
10
11
13
*
14
15
16
17
18
19
20
21
22
*
*
*
*
Qty.
Description
1
1
1
1
1
1
1
1
4
2
1
3
6
6
6
1
1
1
1
4
4
1
Drive End Cap
Seal
O-Ring
Locknut
Lockwasher
Drive End Bearing
Spacer
Drive End Plate
Dowel Pin
Spacer Gasket
Body
Rotor Assembly
Push Pin
Vane Spring
Vane
Dead End Plate
Dead End Bearing
End Cap Gasket
Dead End Cap
Dead End Plate Bolts
Dead End Plate Cap Bolts
Service Kit 652-308 (order code 53034)
*) are available only as part of service kit (code 53034).
Note: Parts Identified with a star (
Remaining part
numbers are not available for reparis. Requires replacement with an air motor (code 53002).
39
Note: When ordering parts, always furnish Hoist Model and Serial Number,
Motor Horsepower, Voltage, Phase, Frequency and Rated Capacity of hoist on
which the parts are to be used.
For the location of the nearest Master Parts Depot, see the list located on the
inside front cover.
LIMITATION OF WARRANTIES, REMEDIES AND DAMAGES
THE WARRANTY STATED BELOW IS GIVEN IN PLACE OF ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED, OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR
OTHERWISE, NO PROMISE OR AFFIRMATION OF FACT MADE
BY ANY AGENT OR REPRESENTATIVE OF SELLER SHALL CONSTITUTE A WARRANTY BY SELLER OR GIVE RISE TO ANY LIABILITY OR OBLIGATION.
Seller warrants that on the date of delivery to carrier the
goods are free from defects in workmanship and materials.
SELLER’S SOLE OBLIGATION IN THE EVENT OF BREACH OF
WARRANTY OR CONTRACT OR FOR NEGLIGENCE OR OTHERWISE WITH RESPECT TO GOODS SOLD SHALL BE EXCLUSIVELY
LIMITED TO REPAIR OR REPLACEMENT, F.O.B. SELLER’S POINT
OF SHIPMENT, OF ANY PARTS WHICH SELLER DETERMINES TO
HAVE BEEN DEFECTIVE or if Seller determines that such repair
or replacement is not feasible, to a refund of the purchase
price upon return of the goods to Seller.
Any action against Seller for breach of warranty, negligence
or otherwise, must be commenced within one year after such
cause of action accrues.
NO CLAIM AGAINST SELLER FOR ANY DEFECT IN THE GOODS
SHALL BE VALID OR ENFORCEABLE UNLESS BUYER’S WRITTEN
NOTICE THEREOF IS RECEIVED BY SELLER WITHIN ONE YEAR
FROM THE DATE OF SHIPMENT.
Seller shall not be liable for any damage, injury or loss arising
out of the use of the goods if, prior to such damage, injury or
loss, such goods are (1) damaged or misused following Seller’s
delivery to carrier; (2) not maintained, inspected, or used in
compliance with applicable law and Seller’s written instructions and recommendations; or (3) installed, repaired, altered
or modified without compliance with such law, instructions or
recommendations.
UNDER NO CIRCUMSTANCES SHALL SELLER BE LIABLE FOR
INCIDENTAL OR CONSEQUENTIAL DAMAGES AS THOSE
TERMS ARE DEFINED IN SECTION 2-715 OF THE UNIFORM
COMMERCIAL CODE.
INDEMNIFICATION AND SAFE OPERATION
Buyer shall comply with and require its employees to comply
with directions set forth in instructions and manuals furnished by Seller and shall use and require its employees to
follow such instructions and manuals and to use reasonable
care in the use and maintenance of the goods. Buyer shall
not remove or permit anyone to remove any warning or
instruction signs on the goods. In the event of personal injury
or damage to property or business arising from the use of the
goods, Buyer shall within 48 hours thereafter give Seller written notice of such injury or damage. Buyer shall cooperate
with Seller in investigating any such injury or damage and in
the defense of any claims arising therefrom.
If Buyer fails to comply with this section or if any injury or
damage is caused, in whole or in part, by Buyer’s failure to
comply with applicable federal or state safety requirements,
Buyer shall indemnify and hold Seller harmless against any
claims, loss or expense for injury or damage arising from the
use of the goods.
! WARNING
Alterations or modifications of equipment and use of
non-factory repair parts can lead to dangerous operation and injury.
TO AVOID INJURY:
• Do not alter or modify equipment
• Do use only factory provided replacement parts.
®
Columbus McKinnon Corporation
140 John James Audubon Parkway
Amherst, New York 14228-1197
Phone: (800) 888-0985
Fax: (716) 689-5644
© 2008 Columbus McKinnon Corp.
Printed in USA
">