Herculink HA2 (12,25,37,50)

Form MHD56298
IMPORTANT INFORMATION:
A copy of our Safe Operating Practices Manuals are always available free of charge either by downloading it from our
Technical Publications website @ www.airwinch.com or by contacting the Factory at (800) 866-5457 for North America and
(206) 624-0466 for International. The Safe Operating Practices manual must be read prior to anyone operating a
Ingersoll-Rand winch or hoist. The manual form numbers are as follows:
Safe Operating Practices Non-Man Rider Winches Manual, Form No. MHD56250
Safe Operating Practices for Man Rider Winches Manual, Form No. MHD56251
Safe Operating Practices for Pneumatic, Hydraulic and Electric Hoists Manual, Form No. MHD56295
Available winch options may require additional supplements to the basic winch manual.
For Man Rider winches ensure a copy of the Man Rider supplement is made available to the operator prior to winch
operation.
Winch Man Rider Supplements:
Model: Publication No. Model: Publication No.
FA2, FA2.5, LS500RLP SAM0011
MHD56046
FH2, FH2.5 LS1000RLP SAM0012
MHD56042 and LS150RLP SAM0082
FA5
MHD56220 LS150RLP/500/
SAM0115
FA10 MHD56252 1000
FA2.5A MHD56236 LS150RLP and
SAM0120
LS150PLP-PH
FA2B and
MHD56207
HU40A LS500RLP-E SAM0122
FH10MR MHD56212 LS150RLP-
SAM0184
Fulcrum Electric MHD56277 DP5M-F
LS500HLP/ LS150HLP SAM0222

SAM0004
LS1000HLP
We strongly recommend that ALL maintenance on Ingersoll-Rand equipment be carried out by personnel certified by
Ingersoll-Rand, or by Ingersoll-Rand Authorized Service Centers.
Contact the Factory if in doubt about installation, operation, inspection and maintenance instructions.
Use only Genuine Ingersoll-Rand parts when maintaining or repairing a winch, hoist or any component of a winch or hoist.
ANSI / ASME recommends that a winch or hoist (or any components of a winch or hoist) that has been repaired be tested
prior to being placed into service:
* Winches - ANSI / ASME B30.7 (BASE MOUNTED DRUM HOISTS) Refer to section 7.2.2 - Testing.
* Hoists - ANSI / ASME B30.16 (OVERHEAD HOISTS - UNDERHUNG) Refer to section 16.2.2 - Testing.
Form MHD56298
Edition 2
November 2004
71441844
2004 Ingersoll-Rand Company
Form MHD56055
PARTS, INSTALLATION AND MAINTENANCE MANUAL

for
AIR HOISTS
TM
MODELS
HA2-012 HA2-025
(12.5 metric tons) (25 metric tons)
HA2-037 HA2-050
(37.5 metric tons) (50 metric tons)
(Dwg. MHP2246)
Tons in this manual are metric tons (1 metric ton = 2,200 lbs.)
READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual

contains important safety, installation, and maintenance information. Make
this manual available to all persons responsible for the installation, operation,
and maintenance of these products.
Do not use this hoist for lifting, supporting, or transporting people or lifting or
supporting loads over people.
Always operate, inspect and maintain this hoist in accordance with applicable safety
codes and regulations.
Form MHD56055
Edition 2
September 2001
71082150
2001 Ingersoll-Rand Company
TABLE OF CONTENTS
Description Page No.
Safety Information
Danger, Warning, Caution and Notice .................................................................................................................................................................3
Safe Operating Instructions .................................................................................................................................................................................4
Warning Labels And Tags....................................................................................................................................................................................5
Specifications
Model Code Explanation .....................................................................................................................................................................................6
General Specifications .........................................................................................................................................................................................7
Installation
Mounting..............................................................................................................................................................................................................8
Installing Trolley..................................................................................................................................................................................................8
Rack Drive ...........................................................................................................................................................................................................9
Chain Container .................................................................................................................................................................................................10
Air Supply..........................................................................................................................................................................................................11
Pendant (Optional Style)....................................................................................................................................................................................12
Storing Hoist ......................................................................................................................................................................................................13
Air Schematics ...................................................................................................................................................................................................14
Operation
Initial Operating Checks ....................................................................................................................................................................................15
Hoist Controls ....................................................................................................................................................................................................15
Emergency Stop .................................................................................................................................................................................................16
Rope Pull............................................................................................................................................................................................................17
Inspection
Records and Reports ..........................................................................................................................................................................................17
Frequent Inspection............................................................................................................................................................................................18
Periodic Inspection ............................................................................................................................................................................................19
Hoists Not in Regular Use .................................................................................................................................................................................19
Inspection And Maintenance Report .................................................................................................................................................................20
Lubrication
Pivot Points and Bushings..................................................................................................................................................................................21
Hoist Motor........................................................................................................................................................................................................21
Piston Trolley Drive Motor ................................................................................................................................................................................21
Bottom Hook Block Assembly ..........................................................................................................................................................................21
Load Chain.........................................................................................................................................................................................................21
Trolley Drive Assembly .....................................................................................................................................................................................22
Reduction Gear Assembly .................................................................................................................................................................................22
Seals and Bearings .............................................................................................................................................................................................23
Troubleshooting................................................................................................................................................................................................24
Maintenance
Maintenance Intervals ........................................................................................................................................................................................26
Disc Brake Adjustment ......................................................................................................................................................................................26
Load Chain Replacement...................................................................................................................................................................................26
General Disassembly .........................................................................................................................................................................................29
Cleaning, Inspection and Repair ........................................................................................................................................................................32
Assembly Instructions........................................................................................................................................................................................33
Load Test............................................................................................................................................................................................................38
Parts Information
Hoist Drawings & Parts List Table of Index......................................................................................................................................................39
Parts Ordering Information ................................................................................................................................................................................82
Return Goods Policy ..........................................................................................................................................................................................82
Warranty.............................................................................................................................................................................................................83
2 MHD56055 - Edition 2
SAFETY INFORMATION
This manual provides important information for all personnel The National Safety Council, Accident Prevention Manual for
involved with safe installation, operation and proper maintenance Industrial Operations, Eighth Edition, and other recognized safety
of this product. Even if you feel you are familiar with this or sources make a common point: Employees who work near
similar equipment, you should read this manual before operating suspended loads or assist in hooking on or arranging a load should
product. be instructed to keep out from under load. From a safety
standpoint, one factor is paramount: conduct all lifting or pulling
operations in such a manner that if there were an equipment
Danger, Warning, Caution and Notice
failure, no personnel would be injured. This means keep out from
Throughout this manual there are steps and procedures which, if under a raised load and keep out of intended path of any load.
not followed, may result in a injury. The following signal words
are used to identify the level of potential hazard. Ingersoll-Rand hoists are manufactured in accordance with the
latest ASME B30.16 standards.
Danger is used to indicate the presence
of a hazard which will cause severe
The Occupational Safety and Health Act of 1970 generally places
injury, death, or substantial property
the burden of compliance with user, not manufacturer. Many
damage if the warning is ignored.
OSHA requirements are not concerned or connected with the
Warning is used to indicate the presence manufactured product but are, rather, connected with final
of a hazard which can cause severe installation. It is the owners and users responsibility to determine
injury, death, or substantial property the suitability of a product for any particular use. It is
damage if the warning is ignored. recommended that all applicable industry, trade association,
federal, state and local regulations be checked. Read all operating
Caution is used to indicate the presence instructions and warnings before operation.
of a hazard which will or can cause
injury or property damage if the warning Rigging: It is the responsibility of the operator to exercise caution,
is ignored. use common sense and be familiar with proper rigging techniques.
Notice is used to notify people of Refer to ASME B30.9 for rigging information, American National
installation, operation, or maintenance Standards Institute, 1430 Broadway, New York, NY 10018.
information which is important but not
hazard-related. This manual has been produced by Ingersoll-Rand to provide
dealers, mechanics, operators and company personnel with the
information required to install, operate, maintain and repair the
products described herein.
Safety Summary
It is extremely important that mechanics and operators be familiar
with the servicing procedures of these products, or like or similar
products, and are physically capable of conducting the procedures.
Do not use this hoist or attached equipment for lifting, These personnel shall have a general working knowledge that
supporting or transporting people or lifting or supporting includes:
loads over people. 1. Proper and safe use and application of mechanics common
Air powered hoists are designed to provide a 5 to 1 safety hand tools as well as special Ingersoll-Rand or
factor and are factory tested to 125% of rated load. The recommended tools.
supporting structures and load-attaching devices used in 2. Safety procedures, precautions and work habits established
conjunction with this hoist must provide adequate support to by accepted industry standards.
handle all hoist operations plus weight of hoist and attached
equipment. This is the customers responsibility. If in doubt, Ingersoll-Rand cannot know of, or provide all procedures by
consult a registered structural engineer. which product operations or repairs may be conducted and hazards
and/or results of each method. If operation or maintenance
procedures not specifically recommended by manufacturer are
conducted, it must be ensured that product safety is not
Lifting equipment is subject to different regulations in each endangered by actions taken. If unsure of an operation or
country. These regulations may not be specified in this maintenance procedure or step, personnel should place the product
manual. in a safe condition and contact supervisors and/or factory for
technical assistance.
MHD56055 - Edition 2 3
SAFE OPERATING INSTRUCTIONS
The following warnings and operating instructions have been 11. Do not side pull or yard.
adapted in part from American National (Safety) Standard ASME 12. Make sure everyone is clear of load path and there are no
B30.16 and are intended to avoid unsafe operating practices which objects in way of load. Do not lift a load over people.
might lead to injury or property damage. 13. Never use hoist for lifting or lowering people, and never
allow anyone to stand on a suspended load.
Ingersoll-Rand recognizes that most companies who use hoists 14. Ease slack out of chain when starting a lift. Do not jerk load.
have a safety program in force at their facility. In the event that 15. Do not swing a suspended load.
some conflict exists between a rule set forth in this publication and 16. Never suspend a load for an extended period of time.
a similar rule already set by an individual company, the more 17. Never leave a suspended load unattended.
stringent of the two should take precedence. 18. Pay attention to load at all times when operating hoist.
19. After use, properly secure hoist and all loads.
Safe Operating Instructions are provided to make an operator 20. The operator must maintain an unobstructed view of load at
aware of dangerous practices to avoid and are not necessarily all times.
limited to the following list. Refer to specific sections in the 21. Never operate a hoist with twisted, kinked or damaged chain.
manual for additional safety information. 22. After use, or when in a non-operational mode, unit should be
secured against unauthorized and unwarranted use.
1. Only allow personnel trained in safety and operation of this 23. Do not do anything you believe may be unsafe.
product to operate and maintain unit. 24. Never splice a load chain by inserting a bolt between links or
2. Only operate a hoist if you are physically fit to do so. by any other means.
3. When a DO NOT OPERATE sign is placed on hoist, or 25. Do not force a chain or hook into place by hammering. Do
controls, do not operate hoist until sign has been removed by not insert point of hook into a chain link.
designated personnel. 26. Do not expose load chain to freezing temperatures, and do
4. Before each shift, check both hoist and trolley for wear and not apply sudden loads to a cold chain.
damage. Never use a unit that inspection indicates is worn or 27. Follow lubrication instructions.
damaged. 28. Do not attempt to repair load chains or hooks. Replace them
5. Never lift a load greater than rated capacity of hoist. Refer to when they become worn or damaged.
SPECIFICATIONS section on page 7. 29. Periodically inspect hoist thoroughly and replace worn or
6. Keep hands, clothing, etc., clear of moving parts. damaged parts.
7. Never place your hand in throat area of a hook. 30. Shut off air supply before performing maintenance on hoist
8. Always rig loads properly and carefully. or trolley.
9. Never use load chain as a sling. 31. Do not use load chain as a ground (earth) for welding. Do not
10. Be certain load is properly seated in saddle of hook. Do not attach a welding electrode to a hoist or chain.
tipload hook as this leads to spreading and eventual failure of 32. Avoid collision or bumping of trolley.
hook.
WARNING LABELS AND TAGS
Each hoist is supplied from factory with warning labels and tags shown. If labels or tags are not attached to your hoist, order new labels or
tags and install them. Refer to Label and Tag parts list in PARTS section on page 80. Read and obey all warnings and other safety
information attached to this hoist. Labels or tags may not be shown actual size.
Tag part number 71042121 is attached to inlet air supply Tag part number 71107148 is attached to power head reduction
components. gear assembly.
Label part number 71107130 is attached to trolley side plate.
Tag part number 71042147 is attached to lubricator in inlet air

supply line.
Tag part number 71107155 is attached to power head reduction

gear assembly fill plug.
Tag part number 71059612 is attached to pendant assembly.
MODEL CODE EXPLANATION
Example: HA2-025MA3-10-6PA HA 2 - 025 M A 3 - 10 - 6 P A

Series
HA = Hercu-Link Air Powered Hoist
Frame Size
2 = 22 mm Load Chain
Capacity
012 = 12.5 ton (27,500 lbs)
025 = 25 ton (55,000 lbs)
037 = 37.5 ton (82,500 lbs)
050 = 50 ton (110,000 lbs)
Suspension
H = Hook mount
C = Clevis mount *
D = Deck mount *
P = Plain trolley
G = Geared trolley
V = Vane motor trolley
M = Piston motor trolley
R = Rack/pinion drive
Trolley Flange Adjustment
M = No trolley used with hook, clevis and deck mount
A = Standard
B = 2 in. (51 mm) extension
C = 4 in. (102 mm) extension
D = 6 in. (152 mm) extension
Control Options
1 = Pull rope
2 = 1 motor pendant (2 button)
5 = 1 motor pendant with on/off
Lift
10 = 10 ft. (3 m) is Standard
XX = Length of lift. (XX = Specify hose length (ft.). Max 60 ft. (18 m))
Control Drop
6 = 6 ft. (1.85 m)(or Lift minus 4 ft.(1.22 m)) Standard
Standard Hand Chain Drop for Geared Trolleys
XX = Control Drop Pendant or Hand Chain Length
Options
C = Low Temperature (10 or 20 C)
D = Trolley drive disc brake *
P = Marine 812 protection package
Q = 60 psi (4 bar/414 kPa) application package
R = Copper plate SCORE package
S = Solid bronze SCORE package (12.5 ton models only)
T = Galvanized chain container (not available on hook mounted 12.5 ton models)
Y = Hull bumper (for hook mounted shipyard hoists only)
Z = Sandblast and carbozinc primer only
- E = Compliance with European Machinery Directive and includes:
emergency stop on pendant, main air shut-off valve overload protection device and upper/lower limit switch.
**M1 = Material Traceability (Typical material results)
**M2 = Material Traceability (Actual material results)
**M3 = Material Traceability (Actual material results for these parts in finished, as-delivered condition)
**N = Special paint *
Control Option
A = Accu-Trol pendant *
(For information refer to Accu-Trol Parts, Operation and Maintenance Manual MHD56014.)
* Features not covered in this manual. For additional information contact your nearest Ingersoll-Rand Office or distributor.
** Documentation, witness testing and material traceability available; must be requested at time of order. Specify options or contact the
factory or your nearest Ingersoll-Rand distributor for information.
GENERAL SPECIFICATIONS
Motor-driven brake shaft is connected to brake through a sprag

Description
clutch. In hoist UP direction, clutch allows shaft to rotate
The HA2 air-powered hoist consists primarily of a power head without releasing brake. No air pressure is applied to brake piston
assembly that acts as control for lower hook block movement. The in UP direction.
power head assembly is made up of three main sections: gear
reducer section, brake/motor section and sheave section. Brake shaft cannot rotate in hoist DOWN direction until brake
has been released. Brake is released by air pressure applied to
Output shaft from piston motor is connected to brake shaft. The annular brake piston and piston compresses brake springs,
brake shaft is connected to drive shaft by way of a coupling that releasing brake discs. There are four sintered, bronze-type brake
passes through center of brake and sheave section and acts as sun friction discs and five stationary brake discs.
gear for first stage planetary reducer. The gear reducer section
consists of three planetary assemblies with each planetary Brake piston is actuated by air from main control valve. When
assembly being driven by sun gear from previous planetary control pendant DOWN button is pushed, it moves main control
assembly. Output from planetary reduction section is transmitted valve spool. The spool is designed to send air to brake in
directly to load chain sheave(s). DOWN direction only. When pendant DOWN button is
released, exhaust valves allow brake to set quickly and avoid
downward load drift.
Table 1 Specifications
Hoist Model HA2-012 HA2-025 HA2-037 HA2-050

Capacity metric tons 12.5 25 37.5 50
Load Chain Size mm 22
Chain Falls 1 2 3 4
ft 10
Standard Lift
m 3
fpm 8 4 2.5 2
Lift
Speed at 105 psi m/min 2.4 1.2 0.76 0.61
(700kPa/7 bar) fpm 12 6 3.75 3
Lower
m/min 3.7 1.8 1.1 0.9
Horsepower 9.4
scfm 280
Air Consumption
cu. m/min 8
fpm 3.4 1.7 1.1 0.8
Lift
Speed at 60 psi m/min 1.04 0.5 0.3 0.2
(400 kPa/4 bar) fpm 4.6 2.3 1.5 1.1
Lower
m/min 1.4 0.7 0.5 0.3
in. 38.5 51.2 66.5 75.1
Hook Mount
mm 978 1299 1689 1907
Head Room
in. 24.7 41 49 53
Trolley Mount
mm 627 1040 1243 1346
lbs 965 1235 2230 2955
Hook Mount
kg 439 561 1014 1343
Unit Weight
Trolley Mount lbs 1415 1660 3700 4665
(Piston Motor) kg 643 755 1681 2120
Traceability M1Material Traceability certificates according to EN 10204 (Ex

DIN 50049) 2.2 on load bearing parts. Conformity documents
Load bearing parts are documented to provide traceability. The affirm (by the manufacturer) that parts are in compliance with the
documentation includes chemical and physical properties of the requirements of the order based on non-specific inspection and
raw material, heat treating, hardening, tensile and charpy tests as testing (i.e. results are typical material properties for these parts).
required for the part.
Units with M1, M2 or M3 in the model code have traceable load- M2Material Traceability certificates according to EN 10204 (Ex
bearing components. DIN 50049) 3.1b on load bearing parts. Conformity documents
affirm (by a department independent of the manufacturing
department) that the actual parts are in compliance with the compliance with the order based on specific inspection and testing
requirements of the order based on specific inspection and testing (i.e. results are actual material properties for these parts in a
(i.e. results are actual material properties for these parts). finished, as delivered condition).
M3Material Traceability certificates according to EN 10204 (Ex Components with part numbers ending in CH are charpy parts for
DIN 50049) 3.1b on load bearing parts. Conformity documents use under extreme cold conditions. Traceability requirements must
affirm (by a department independent of the manufacturing be stated when reordering these parts for continued certification.
department) that the actual parts used in the product are in
INSTALLATION
Prior to installing hoist, carefully inspect it for possible shipping

Installing Trolley from Underneath Beam
damage.
Refer to Dwg. MHP0340 on page 9 and to items in Dwg.
MHP0352 on page 9.
1. Measure beam flange width Y and compare with
Before installing hoist read SAFETY INFORMATION
measurement between trolley wheel flanges X. The correct
section on page 3.
total clearance (X-Y) between beam and trolley wheel
flanges is 1/16 to 3/16 in. (1.6 to 4.7 mm). Refer to Dwg.
Hoists are supplied from factory with correct grade and quantity of
MHP0340 on page 9.
lubricating oil. Before operation all oil levels must be checked
2. To adjust trolley wheel spacing remove eight cotter pins
and/or topped off with type of oil recommended in
(173) and four pins (174) at each side plate (150) or (184).
LUBRICATION section on page 21. Lubricate load chain
Remove adjusting spacers (156) and side plates and add or
before operating hoist.
subtract an equal number of adjusting spacers (156) between
suspension yokes (170) and side plates.
3. When desired trolley wheel spacing measurement is
Owners and users are advised to examine specific, local or achieved, install remaining adjusting spacers (156) on outside
other regulations, including American National Standards of one pair of side plates. Install suspension yoke pins (174)
Institute and/or OSHA Regulations which may apply to a and cotter pins (173) on ends of suspension yokes (170) bend
particular use of this product before installing or putting hoist ends appart to secure. Use lifting lugs on trolley side plates to
to use. adequately support hoist and side plates and raise into place
on beam flange.
Remove cover from shipping crate. Carefully remove steel straps.
On units equipped with a trolley, attach wire rope sling to
suspender lugs on trolley side plates and slowly lift into position.
To avoid an unbalanced load which may damage trolley,
Lift hook-mounted hoists into position using hoist top hook.
hoist must be centered under trolley using spacers (156).
Attach chain container to hoist with chain container bolt (317). For
4. Using lifting lugs on second pair of trolley side plates raise
hook-mounted hoists, hang hook (320) on end of chain from top
into place beneath beam flange. Slide side plates onto
hook mounting structure. For trolley-mounted hoists, bolt chain to
suspension yokes and push side plates together.
bracket under trolley suspension yoke. For both hoist mountings,
5. Slide extra spacers (156) over free end of suspension yoke
refer to Dwg. MHP1524 on page 70.
(170). Insert suspension yoke pin (174) into hole in
suspension yoke (170). Secure by installing cotter pins (173)
and bending ends apart.
A falling load can cause injury or death. Before installing
trolley and hoist, read SAFETY INFORMATION on page 3
Depending on size of hoist selected it could weigh as much as
4665 lbs (2120 kg). If parts of trolley or hoist are dropped, they
could cause injury or damage property. Adequately support
hoist and trolley when lifting them into place on beam.
Hook Mounted Hoist

Place top hook (408) over mounting structure. Make sure hook
latch is engaged.
Installing Trolley Over End of Beam

Preadjust trolley width for beam flange measurement. Refer to
Installing from Underneath Beam. Remove rail stop and slide
trolley on end of beam. Reinstall rail stop. If this procedure cannot
be used due to insufficient space or fixed limit stops the trolley
must be installed from underneath beam using the procedure
which follows.
Beam Clearance and Trolley Spacer Placement
Item numbers on Dwg. MHP0352 reference items numbers

shown on Dwg. MHP1525 on page 60 and Dwg. MHP0282 on
page 62.
Rack Drive (optional feature)
Pre-Installation Checks
Refer to Dwg. MHP1177 on page 9.

Before welding rack segments onto trolley beam, install rack
segments on the bottom of the beam lower flange and clamp in
place. Mount trolley on the lower beam flange.
Measure gap between outside diameter of drive pinion and root of
rack segment teeth. Trolley drive pinion and rack teeth must have a
0.06 to 0.10 inch (1.5 to 2.5 mm) clearance.
Adjust clearance:
There is an adjustment screw located below reducer adapter.
1. Loosen capscrews attaching trolley drive to sideplate.
2. Loosen jam nut and rotate adjustment screw to achieve
clearance, refer to Dwg. MHP1177 on page 9.
3. Tighten jam nut and mounting screws.
(Dwg. MHP0340) If a larger adjustment is required.

1. Add shims between rack segment and beam to decrease
distance.
2. Remove material from rack segment to increase distance.
Trolley wheels ride on top of lower flange of beam.
Installing Rack Segments Onto Beam
6. The pin (174) and outside spacers (156) must hold trolley to
adjustment in step 1. If side plates can be spread farther apart, Refer to Dwgs. MHP1178 on page 10 and MHP1632 on page 10.
install more outside spacers (156) between side plate (150) Rack segments should be installed on outside edge of lower flange
and pin (174). of the trolley beam. Allow 1/4 inch (6.5 mm) clearance between
7. Measure beam flange width Y and compare with edge of lower flange and rack segment for fillet weld. Rack
measurement between rollers Z. Side roller spacing segments should be clamped tight against lower flange so that
measurement should be 1/16 to 3/16 in. (1.6 to 4.7 mm) there is no sagging. Sagging of the rack could cause drive pinion
greater than beam flange width. to bind as it traverses along runway beam.
8. Prior to using, test trolley. Check that trolley side plates are Racks are provided in segments. These segments should be tack
vertical. Raise a load equal to rated capacity of hoist 6 to 7 welded (refer to Dwg. MHP1632 on page 10) in place and trolley
ins. (130 to 180 mm) off floor and operate trolley along entire traversed the entire length. During this movement observe for any
length of beam. high or low spots and correct. Also check each segment
9. Remove connecting plates (159) by removing capscrews connection for drive tooth contact and correct as necessary.
(157) and lockwashers (158) after installation is complete. When all clearances are achieved, weld both sides of rack to beam
Ensure beam stops are installed. flange to prevent corrosion between rack segment and beam.
Maintain clearance between rack and

Rack pinion teeth of 0.06 inch (minimum) to
0.10 inch (maximum) [1.5 to 2.5 mm] to
prevent pinion binding during operation.
Measure gap between outside
diameter of drive pinion and root of
rack segment.
Pinion Note: 0.08 inch feeler gauge use is
recommended.
0.06 to 0.10 inch

(1.5 to 2.5 mm)
(Dwg. MHP0352) (Dwg. MHP1177)
Rack Drive
Normal trolley drive mounted

above support beam between
trolley wheels
Located behind
motor housing
(Dwg. MHP1178)
Reducer
Trolley rack dirve
Adapter
mounted below
support beam
Mounting
Capscrew
Side
Jam Plate
(Dwg. MHP1632) Nut
Adjustment
Capscrew
(Dwg. MHP1605)
Converting from normal trolley drive to Rack Drive requires

new sideplates in addition to other items. Contact Technical
Support for assistance.
Chain Container
Adjust container support so that chain container does not

contact load chain or hook.
Operate hoist to naturally pile chain into chain container.
Piling chain carelessly into container by hand may lead to
kinking or twisting that can cause chain to jam the hoist.
1. Check chain container size to make sure length of load chain

is within capacity of chain container. Replace with a larger
chain container, if required.
2. Attach chain stopper (241) to last link of load chain free end.
3. Attach chain container to hoist.
4. Run bottom block to lowest point and run hoist in up
direction to feed chain back into container.
Lubricator must be located no more than 10 ft. (3 m) from
hoist and trolley motors.
When feeding chain into chain container, begin with chain The air line lubricator should be replenished daily and set to
stopper end of chain so that it piles naturally. provide 4 to 6 drops per minute of ISO VG 32 (10W SAE) oil at
maximum motor speed. A fine mist will be exhausted from throttle
control valve when operated and air line lubricator is functioning
Attaching Free End of Load Chain properly.
Attach free end of load chain to hoist or bottom hook assembly.
Refer to Chaining Drawings in MAINTENANCE section on Air Line Filter
page 26.
It is recommended that an air line strainer/filter be installed as
Air Supply close as practical to motor air inlet port to prevent dirt from
entering motor. The strainer/filter should provide 20 micron
The air supply must be clean and free from moisture. Due to
filtration and include a moisture trap. Clean strainer/filter
efficiency losses in air lines and air line components, air pressures
periodically to maintain its operating efficiency.
should be checked at hoist motor. A minimum of 105 psi (7.2
bar/724 kPa) at hoist motor is required to provide rated hoist
capacity. Due to efficiency losses in air lines, pressures of up to Moisture in Air Lines
130 psi (8.9 bar/896 kPa) at air supply may be required to achieve
required operating pressure. Contact Technical Support Moisture that reaches air motor through supply lines is the chief
Department for operating requirements with optional 60 psi (4 factor in determining length of time between service overhauls.
bar/414 kPa) system. Moisture traps can help to eliminate moisture and other methods,
such as an air receiver which collects moisture before it reaches
motor or an aftercooler at compressor that cools the air prior to
Air Lines distribution through supply lines, are also helpful.
The inside diameter of hoist air supply lines must not be smaller
than 1 in. (25 mm) based on a maximum of 50 ft. (15 m) between Hoist and Trolley Motors
air supply and hoist. Contact factory for recommended air line
sizes for distances greater than 50 ft. (15 m). All air supply lines For optimum performance and maximum durability of parts,
should be purged before making final connections and connecting provide an air supply to operate hoist and trolley motors with 105
to unit inlet. Supply lines should be as short and straight as psi at 280 scfm (7.2 bar/724 kPa at 8 cu.m/m). The air motor
installation conditions will permit. Long transmission lines and should be installed as near as possible to compressor or air
excessive use of fittings, elbows, tees, globe valves etc. cause a receiver.
reduction in pressure due to restrictions and surface friction in
lines. * Contact Technical Support Department for operating
requirements with optional 60 psi (4 bar/414 kPa system).
Shipping Plug Removal

Remove shipping plugs from brake housing and reducer assembly
and trolley drive piston motor O ring, item (360) on Dwg.
MHP0381 on page 58 before operating hoist.
Failure to remove shipping plugs in brake housing can result

in brake malfunction.
Pendant
Check that all hose connections are tight and that hoses are not
twisted or crimped. Refer to Dwg. MHP2234 on page 12 for hose
(Dwg. MHP0191)
connections. Pendant lengths up to 66 ft (20 m) are available.
Contact the factory for pendant lengths greater than 66 ft (20 m).
Air Line Lubricator

Always use an air line lubricator with these motors. Use a To avoid damaging the pendant hose, make sure the strain
lubricator having an inlet and outlet at least as large as inlet on relief cable, not the pendant hose, is supporting the weight of
motor. Install air line lubricator as close to air inlet on motor as the pendant.
possible.
Single Motor Pendant PHS2E(-U)
(Top View)
A
(Supply) D
(E Stop)
B
(Up)
B
(Down)
C
(On)
On Button
E Stop Button
Two Motor Pendant PHS4E(-U)

A (Top View) D
(Supply) (E Stop) (Dwg. MHP0094)
E Pendant control block shown is for standard pendant assembly

E illustrated on page 50. Refer to Accu-Trol Pendant manual
(Left) (Right) (Form number MHD56014) for optional Accu-Trol Pendant
B control block.
(Up)
B
C (Down)
(On)
On Button
E Stop Button
(Dwg. MHP2234)
Pendant (Optional Style)

Pendant control is installed at factory. Hose fittings are color
coded to ensure correct assembly. Check all hose connections are
tight and that hoses are not twisted or crimped. Refer to Dwg.
MHP0094 on page 12 and MHP0095 on page 12 for correct
pendant hose connections.
Do not attempt to reverse air lines either at pendant station (Dwg. MHP0095)
or hoist. This will give a false indication of operation which
may result in serious damage to hoist.
To avoid damaging pendant hose, make sure strain relief

chain, not pendant hose, is supporting weight of pendant.
Check strain relief chain (188) is properly connected to hoist and

pendant body.
Emergency Air Shutoff
If supply air is wet and unfiltered, and/or hoist is operated in a

dirty environment, hoist or trolley control valves may malfunction
and become stuck in ON position. As a safeguard, an emergency
main line shut-off valve is provided at pendant. The emergency
valve shuts off air supply to entire unit when red pull/push button
is pressed.
If it is necessary to use emergency air shut off valve, then

malfunctioning control valve should be disassembled, cleaned,
and/or repaired as required to clear malfunction before resuming
operation.
Storing Hoist
For hoists that have been in storage for a period of more than one
month the following start-up procedure is required.
1. Give hoist an inspection conforming to requirements of
Hoists Not in Regular Use in INSPECTION section on
page 17.
2. Pour a small amount of ISO VG 32 (10W SAE) oil in motor
inlet port.
3. Operate motor for 10 seconds to flush out any impurities.
4. The hoist is now ready to work.
Trolley Drive Assembly Run-In Period
Maximum efficiency of trolley drive worm gear is obtained after a

run-in period. The length of time required will depend on load
applied and will be 30 minutes to one hour at rated load and
considerably longer at lighter loads.
Overloading will not decrease run-in time and it may damage

worm gear.
During run-in higher than normal temperature rise and lower

efficiency and output torque can be expected.
AIR SCHEMATICS
Hoist without air powered trolley
Brake Release Hoist

(DOWN only) Motor
Spring
Set
Limit
Paddle
Lubricator
Main Air
1 in. 1 in.
Hoist
Pendant Filter/
Separator
Emergency
Shut-off
(Optional)
Hoist Hoist
UP DOWN
(Dwg. MHP0313)
Hoist with air powered vane or piston motor trolley

Trolley Motor Brake Hoist Motor
Spring
Set Release
(DOWN only)
Limit
Paddle
Lubricator Main Air
1 in. 1 in.
Trolley Hoist
Filter/
Pendant Pendant
Separator
Emergency
Shut-off
(Optional)
Hoist Hoist
Trolley Trolley
UP DOWN
FORWARD REVERSE
(Dwg. MHP0312)
OPERATION
The four most important aspects of hoist operation are:

Hoist Controls
1. Follow all safety instructions when operating hoist and
trolley.
2. Allow only people trained in safety and operation of this Pendant
product to operate hoist and trolley.
3. Subject each hoist to a regular inspection and maintenance The pendant can have from two to six levers. The two-lever
procedure. pendant will control hoist movement up and down. A four-lever
4. Be aware of hoist capacity and weight of load at all times. pendant will control trolley movement and hoist operation. A six-
lever pendant would include the above movements plus control a
bridge assembly allowing hoist movement in four directions.
Always apply smooth even pressure to pendant levers, avoid quick
Only allow personnel trained in safety and operation of this starts and abrupt stops. This will allow safer control of suspended
product to operate hoist and trolley. loads and reduce stress on components.
Do not use this hoist for lifting, supporting or transporting
people or lifting or supporting loads over people. Two Lever Pendant Operation
Operators must be physically competent. Operators should have

no health condition which might affect their ability to react, and
they must have good hearing, vision and depth perception. The
hoist operator must be carefully instructed in his duties and must
understand operation of hoist, including a study of the
manufacturers literature. The operator must be aware of proper
methods of hitching loads and should have a good attitude
regarding safety. It is the operators responsibility to refuse to
operate hoist under unsafe conditions.
Initial Operating Checks Raise Load
Hoists are tested for proper operation prior to leaving factory. Lower Load
Before hoist is placed into service the following initial operating
checks should be performed.
1. After installation of trolley mounted hoists, check to ensure
hoist is centered below trolley.
2. Check for air leaks in supply hose and fittings to pendant, and
from pendant to manifold.
(Dwg. MHP2299)
3. When first running hoist or trolley motors a small amount of
light oil should be injected into inlet connection to allow
Operation of hoist is same for all pendants listed in this section:
good lubrication.
1. To lift a load, depress hoist pendant raise lever.
4. When first operating hoist and trolley it is recommended that
2. To lower a load depress hoist pendant lower lever.
motors be driven slowly in both directions for a few minutes.
3. To throttle lift or lowering speed, regulate the amount
5. Operate trolley along entire length of beam.
pendant lever is depressed. Depress lever completely for
6. Inspect hoist and trolley performance when raising, moving
maximum speed; depress lever partially for slower speeds.
and lowering test load(s). Hoist and trolley must operate
4. To stop lift or lowering function, release lever. Lever will
smoothly and at rated specifications prior to being placed in
spring back to OFF and hoist motor will stop.
service.
7. Check that trolley (if equipped) and hook movement is in
same direction as arrows or information on pendant control. Single Function, Two Lever Pendant
8. Raise and lower a light load to check operation of hoist brake.
9. Check hoist operation by raising and lowering a load equal to Refer to Dwg. MHP0427 on page 16.
rated capacity of hoist 4 to 6 inches (100 to 150 mm) off The two lever pendant is standard pendant supplied with hook
floor. mounted hoists and is designed to provide hoist operation only.
10. Check operation of limit devices. Hoist operation must correspond to directions indicated by arrows
11. On trolley units, check O ring (360) on breather plug (362) located on pendant levers.
in trolley drive piston motor has been removed.
12. Check that solid plug (necessary only for shipping) is
removed from power head reduction gear assembly and
replaced with breather (421) attached to notice tag supplied
with hoist.
Two Lever Pendant Operation (old style) Four Lever Pendant with Emergency Stop Operation
Emergency
Stop Button
ON
Button
Trolley Control
Levers
Pendant Hoist Control

Handle Levers
(Dwg. MHP1547)
Pilot Pendant Throttle with Emergency Stop

(Dwg. MHP0427) (Old Style)

Emergency Stop (optional feature) The pendant control throttle is equipped with two separate levers
for hoist operation. Pilot pressure from pendant throttle activates
The Emergency Stop button, when activated, will immediately hoist control valve. Direction of hook travel is controlled by
stop all operations of the trolley and hoist. The Emergency Stop whichever lever is pressed.
button will remain depressed after activation. To reset Emergency Trolley operation is controlled by two buttons located above hoist
Stop button, twist (rotate) Emergency Stop button clockwise until control levers.
button releases and spring returns to its original position. Depress Additionally, an emergency shut-off feature is available on this
ON button. pendant model.
Two Lever Pendant with Emergency Stop Operation Four Lever Pendant with Emergency Stop Operation
Emergency Stop
Button
ON
Button
Hoist
Control Levers
Pendant
Handle (Dwg. MHP0395)
(Dwg. MHP1649) Accu-Trol Pendant (Push Button Type)
The optional Accu-Trol Pendant is available with 2, 4 or 6

buttons. Refer to Accu-Trol Pendant manual form number
MHD56014 for additional information.
Accu-Trol Pendant Operation The pull rope provides operator with a local hoist operating
station. The following operating directions are as viewed facing
motor end of hoist.
1. To LIFT a load pull down on RIGHT pull rope.
2. To LOWER a load pull down on LEFT pull rope.
3. Pull rope to full travel for maximum speed; pull rope partially
for slower speeds.
4. To stop lift or lowering of load, release pull rope. Hoist motor
will stop.
Pull Rope Operation
(Dwg. MHP0434)
Pull Rope
The hoist can be supplied with an optional manual pull rope

(Dwg. MHP1704)
control.
INSPECTION
Inspection information is based in part on American National Careful inspection on a regular basis will reveal potentially
Standards Institute Safety Codes (ASME B30.16). dangerous conditions while still in the early stages, allowing
corrective action to be taken before condition becomes dangerous.
Deficiencies revealed through inspection, or noted during

All new, altered or modified equipment should be inspected operation, must be reported to designated personnel instructed in
and tested by personnel instructed in safety, operation and safety, operation and maintenance of this equipment. A
maintenance of this equipment to ensure safe operation at determination as to whether a condition constitutes a safety hazard
rated specifications before placing equipment in service. must be made, and correction of noted safety hazards
Never use a hoist that inspection indicates is damaged. accomplished and documented by written report before placing
equipment in service.
Frequent and periodic inspections should be performed on
equipment in regular service. Frequent inspections are visual
examinations performed by operators or personnel trained in Records and Reports
safety and operation of this equipment and include observations
Inspection records, listing all points requiring periodic inspection
made during routine hoist operation. Periodic inspections are
should be maintained for all load bearing equipment. Written
thorough inspections conducted by personnel trained in safety,
reports, based on severity of service, should be made on the
operation and maintenance of this equipment.
condition of critical parts as a method of documenting periodic
inspections. These reports should be dated, signed by person who
ASME B30.16 states inspection intervals depend upon the nature
performed inspection, and kept on file where they are readily
of the critical components of equipment and severity of usage. The
available for review.
inspection intervals recommended in this manual are based on
intermittent operation of hoist eight hours each day, five days per
week, in an environment relatively free of dust, moisture and Load Chain Reports
corrosive fumes. If hoist is operated almost continuously or more
than eight hours each day, more frequent inspections will be Records should be maintained documenting condition of load
required. chain removed from service as part of a long-range load chain
inspection program. Accurate records will establish a relationship
between visual observations noted during frequent inspections and
actual condition of load chain as determined by periodic
inspection methods.
Frequent Inspection
On hoists in continuous service, frequent inspection should be
made at the beginning of each shift. In addition, visual inspections
should be conducted during regular service for any damage or
evidence of malfunction.
1. OPERATION. Check for visual signs or abnormal noises
(grinding etc.) which could indicate a problem. Make sure all
controls function properly and return to neutral when
released. Check chain feed through hoist and bottom block. If
chain binds, jumps, is excessively noisy or clicks, clean and
lubricate chain. If problem persists, replace chain. Operate
trolley along entire length of beam. Trolley should operate
smoothly without sticking or binding. Do not operate hoist
(Dwg. MHP0111)
until all problems have been corrected.
2. HOOKS. Check for wear or damage, increased throat width,
3. UPPER AND LOWER LIMIT DEVICE. Test operation with
bent shank or twisting of hook. Replace hooks which exceed
no load. Upward travel must stop when bottom block hits
throat opening discard width specified in Table 2 (refer to
hoist limit arm. Downward travel must stop when stop buffer
Dwg. MHP0040 on page 18) or exceed a 10 (degree) twist
at unloaded end of chain activates limit arm.
(refer to Dwg. MHP0111 on page 18). If hook latch snaps
4. AIR SYSTEM. Visually inspect all connections, fittings,
past tip of hook, hook is sprung and must be replaced. Refer
hoses and components for indication of air leaks. Repair any
to the latest edition of ASME B30.10 HOOKS for
leaks found.
additional information.
5. CONTROLS. During operation of hoist and/or trolley, verify
response to pendant is quick and smooth. If response is slow
Hook Throat Width
or movement is unsatisfactory, do not operate hoist until all
problems have been corrected.
6. HOOK LATCH. Make sure hook latch is present and
operating. Replace if necessary.
7. CHAIN. Examine each of links for bending, cracks in weld
areas or shoulders, traverse nicks and gouges, weld splatter,
corrosion pits, striation (minute parallel lines) and chain
wear, including load bearing surfaces between chain links,
refer to Dwg. MHP0102 on page 18. Replace a chain that
fails any of inspections. Check chain lubrication and lubricate
(Dwg. MHP0040) if necessary. Refer to Load Chain in LUBRICATION
section on page 21.
Table 2 Hook Throat Normal and Discard Width
Hoist Hook Throat Width Discard Width

Model Type in. mm in. mm
HA2-012 2.5 63.5 2.87 73
HA2-025 4.0 101.6 4.6 116.8
Standard
HA2-037 4.75 120.6 5.46 138.7
HA2-050 6.5 165.1 7.47 189.8
(Dwg. MHP0102)
The full extent of load chain wear cannot be determined by

visual inspection. At any indication of load chain wear inspect
chain and chain wheel in accordance with instructions in
Load Chain listed in Periodic Inspection.
8. LOAD CHAIN REEVING. Ensure welds on standing links

are away from load sheave. Reinstall chain if necessary.
Make sure chain is not capsized, twisted or kinked. Adjust as
required. Refer to MAINTENANCE section on page 26.
Table 3 Load Chain Normal and Discard Length
Periodic Inspection
Chain
According to ASME B30.16, frequency of periodic inspection Hoist Size Normal Length Discard Length
depends on the severity of usage: Model
mm in. mm in. mm
NORMAL HEAVY SEVERE HA2-012
yearly semiannually quarterly HA2-025
22 13.05 331 13.22 336
Disassembly may be required for HEAVY or SEVERE usage. HA2-037
Keep accumulative written records of periodic inspections to HA2-050
provide a basis for continuing evaluation.
Load Chain LengthInspection
Inspect all the items in Frequent Inspection. Also inspect the
following:
1. FASTENERS. Check all rivets, split pins, capscrews and
nuts. Replace if missing or tighten if loose.
2. ALL COMPONENTS. Inspect for wear, damage, distortion,
deformation and cleanliness. If external evidence indicates
the need, disassemble. Check gears, shafts, bearings, sheaves, (Dwg. MHP0041)
chain guides, springs and covers. Replace worn or damaged
parts. Clean, lubricate and reassemble. 12. CHAIN CONTAINER. Check for damage or excessive wear
3. HOOKS. Inspect hooks carefully for cracks using magnetic and that chain container is securely attached to hoist. Secure
particle or other suitable non-destructive method. Inspect or replace if necessary.
hook retaining parts. Tighten, repair or replace if necessary. 13. LIMIT ASSEMBLY. Check limit arm moves freely.
4. LOAD CHAIN SHEAVES. Check for damage or excessive
wear. Replace if necessary. Observe the action of load chain
feeding through hoist. Do not operate a hoist unless load Hoists Not in Regular Use
chain feeds through hoist and hook block smoothly and
1. Hoists which have been idle for a period of one month or
without audible clicking or other evidence of binding or
more, but less than one year, should be given an inspection
malfunctioning.
conforming with the requirements of Frequent Inspection
5. MOTOR. If performance is poor, disassemble motor and
prior to being placed into service.
check for wear or damage to bearings and shafts. The parts
2. Hoists which have been idle for a period of more than one
should be cleaned, lubricated and reassembled. Replace worn
year should be given an inspection conforming with the
or damaged parts.
requirements of Periodic Inspection prior to being placed
6. BRAKE. Raise a load equal to rated capacity of hoist 4 to 6
into service.
inches (100 to 150 mm) off floor and check ability of hoist to
3. Standby hoists should be inspected at least semiannually in
hold load without drift. If drift occurs, disassemble. Remove
accordance with the requirements of Frequent Inspection.
brake discs as described in the MAINTENANCE section
In abnormal operating conditions hoists should be inspected
on page 26. Check and clean brake parts each time hoist is
at shorter intervals.
disassembled. Replace brake friction discs if thickness is less
than 0.072 inch (1.83 mm), or if oil groove pattern is not
clearly visible.
7. SUPPORTING STRUCTURE. Check for distortion, wear
and continued ability to support load.
8. TROLLEY. Check that trolley wheels track beam properly
and clearance between trolley wheel flanges and beam is
correct. Refer to INSTALLATION section on page 8.
Check that wheels and beam are not excessively worn.
Inspect side plates for spreading due to bending. Do not
operate hoist until problems have been corrected.
9. LABELS AND TAGS. Check for presence and legibility.
Replace if necessary.
10. END ANCHORS (Load chain). Ensure load chain end is
securely attached. Check chain stopper is correctly installed
on free end of load chain.
11. LOAD CHAIN. Measure chain for stretching by measuring
across five link sections all along chain, paying particular
attention to most frequently reeved links. Refer to Dwg.
MHP0041 on page 19. When any five-link section in working
length reaches or exceeds discard length, listed in Table 3 on
page 19, replace entire chain. Always use genuine
Ingersoll-Rand replacement chain for regular and nickel-
diffused load chains. When ordering load chain, specify
which unit it will be used on. Chain will then be cut and
tagged with the right number of links.
INSPECTION AND MAINTENANCE REPORT
Ingersoll-Rand HA2 Air Hoist

Model Number: Date:
Serial Number:
Reason for Inspection: (Check Applicable Box) Inspected By:
1. Scheduled Periodic Inspection
( _____ Quarterly _____ Semiannually _____ Yearly) Operating Environment:
2. Discrepancy(s) noted during Frequent Inspection
Normal ______ Heavy ______ Severe ______
3. Discrepancy(s) noted during maintenance
4. Other: ___________________________
Refer to Parts, Operation and Maintenance Manual INSPECTION section on page 17 and to the appropriate National Standards and
Codes of practice for general inspection criteria. If in doubt about an existing condition, contact the nearest Ingersoll-Rand distributor or
factory for technical assistance.
CORRECTIVE
CONDITION ACTION
COMPONENT NOTES
Pass Fail Repair Replace
Fasteners
Gears
Shafts
Bearings ---
Load Bearing Sheaves
Chain Guides
Springs ---
Covers
Hooks ---
Actual Hook Throat Width: ________ inches / _________ mm (Refer to Table 2 on page 18 for max. acceptable widths.)
Top Hook Twist --- (maximum 10%)
Hook Crack Test Method Used: Dye Penetrant ______ Magnetic Particle ______ Other: __________________
Actual Hook Throat Width: ________ inches / _________ mm (Refer to Table 2 on page 18 for max. acceptable widths.)
Bottom Hook Twist --- (maximum 10%)
Hook Crack Test Method Used: Dye Penetrant ______ Magnetic Particle ______ Other: __________________
Hook Latch ---
Brake (10% Load Test) ---
Brake (Visual Inspection)
Tail Pin (End Anchor)
---
Load Chain
Working length(s) maximum wear: ______ inches / ______ mm (refer to Table 3 on page 19)
Supporting Structure
Labels and Tags ---
Other Components
(List in NOTES section)
Testing: Pass Fail NOTES

Operational (No Load)
Operational (10% Load)
Operational (Maximum Test Load*)
* Refer to Load Test in MAINTENANCE section on page 38 for testing information.
This page may be photocopied and used by inspectors or maintenance personnel.
LUBRICATION
To ensure continued satisfactory operation of hoist, all points Table 5 Hoist Motor Recommended Oil
requiring lubrication must be serviced with correct lubricant at the
proper time interval as indicated for each assembly. Correct Ambient Temperature Recommended Oil Type
lubrication is one of the most important factors in maintaining Below 32 F (0 C) ISO VG 32 (10W SAE)
efficient operation.
30 to 80 F (0 to 26 C) ISO VG 68 (20W SAE)*
The lubrication intervals recommended in this manual are based Above 80 F (26 C) ISO VG 100 (30W SAE)
on intermittent operation of hoist eight hours each day, five days * Hoists are shipped from factory with ISO VG 68 (20W SAE)
per week. If hoist is operated almost continuously or more than oil.
eight hours each day, more frequent lubrication will be required.
Also, lubricant types and change intervals are based on operation
in an environment relatively free of dust, moisture, and corrosive Piston Trolley Drive Motor
fumes. Use only those lubricants recommended. Other lubricants
may affect performance of hoist. Approval for use of other The motor is splash lubricated by oil in motor housing and has no
lubricants must be obtained from your Ingersoll-Rand Technical other means of lubrication. It is therefore important to use only
Support Department or distributor. Failure to observe this high quality, rust and oxidation-inhibiting lubricant to insure
precaution may result in damage to hoist and/or its associated maximum performance and minimum down time for repairs.
components. Allow oil to settle prior to topping off. Oil capacity for HA2
trolley drive motor is 0.1 pints (65 ml). Refer to Table 6 for
recommended oil.
INTERVAL LUBRICATION CHECKS
Start of each shift Check flow and level of air line Table 6 Piston Trolley Motor Recommended Oil
lubricator (approximately 4 to 6 drops Ambient Temperature Recommended Oil Type
per minute required at maximum
motor speed). Below 32 F (0 C) ISO VG 68 (20W SAE)
Check oil levels in hoist and trolley 30 to 80 F (0 to 26 C) ISO VG 100 (30W SAE)*
piston motors. Above 80 F (26 C) ISO VG 150 (40W SAE)
Monthly Inspect and clean or replace air line * Trolley Motors are shipped from factory with ISO VG 100
filter. (30W SAE) oil.
Lubricate all grease fittings.
Check oil level in brake and reduction Bottom Hook Block Assembly
gear assembly.
Refer to Dwgs. MHP0314, MH P0315, MHP0316 and MHP0317
Semiannually Drain and replace oil in trolley and
on pages 68 and 69.
hoist piston drive motors.
To prevent moisture entering bottom block assemblies they should
Yearly Drain and refill oil in hoist brake and periodically be disassembled and repacked with grease. Apply
reduction gear assembly. grease to grease fitting until grease escapes through breather
(421). Refer to Table 4 on page 21 for recommended grease types
at specific temperature ranges. Refer to Table 7 on page 21 for
Pivot Points and Bushings required quantity of grease.
Lubricate grease fittings monthly with 2 or 3 pumps from a grease
Table 7 Bottom Hook Lubrication Quantities
gun or more frequently, depending on severity of service.
Capacity Grease Required to Pack
Table 4 Recommended Lubricants Hoist Hook Assembly
Model
Ambient Temperature Recommended Grease Type metric tons oz grams
EP 1 multipurpose HA2-012 12.5 1.1 31
-20 to 50 F (-30 to 10 C)
lithium-based HA2-025 25 7.2 204
EP 2 multipurpose lithium- HA2-037 37.5 16.5 468
30 to 120 F (-1 to 49 C)
based
HA2-050 50 30.8 873
Hoist Motor
Load Chain
The motor is splash lubricated by oil in motor housing and has no
other means of lubrication. It is therefore important to use only
high quality, rust- and oxidation-inhibiting lubricant to ensure
maximum performance and minimum downtime for repairs. Refer Failure to maintain clean and well lubricated load chain will
to Table 5 on page 21 for recommended oil type. Allow oil to result in rapid load chain wear that can lead to chain failure
settle prior to topping off. Oil capacity for HA2 hoist motor is 0.2 which can cause severe injury, death or substantial property
gals (0.76 lts). damage.
1. Lubricate load chain weekly, or more frequently, depending Table 9 Reduction Gear Recommended Lubricants
on severity of service.
Ambient Temperature Recommended Lubricant
2. In a corrosive environment, lubricate more frequently than
normal. Below 32 F (0 C)
3. Lubricate each link of load chain and apply new lubricant 30 to 80 F (0 to 26 C)
over existing layer.
4. Lubricate hook and hook latch pivot points. Above 80 F (26 C) ISO VG 200 EP
5. If required, clean chain with acid free solvent to remove rust
or abrasive dust build-up and lubricate chain. Reduction Gear Level and Fill Plug Locations
6. Use Ingersoll-Rand LUBRI-LINK-GREEN or an ISO VG
320 to 220 (SAE 50 to 90 EP) oil. Vented
Fill Plug
Trolley Drive Assembly
The gear housing is filled at the factory and shipped with oil, a
non-toxic, high quality, Extreme Pressure (EP), rust- and
oxidation-inhibiting worm gear AGMA #7 lubricant that is
suitable for an ambient temperature of 50 F to 125 F (10 C to
52 C).
Before placing hoist in operation, make certain that vented pipe
plug (210) has been installed in gear housing (212).
Fill gear housing (212) through vented fill plug (210) hole to
height of level plug (201) hole located in cover (202). The gear
housing oil capacity is approximately 0.4 gals (1.5 lts.).
After first 10 hours of operation oil should be changed. Thereafter Drain Plugs
Disc Brake Level
it should be changed every 100 hours of service or every 6 months, Located
Plug Oil Level
whichever occurs first. At Bottom
The oil is drained by removing pipe plug (213) located underneath Plug
gear housing (212). If oil drains too slowly, removing vented fill (Dwg. MHP0343)
plug (210) may speed up draining. The oil should be replaced
using one of the recommended lubricants or its equivalent. Disc Brake
Table 8 Trolley Drive Recommended Lubricants Refer to Dwg. MHP0353 on page 40.
Ambient Temperature Recommended Lubricant The disc brake housing is filled and shipped with oil from
thefactory. Check oil level before initial hoist operation. If hoist is
-10 to 50 F (-23 to 10 C) AGMA #5 (EP 5) used at a normal frequency replace oil in disc brake housing once
50 to 125 F (10 to 52 C) AGMA #7 (EP 7) every year.
To ensure correct performance, highest efficiency and long life, it

Reduction Gear Assembly is essential that lubricating oil be maintained at correct level. Oil
capacity for disc brake housing is 0.2 gals (0.76 lts).
The reduction gear assembly is shipped with oil from the factory.
Check oil level before initial hoist operation. If hoist is used at a
normal frequency replace oil in reduction housing once every year.
Do not over fill. Excess oil will reduce operating efficiency
To ensure correct performance, highest efficiency and long life, it and increase oil temperature.
is essential that lubricating oil be maintained at correct level. Oil
capacity for reduction gear assembly is 1.1 gals (4.2 lts). Use only high quality lubricants in disc brake housing assembly
such as ISO VG 200 EP motor oil or high grade EP4 type gear oil.
The recommended grade of oil must be used at all times since use
Do not over fill. Excess oil will reduce operating efficiency of unsuitable oil may result in excessive temperature rise, loss of
and increase oil temperature. efficiency and possible damage to brake discs and sprig clutch.
Use only high quality lubricants in reduction gear assembly such Fill brake housing (27) to height of level plug (28).
as ISO VG 200 EP motor oil or high grade EP4 gear oil.
Table 10 Disc Brake recommended Lubricants
The recommended grade of oil must be used at all times since use
of unsuitable oil may result in excessive temperature rise, loss of Ambient Temperature Recommended Lubricant
efficiency and possible damage to gears. Check vented fill plug is Below 32 F (0 C)
unrestricted.
30 to 80 F (0 to 26 C)
Above 80 F (26 C) ISO VG 200 EP
provide a good protective coat. Lubricate grease fittings monthly
Seals and Bearings
with 2 or 3 pumps of a grease gun. For correct grease type, refer to
If hoist is disassembled, clean all parts thoroughly and coat Table 4 on page 21.
bearings and seals with clean grease. Use sufficient grease to
Hoist Lubrication Points
(Dwg. MHP0338)
TROUBLESHOOTING
This section provides basic troubleshooting information. Determination of specific causes to problems are best identified by thorough
inspections performed by personnel instructed in safety, operation and maintenance of this equipment. The chart below provides a brief
guide to common hoist symptoms, probable causes and remedies.
Symptom Cause Remedy

Hoist will not operate. No air supply to hoist, or too little CFM or Check PSI (bar) at hoist inlet. Refer to SPECIFICATIONS
PSI. section on page 7 for correct CFM (cu.m/min) and PSI (bar).
Valve or limit arm sticking. Check limit arm for free movement.
Emergency stop valve OFF. Reset Emergency stop and push ON button.
Pendant malfunction. Check PSI (bar) at pendant. Minimum operating pressure in
pendant line is 55 PSI (380 kPa/3.8 bar).
Hoist is overloaded. Reduce load to within rated capacity.
Motor is damaged. Repair or replace. Refer to MAINTENANCE section on page
26. Check oil level in motor and gearbox.
Lubricator is low on oil. Fill lubricator.
Brake is not releasing (DOWN direction Check brake release circuit and PSI (bar) at brake inlet (55 PSI
only). (380 kPa/3.8 bar) minimum).
Load continues to move Valve or limit arm sticking. Check limit arm for free movement.
when hoist is stopped. Dump valves not releasing. Check pendant hose dump valves.
UP direction.
Pendant lever sticking. Check lever and restore free movement.
Load continues to move Valve or limit arm sticking. Check limit arm for free movement.
when hoist is stopped. Dump valves not releasing. Check pendant hose dump valves.
DOWN direction.
Brake is slipping. Check brake springs and brake disc linings for wear. Refer to
MAINTENANCE section on page 26.
Break release screws incorrectly set. (old Check brake release screws in brake housing. Adjust as needed:
style hoists Refer to Dwg. MHP0397 on page 34.
Hoist is overloaded. Reduce load to within rated capacity.
Pendant lever sticking. Check lever and restore free movement.
Hoist will not lift rated Hoist is overloaded. Reduce load to within rated capacity.
capacity. No air supply to hoist or too little CFM or Check PSI (bar) at hoist inlet. Refer to SPECIFICATIONS
PSI. section on page 7 for correct CFM (cu.m/min) and PSI (bar).
Main air valve travel is restricted. Check limit arm and linkage for free movement.
Exhaust is restricted. Inspect vents and replace muffler.
Motor is damaged. Check for worn motor bearings. Repair as needed.
Motor or gearbox is out of oil. Check oil levels in motor and gearbox. Fill to recommended
level.
Hook can be lowered Hoist is overloaded. Reduce load to within rated capacity.
but not raised. No air supply to hoist or too little CFM or Check at hoist power supply connection with hoist under load.
PSI. Raise pressure to rated capacity.
Pendant malfunction. Check PSI (bar) at air inlet connection (green fitting) on pendant.
Hook can be raised but Brake is not releasing. Check PSI (bar) at brake inlet. (55 PSI (380 kPa/3.8 bar)
not lowered. minimum.) Check brake and pendant dump valves.
No breather in gearbox. Remove solid square head plug in outboard end of gearbox only
and install vented (breather) plug.
Brake piston seals leaking (old style). Install upgrade kit. Refer to Parts section.
Low air pressure. Check PSI (bar) at valve inlet. Raise pressure to rated capacity.
Pendant malfunction. Check PSI (bar) at yellow fitting connection on pendant.
Symptom Cause Remedy
Load chain jumps on Worn or rusted chain. Refer to INSPECTION section on page 19 to determine wear
sheave or is making a limit. Replace if necessary.
snapping sound.
Incorrect chain. Replace with correct chain.
Worn sheave or chain guide. Replace worn parts.
Capsized hook. Correct as described in MAINTENANCE section on page 27.
Hoist not in line with load. Align hoist with load. Do not yard or side pull.
Incorrectly reeved load chain. Check load chain is correctly reeved.
No oil on load chain. Lubricate load chain.
Trolley
Trolley will not stop or Damaged beam. Repair or replace beam.
trolley wheels slip.
Excessive oil, grease or paint on track of Clean off oil, grease or paint.
beam.
Trolley not spaced for beam clearance. Check trolley spacing. Refer to INSTALLATION section on
page 8.
Air-powered trolley Pendant lever sticking. Check lever and restore free movement.
does not operate.
Emergency valve in OFF position. Reset Emergency stop and push ON button.
No air supply to trolley or too little CFM Check PSI (bar) at trolley inlet. Refer to manufacturers
(cu. m/min.) or PSI (kPa/bar). specifications.
Control valve is sticking. Refer to MAINTENANCE section on page 26.
No oil in trolley motor or gearbox. Check oil levels in trolley motor and gearbox and fill to required
level.
Wheels are obstructed. Remove obstruction.
Motor is damaged. Repair or replace. Refer to MAINTENANCE section on page
26.
MAINTENANCE
Load Chain Replacement
Never perform maintenance on hoist while it is supporting a Load Chain Weld Placement
load.
Before performing maintenance, tag controls: It is suggested that a short length of 22 mm load chain be available
WARNING - DO NOT OPERATE - when replacing hoist load chain. Feeding a short length of load
EQUIPMENT BEING REPAIRED. chain through bottom block assembly or power head assembly
Only allow personnel trained in operation and service of this prior to installing new load chain may simplify installation.
hoist to perform maintenance. Weld on perpendicular load chain must always face away from
After performing any maintenance on hoist dynamically test sheaves. Refer to Dwg. MHP0042 on page 26.
hoist to 100% of its rated capacity, in accordance with ASME
B30.16 standards, before returning hoist to service. Testing to
more than 100% of rated capacity may be required to comply
with standards and regulations set forth in areas outside the
USA.
Shut off air system and depressurize air lines before
performing any maintenance.
Proper use, inspections and maintenance increase the life and

usefulness of your Ingersoll-Rand equipment. During assembly,
lubricate gears, nuts, capscrews and all machined threads with
(Dwg. MHP0042)
applicable lubricants. Use of antiseize compound and/or thread
lubricant on capscrew and nut threaded areas prevents corrosion
and allows for easy disassembly of components. Replacement Load Chain Link Arrangement
Correct load chain installation requires that load chain have either
Maintenance Intervals an even or odd number of total chain links. Refer to Dwg.
MHP1990 on page 26 for illustration of how to determine chain
The Maintenance Interval Chart below is based on intermittent
arrangement.
operation of equipment for eight hours each day, five days per
week. If equipment is in operation for more than eight hours a day
or is operated in severe applications or environments, more Chain Link
frequent maintenance should be performed. (view facing Motor)
INTERVAL MAINTENANCE CHECK 122550 First 371/2

Ton Link Ton
Start of each shift Make a thorough visual inspection of hoist Hoists Hoist
for damage. Do not operate hoist if damage Only
Chain
is found. Weld
Operate in both directions. Hoist must
operate smoothly without sticking, binding
or abnormal noises.
Check operation of pendant control and
brake.
Semiannually Inspect disc brake friction linings and
Chain
sprag clutch assembly. Clean or replace Weld
parts as required. located
End on back
Yearly Inspect hoist gearing, shafts and bearings Link side
for damage or wear. Repair or replace as
necessary.
Check all of supporting members,
including trolley if used. Repair or replace (Dwg. MHP1990)
as required.
Load Chain C Link
Disc Brake Adjustment
Load chain replacement for all hoist models can be accomplished
No disc brake adjustment is required. If brake fails to hold load, efficiently and easily by using existing load chain to install new
brake must be disassembled, inspected, repaired and tested prior to load chain.
placing hoist in service. Refer to Power Head Disassembly on 1. Using an abrasive wheel, cut a section from end link of
page 30. When any part of friction disc thickness measures 0.072 existing chain to form a C link. Refer to Dwg. MHP1219
in. (1.83 mm) or less, or if oil groove pattern is not clearly visible, on page 27.
friction discs must be replaced.
C Link Dimension HA2-012 Hoist

1. The hoist should be installed and connected to air supply.
Reduce hoist air pressure to 60 psi (4 bar/414 kPa).
2. Remove chain bucket, if used.
3. Remove load chain stopper (241).
4. Remove bottom block assembly (11).
5. Cut new load chain to length. Load chain must have an even
number of links (first and last links must be at 90 to each
(Dwg. MHP1219) other). Refer to Dwg. MHP1990 on page 26.
6. Run hoist slowly in lifting direction until load chain free end
is approximately 2 ft. (0.6 m) from hoist.
7. Using a C link which is the same size as load chain join new
Do not distort link in any manner. The link must be able to
load chain to old taking care that weld on perpendicular
pass over chain sheaves without binding.
standing links on new load chain are facing away from hoist
load sheave.
2. Connect new chain to old chain by inserting end of new chain
8. Run hoist slowly until new load chain has passed 2 to 3 feet
into C link. Make certain welds and links on new chain
(0.6 to 1 m) through hoist. Remove C link and old chain.
match positioning of welds and links on chain being
9. Install chain stopper (241) in last link of load chain free end.
replaced. For model-specific information, refer to the
10. Install bottom block assembly (11).
appropriate hoist model diagram.
11. Lubricate entire length of load chain before operating hoist.
Refer to LUBRICATION section on page 21.
Twisted, Kinked or Capsized Load Chain
HA2-012 Chain Reeving
Ensure chain is not twisted, kinked or capsized during
installation. Refer to Dwgs. MHP0020 on page 27 and MHP0043 Weld Power Head
on page 27. Load Sheave
Twisted Chain Feed first link

perpendicular
to load sheave Hoist Motor
Side
B
A
Chain
Stopper
(Dwg. MHP0020) (241)
Weld on perpendicular
Capsized Chain chain link must face
Bottom
away from top sheave
Block
Weld on flat chain link
must face away from
hoist motor side
(Dwg. MHP0428)
HA2-025 Hoist
Refer to Dwgs. MHP0337 on page 28 and MHP0353 on page 40.

1. The hoist should be installed and connected to air supply.
Reduce hoist air pressure to 60 psi (4 bar/414 kPa).
2. Remove chain bucket, if used.
3. Remove load chain stopper (241).
(Dwg. MHP0043) 4. Run hoist slowly in lifting direction until bottom block
assembly (11) is approximately 3 ft. (1 m) from hoist power
head. Firmly support and secure bottom block assembly (11)
in this position.
head. Firmly support and secure bottom block assembly (70)
in this position.
Do not begin chain replacement until bottom block assembly
is fully secured and supported. If bottom block assembly or
chain are dropped, they could cause injury or damage Do not begin chain replacement until bottom block assembly
property. is fully secured and supported. If bottom block assembly or
chain are dropped, they could cause injury or damage
5. Cut new load chain to length. Load chain must have an even property.
number of links (first and last links must be at 90 to each
other). Refer to Dwg. MHP1990 on page 26. 5. Cut new load chain to length. Load chain must have an odd
6. Remove pins (46) and (47) that anchor load chain to power number of links (first and last links must be in same
head assembly. plane/parallel to each other). Refer to Dwg. MHP1990 on
7. Using a C link which is the same size as load chain join new page 26.
load chain to free end on old chain taking care that weld on 6. Remove capscrew (416) and cotter pin (414) that anchor load
perpendicular standing links on new chain are facing away chain to bottom block assembly.
from hoist load sheave. 7. Using a C link which is same size as load chain, join new
8. Run hoist slowly until new load chain has passed through load chain to free end on old chain taking care that weld on
hoist. Continue running hoist and pull chain by hand through perpendicular standing links on new chain are facing away
bottom block assembly (11). Begin feeding chain at position from hoist load sheave.
A and work alphabetically. Remove C link and old chain. 8. Run hoist slowly until new load chain has passed through
9. Anchor end of load chain to power head assembly. Install hoist. Continue running hoist and pull chain by hand through
chain stopper (241) in last link of load chain free end. bottom block assembly (11). Begin feeding chain at position
10. Lubricate entire length of load chain before operating hoist. A and work alphabetically. Remove C link and old chain.
Refer to LUBRICATION section on page 21. 9. Attach end of load chain to bottom block assembly. Install
chain stopper (241) in last link of load chain free end.
HA2-025 Chain Reeving 10. Lubricate entire length of load chain before operating hoist.
Refer to LUBRICATION section on page 21.
Feed first link Weld
perpendicular Power Head
to load sheave HA2-037 Chain Reeving
Load Sheave
Feed first link Power Head
flat to load Load Sheave
Hoist Motor
sheave
A Side
Power Head
Idle Sheave
Chain B Anchor Chain Weld on
A
Stopper at this point perpendicular
(241) chain links Hoist Motor
must face Side
Weld on perpendicular
chain links must face
away from
away from sheaves sheaves
Bottom
Weld on flat chain Block
Chain C
C links must face away Stopper D B
from hoist motor side
(241)
Anchor chain
at this point
Bottom
Block
37 1/2 Ton
(Dwg. MHP0337) Hoist
Only
HA2-037 Hoist Chain
Weld
Refer to Dwgs. MHP0332 on page 28 and MHP0316 on page 68. Weld on flat
1. The hoist must be installed and connected to air supply. chain links Chain
Reduce hoist air pressure to 60 psi (4 bar/414 kPa). must face Weld
2. Remove chain bucket, if used. away from located
3. Remove chain stopper (241). hoist motor on back
4. Run hoist slowly in lifting direction until bottom block side side
assembly (11) is approximately 3 ft. (1 m) from hoist power (Dwg. MHP0332)
HA2-050 Hoist 8. Run hoist slowly until the new load chain has passed through
hoist. Continue running hoist and pull chain through bottom
Refer to Dwgs. MHP0331 on page 29 and MHP0353 on page 40. block assembly (11). Begin feeding chain at position A and
1. The hoist must be installed and connected to air supply. work alphabetically. Remove C link and old chain.
Reduce hoist air pressure to 60 psi (4 bar/414 kPa). 9. Anchor end of load chain to power head assembly. Install
2. Remove chain bucket, if used. chain stopper (241) in last link of load chain free end.
3. Remove chain stopper (241). 10. Lubricate entire length of load chain before operating hoist.
4. Run hoist slowly in lifting direction until bottom block Refer to LUBRICATION section on page 21.
assembly (11) is approximately 3 ft. (1 m) from hoist power
head. Firmly support and secure bottom block assembly (11) General Disassembly
in this position.
The following instructions provide the necessary information to
disassemble, inspect, repair, and assemble the hoist. Complete
assembly drawings of the hoist components are provided in the
Do not begin chain replacement until bottom block assembly PARTS section beginning on page 39.
is fully secured and supported. If bottom block assembly or
chain are dropped, they could cause injury or damage If hoist is being completely disassembled for any reason, follow
property. the order of the topics as they are presented. It is recommended
that all maintenance work on hoist be performed on a bench in a
HA2-050 Chain Reeving clean dust-free work area.
Feed first link
Weld In the process of disassembling hoist, observe the following:
perpendicular
to load sheave 1. Turn off air system and depressurize air lines before
performing any maintenance. Disconnect hoses from hoist
Power Head and trolley. Plug or cap openings to keep out dirt and
Anchor chain
at this point Load Sheave contaminants.
Idle Sheave
2. Never disassemble hoist any further than is necessary to
accomplish the needed repair. A good part can be damaged
during the course of disassembly.
A Hoist Motor 3. Never use excessive force when removing parts. Tapping
Side gently around the perimeter of a cover or housing with a soft
hammer, for example, is sufficient to break the seal.
D B
4. Do not heat a part with a flame to free it for removal, unless
the part being heated is already worn or damaged beyond
C repair and no additional damage will occur to other parts.
5. In general, hoist is designed to permit easy disassembly and
Chain assembly. The use of heat or excessive force should not be
Stopper required.
(241) 6. Keep the work area clean to prevent dirt and other foreign
E matter from getting into bearings and other moving parts.
7. All seals and O rings should be discarded once they have
been removed. New seals and O rings should be used when
assembling the hoist.
8. When grasping a part in a vise, always use leather or copper
Bottom covered vise jaws to protect the surface of part and help
Block
prevent distortion. This is particularly true of machined
surfaces, threaded members and housings.
Weld on perpendicular 9. Do not remove any part which is press fit in or on a
chain links must face subassembly unless the removal of that part is necessary for
away from sheaves repairs or replacement.
Weld on flat chain links 10. To avoid damaging bearings during hoist assembly or
must face away from disassembly always tap or press on bearing inner race for
hoist motor side shaft fit bearings or outer race for bore fit bearings.
Geared Trolley Disassembly

(Dwg. MHP0331)
5. Cut new load chain to length. Load chain must have an even 1. Remove capscrews (236), lockwashers (142) and separate
number of links (first and last links must be at 90 to each trolley drive assembly from side plate (184).
other). Refer to Dwg. MHP1990 on page 26. 2. Remove capscrews (178) and remove power head assembly.
6. Remove pins (46) and (47) which anchor load chain to power 3. Remove capscrews (157), lockwashers (158), cap (169) and
head assembly. bracket (175) from trolley brackets (177).
7. Using a C link which is the same size as load chain join new 4. Remove cotter pins (173) and tap pins (174) out of
load chain to free end on old load chain taking care that weld suspension yokes (170). Note position of spacers (156) for
on perpendicular standing links on new load chain are facing reassembly.
away from hoist load sheave. 5. Separate side plates (150) and remove suspension yokes
(170).
6. Remove retainer ring (155) and pull wheels (151) or (179)
from side plates.
7. Remove oil seal (152) and retainer ring (153) from wheels
(151) or (179). Press bearing (154) out of wheels (151) or Hoists with serial numbers lower than HL0510992 used O
(179). Refer to Dwg. MHP0414 below. rings on brake piston (7). Parts are not interchangeable. If
brake piston requires replacement refer to Hoist Upgrades
Bearing ReplacementTrolley Wheels on page 81 for kit.
When any part of friction disc thickness measures 0.072 in.
(1.83 mm) or less, or if oil groove pattern is not clearly visible,
friction discs must be replaced.
9. Remove brake hub assembly, brake discs (23) and friction

discs (22).
10. Remove capscrews (25) and pry brake housing (27) from
frame (36).
11. If brake hub must be disassembled for inspection or repair
remove retainer ring (9) and washer (10) from shaft (12).
Carefully tap or press bushing (18) out of back side. Take
sprag clutch (19) out of brake hub (20).
If sprag clutch (19) is removed from brake hub (20), use

extreme care as individual sprags will fall out and may be lost.
Reposition power head assembly vertically so brake end is down.
12. Remove capscrews (66) and pry complete reducer assembly

from frame (45). Separate housings and ring gears only if O
rings are being replaced or gear teeth in ring gears are
damaged.
13. If housings are separated remove thrust washer (74),
planetary assembly (73) and sun gear (72).
(Dwg. MHP0414) 14. Remove remaining planetary assemblies (64), (60) and sun
gear (63).
15. Remove capscrews (35) and separate frames (36), (45) and
Power Head Disassembly (82). Frame (82) is used in 37-1/2 and 50 ton units only.
16. Remove drive sheave (40). Remove capscrews (25) and lift
Refer to Dwgs. MHP0353 on page 40 and MHP0359 on page 42. stripper (43) from frames.
1. Disconnect all hoses from hoist motor. On trolley mounted 17. Remove capscrews (39) and inserts (38) from frames.
hoists remove power head assembly from trolley. Drain oil 18. Pull bearings (32) from drive sheave (40) if bearing or seal
from reducer, brake and motor assemblies. Position power replacement is required.
head assembly vertically so brake end is up. Remove valve
and manifold assembly.
2. Remove capscrews (468) and lockwashers (54) and pry Top Hook Disassembly
motor assembly (450) from adapter (2). Set motor assembly
to one side for later disassembly. Refer to Dwgs. MHP0344, MHP0345, MHP0346 and MHP0347
3. Remove capscrew (48), nut (56), washers (49), bushing (50), on page 66.
spacer (87) and limit arm (52). 1. Remove hoist from mounting structure.
4. On trolley mounted hoists remove capscrews (81) and plate 2. To remove hook and plate assembly (hook cannot be
(80). On hook mounted hoists remove top hook assembly removed before hook plate) remove capscrews (283) and
(149). (178) to separate hook plate assembly from power head. On
5. Carefully loosen each of the eight capscrews (1) 4 or 5 turns HA2-012 hoists capscrew (284) must also be removed.
each progressively around adapter (2) until brake spring 3. To remove hook (408) from hook plate (280) drive out roll
compression is relaxed. Do not allow adapter to become pin (406) and remove nut (405) from threaded hook end.
cocked during removal. 4. Remove hook (408) and bearing (407) from hook plate (280).
6. When brake spring compression is relaxed remove capscrews
(1), adapter (2) and brake springs (5). Bottom Block Disassembly
7. Remove cylinder (14) and brake piston (7) as an assembly
from brake housing (27). HA2-012 Hoist
8. Tap brake piston (7) out of cylinder (14) and remove seals (6) Refer to Dwg. MHP0314 on page 69.
and (8). 1. Always make sure load chain is removed before disassembly.
2. Remove capscrews (402) and nuts (403) securing hook
blocks (400). Pry hook blocks (400) apart.
3. Drive out pin (406) and remove nut (405) on threaded hook
section. Remove bearing (407).
4. Remove pin (414).
HA2-025 Hoist 6. Pull the crankshaft assembly (473) with attached connecting
Refer to Dwg. MHP0315 on page 69. rods (459) out of the motor housing (463) by shifting the
1. Always make sure load chain is removed before disassembly. connecting rods (459) to clear the cylinder holes. The
2. Remove capscrews (402) and nuts (403) securing hook connecting rods (459) are joined through a common journal
blocks (400). Partially drive out dowel pins (412) and pry on the crankshaft and are held in place by connecting rod
hook blocks (400) apart. rings (474) on each side of the main rib.
3. Drive out pin (406) and remove nut (405) from threaded hook 7. To remove the connecting rods (459) from the crankshaft
section. Remove bearing (407). assembly (473).
4. Remove bearings (32), sheave (41) and quad seals (34) from 8. Loosen capscrew (166) and drive out the taper pin (479)
hook blocks (400). securing the counterbalance section to the crankshaft section.
9. Remove counterbalance section, then pull off connecting rod
HA2-037 Hoist rings (474), connecting rods (459), bushing (476) and sleeve
Refer to Dwg. MHP0316 on page 68. (475).
1. Always make sure load chain is removed before disassembly.
2. Remove capscrews (402) securing side block (400) to hook Trolley Drive Disassembly
center block (413) and pry hook block (400) from hook
center block (413). (Engagement of dowel pins (412) may Refer to Dwg. MHP0306 on page 64.
make removal difficult). 1. Remove capscrews (236) and lockwashers (70) then pull
3. If hook (408) is being removed it will be necessary to remove trolley drive assembly from trolley side plate (184).
side plate (415). Remove capscrews (402) and pry off side 2. Remove retainer ring (180) and drive gear (182) from shaft
plate (415). (Engagement of dowel pins (412) may make (208).
removal difficult.) 3. Remove capscrews (234) and lockwashers (233) from
4. Drive out pin (406) and remove nut (405) from threaded hook reducer adapter (232). Carefully pry reducer adapter (232)
section. Pull hook (408) from hook center block (413) and from housing (212).
remove bearing (407). 4. Remove spacer (230) and sleeve (229) from shaft (208).
5. Remove bearings (32), sheave (41) and O rings (410) from Remove oil seal (228) from reducer adapter (232). Pull shaft
hook block (400) and hook center block (413). (208) with worm gear (226) and bearing cones (205) from
housing (212).
HA2-050 Hoist 5. Remove motor adapter (220) from housing (212) with
Refer to Dwg. MHP0317 on page 68. bearing cup (218).
1. Always make sure load chain is removed before disassembly. 6. Remove four screws (200), cover (225) and cover shims.
2. Remove capscrews (402) securing hook blocks (400) to hook 7. Pull worm (214) from housing (212).
center block (413) and pry hook blocks (400) from both sides 8. Carefully pull bearing cones (217) from worm (214).
of hook center block (413). (Engagement of dowel pins (412) 9. Remove oil seal (219) from motor adapter (220).
may make removal difficult). 10. Pull bearing cup (218) out of cover (225).
3. Drive out pin (406) and remove nut (405) from threaded hook 11. Remove screws (200), cover (202) and gaskets (203) from
section. Pull hook (408) from hook center block (413) and housing (212).
remove bearing (407). 12. Remove worm gear (226) from shaft (208).
4. Remove bearings (32), sheaves (41) and quad seals (34) from 13. Remove bearing cone (205) and spacer (206).
hook blocks (400) and hook center block (413).
Trolley Drive Piston Motor Disassembly

Motor Disassembly
Refer to Dwg. MHP0381 on page 58 and Dwg. MHP0415 on page
Refer to Dwg. MHP0359 on page 42 and MHP0382 on page 44. 54.
1. Remove plug (486) and drain oil into a suitable container.
2. Remove capscrews (500), lockwashers (54) and valve cap
(502) from manifold (504). Pull out rotary valve (467) and
rotary valve bushing (466). Remove valve and manifold Follow disassembly instructions 1 through 12 and 17 through
assembly. 19 for hoist with serial numbers below HL-19300.
3. Support the weight of motor assembly (450). Remove Follow disassembly instruction 1 through 8 and 13 through
capscrews (468) and lockwashers (54), and pull from power 19 for hoist with serial numbers above HL019300.
head assembly.
1. Remove motor assembly (329) from trolley drive assembly
and move to a clean work surface.
2. Drain oil from motor housing (369) into a suitable container
Air Motor weighs approximately 80 lbs (37 kgs). Adequately by removing pipe plug (379).
support air motor before removing mounting capscrews. 3. Disassembly and reassembly will be simplified if crankshaft
(354) is held vertically in a soft-jawed vise or supported
4. Remove the capscrews (55), copper washers (452) and vertically on suitable packing, to raise crankshaft clear of
cylinders (453) from the motor housing (463). work surface.
5. Rotate the crankshaft assembly (473) to bring each wrist pin 4. Remove capscrews (334) and valve assembly (625).
assembly (457) above the motor housing (463), then push out 5. Remove capscrews (340) and cover (339).
the wrist pin assembly (457) and remove piston assembly 6. Remove capscrews (334) and rotary valve housing (332).
(455). Plugs (456) pressed into ends of wrist pins (457) 7. Support rotary valve housing evenly on flange face. Tap
should not be removed. To avoid breakage use extreme care rotary valve (337) out of rotary valve housing (332) from
when removing compression rings (454). inside outwards. Normal clearance between rotary valve
(337) and rotary valve housing (332) is 0.002 to 0.003 in. accumulated dirt and sediments on the gears and frames. If
(0.05 to 0.075 mm). Replace parts if wear is excessive. bushings have been removed it may be necessary to carefully
8. Remove retaining ring (335) and bearing (336) from rotary scrape old Loctite from the bearing bores. Dry each part using
valve housing (332). low pressure, filtered compressed air.
9. Remove capscrews (334) and cylinders (375) from motor
housing (369). When all four piston assemblies (373) have
been removed, remove bearing (352), ring (351) and spacer
(353). Bearings that are loose, worn or rotate in the housing must
10. Remove setscrew (346) and balance weight (345). Remove be replaced. Failure to observe this precaution will result in
spacer washers (347) and note thickness for subsequent additional component damage.
reassembly. Do not use trichloroethylene to clean parts.
11. Remove ring (351) now exposed. If trolley suspension yoke bushings (176) are loose or worn
12. Remove capscrews (334) and cylinders (375) from motor they must be replaced. Failure to observe this precaution will
housing (369). Slide connecting rod (349) along the bearing result in additional component damage.
(352) towards open end of motor housing (369), until
connecting rod slipper end is clear of the ring (351). Push out Inspection
the complete piston assembly, from inside motor housing
(369). All disassembled parts should be inspected to determine their
13. Remove capscrews (334) and cylinders (375) from motor fitness for continued use. Pay particular attention to the following:
housing (369). 1. Inspect all gears for worn, cracked, or broken teeth.
14. Remove washers (380) and note thickness for subsequent 2. Inspect all bushings for wear, scoring, or galling.
reassembly. 3. Inspect shafts for ridges caused by wear. If ridges caused by
15. Remove pins (384) and connecting rod (382) from wear are apparent on shafts, replace the shaft.
connecting rod (381). Slide connecting rod (381) from along 4. Inspect all threaded items and replace those having damaged
with bearing (383) through open end of motor housing (369). threads.
16. remove bearing (383). 5. Measure the thickness of the friction discs (22). If the friction
17. Remove retainer ring (366) and spacer (367) and shims (365). discs are less than 0.072 in. (1.83 mm) or if oil groove pattern
18. Press out crankshaft (354), aligning oil thrower with opening is not clearly visible replace the friction discs (22).
in motor housing (369). 6. Check mufflers (107), (266) and (566) for damage or
19. Clean off jointing compound from rotary valve housing bore excessive dirt.
(332) and outside of valve bush (136) with Hermetite 7. Inspect yoke bushings (176) for wear, scoring, or galling. If
1325B solvent or similar. wear exceeds discard dimensions in Table 9 replace bushings.
Trolley Drive Vane Motor Disassembly Table 11 Bushing (176) Inspection Specifications
Bushing Original Bore Discard Bore

Refer to Dwg. MHP0379 on page 56. Hoist Item Size Size
1. Remove capscrews (262) from cover (260) and pull vane Model No. Part
No. in. mm in. mm
motor assembly from trolley drive assembly.
2. Remove capscrews (273) and (274). Pull pilot control valve HA2-012 21833 3.253 82.6 3.315 84.2
(270) from valve manifold (267).
HA2-025 16187 3.437 87.3 3.500 89
176
HA2-037
16190 4.500 114.3 4.562 116
Pilot control valve (270) repair should be limited to removal HA2-050
of end caps, bushings and plunger to replace the O rings.
Refer to Dwg. MHP0407 on page 55. 8. Check bearings for ease of rotation and wear. Replace
bearings if rotation is rough or bearings are excessively worn.
3. Remove capscrews (268) and valve manifold (267) from 9. Check the sprag clutch assembly for wear, flat spots on the
cylinder (256). sprags or damage. If any of these conditions exist, replace
4. Remove capscrews (265) and pry cover (260) from cylinder parts.
(256). 10. Inspect sprag clutch wear area on brake hub (20) and on
5. Remove cover (253) from cylinder (256). brake shaft (12) for ridges or galling. If either condition exists
6. Slide shaft and rotor (259) from cylinder (256). Be careful replace parts.
not to drop or damage vanes (258) during this operation.
7. Remove capscrews (264) and cap (263) from cover (260).
8. Tap bearings (251) from motor adapter (220) and cover
(260). If brake hub (20), sprag clutch (19) or brake shaft (12)
require replacement, it is recommended that all three parts be
replaced at the same time.
Cleaning, Inspection and Repair
Use the following procedures to clean, inspect, and repair the Repair
components of the hoist.
Actual repairs are limited to the removal of small burrs and other
minor surface imperfections from gears and shafts. Use a fine
Cleaning stone or emery cloth for this work.
Clean all hoist component parts in solvent (except for the friction
discs). The use of a stiff bristle brush will facilitate the removal of
1. Worn or damaged parts must be replaced. Refer to the 9. Pre-assemble gear reducer outer housings. Install two
applicable parts listing for specific replacement parts capscrews 180 apart in cover (78) and place cover on work
information. bench. Lubricate and install O rings (68) on both sides of
2. Inspect all remaining parts for evidence of damage. Replace ring gear (77) then place on cover (78) so capscrews holes are
or repair any part which is in questionable condition. The aligned.
cost of the part is often minor in comparison with the cost of 10. Tap dowels (76) partially into spacer (75) then install spacer
redoing the job. (75) on ring gear (77). Lubricate and install O rings (68) on
3. Smooth out all nicks, burrs, or galled spots on shafts, bores, both sides of ring gear (69). Install ring gear on spacer (75).
pins, or bushings. 11. Install input housing (65) and remaining capscrews (79).
4. Examine all gear teeth carefully, and remove nicks or burrs. Apply a small amount of Loctite 242 on capscrews (79) and
5. Polish the edges of all shaft shoulders to remove small nicks torque to 32 lb. ft. (44 Nm). Avoid damaging Orings during
which may have been caused during handling. assembly. Tap dowel pins (83) into cover (78) until flush.
6. Remove all nicks and burrs caused by lockwashers. 12. Install large planetary assembly (60) on spline of sheave (40).
7. Replace all seals, Orings and gaskets. Apply a small amount of grease to thrust washer (62) and
press into sun gear (63). Install sun gear (63).
13. Install planetary assembly (64) so it engages with sun gear
Assembly Instructions
(63). Apply a small amount of grease to thrust washer (62)
and press into sun gear (72) and install sun gear (72).
Trolley Assembly 14. Install planetary assembly (73) so it engages with sun gear
(72).
Refer to Dwg. MHP0282 on page 62. 15. Install shaft (30) through center of planetary assemblies so
1. Press bearings (154) into wheels (151) or (179). Install gear end meshes with planet gears in planetary assembly
retainer rings (153) and oil seals (152) in wheels (151) or (73).
(179). 16. Lubricate and install O rings (57) on ring gear (58).
2. Install wheels (151) or (179) on side plates. Install retainer 17. Install ring gear on frame (45). Place thrust washer (74) on
rings (155). the end of shaft (30).
3. Coat suspension yoke ends with grease then install side plates 18. Install pre-assembled outer housings over planetary
(150) or (184) on suspension yokes (170). Install spacers assemblies so fitting (71) and breather (421) are at the top.
(156) in same location as noted during disassembly. (The breather hole can be determined as being the hole which
4. Install pins (174). Secure pins (174) with cotter pins (173) will be directly in line with a dowel pin when capscrew holes
and bend ends apart. are aligned.)
5. Install brackets (177) in suspension yokes (170). Install cap 19. Drive dowel pins (59) through flange into ring gear (58) and
(169) and bracket (175) with capscrews (157) and frame (45).
lockwashers (158). 20. Install capscrews (66) with Loctite 242 and lockwashers
6. Install power head assembly between brackets (177). Install (142) to secure reducer housing to frame (45). Torque
capscrews (178), with a small amount of Loctite 242 on the capscrews (66) to 85 ft.-lb (115 Nm).
threads and torque to 525 ft.-lb (712 Nm)
7. Install trolley drive assembly on side plate (184). To assist parts assembly it is recommended that the power head be
repositioned in a vertical position with the motor end up.
Power Head Assembly
21. Lubricate and install O ring (4) in shoulder recess of brake
Refer to Dwg. MHP0353 on page 40. housing (27). Install brake housing (27) on frame (36).
1. Install insert (38) with screws (39) using Loctite 242 in Secure with capscrews (25) and torque to 85 ft.-lb (115 Nm).
frame (36) (motor side). Lubricate and install O rings (33) Position brake housing (27) so the two valve mounting pads
in large bore of frames (36) and (45). are located at the bottom.
2. Install seals (34) in groove on both sides of sheave(s) (40). 22. Install pipe plugs (26) and (28) in brake housing (27).
Press a bearing (32) onto both sides of load sheave(s) (40). 23. Press one bushing (18) into brake hub (20). Install shaft (12)
3. Install assembled load sheave (40) into frame (45) so splined into assembly. Slide sprag clutch (19) onto shaft (12) and into
end enters first. Be careful not to damage O ring (33) in brake hub (20). Press in second bushing (18). Ensure sprags
bore of frame (45). are assembled all in the same direction and springs are not
4. Install chain stripper (43) on frame (45) and secure with twisted or out of location. Sprag clutch must be installed so
capscrews (25). Apply a small amount of Loctite 242 on the that the end with the stamped arrow is nearest the motor
threads and torque to 110 ft.-lb (149 Nm). adapter. Check that shaft rotates freely counterclockwise
5. Tap dowel pins (37) into frame (45). Install a short length of when looking at the non splined end of brake hub (20) and
22 mm starter chain around load sheave. locks up instantly in the clockwise direction. Check rotation
6. Install insert (38) in frame (45) with screws (39) using of shaft in free sprag clutch direction is smooth. If tightness
Loctite 242. or rough rotation exists disassemble and inspect.
7. Install frame (36) to frame (45) so it positions over the sheave 24. Install washer (10) and retainer ring (9) on shaft (12). Press
(40) and bearing (32). Clamp frames (36) and (45) together bearing (24) onto shaft (12).
with capscrews (35). Use Loctite 242. Torque capscrews to 25. Starting with a friction disc (22) and alternating with brake
400 ft.-lb (542 m). On 37-1/2 and 50 ton units also install discs (23), install friction discs (22) and brake discs (23) in
frame (82) and idle sheave (41). brake housing (27).
8. Install spacer (44) over sheave spline. 26. Install motor coupling (29) on the end of the shaft (12) and
install assembled shaft and brake hub assembly through
To assist parts assembly it is recommended that the power head be brake. Remove pipe plug (26) in brake housing (27) to check
positioned in a vertical position with the gear end up. that brake hub is properly engaged with each friction disc
(22). Use of artificial light will aid inspection. Line up plates
and tap gently on shaft if bearing (24) is tight in brake 30. Install assembled brake piston (7) on brake housing (27) so
housing (27). brake port hole is positioned on the right hand side and
27. On older hoists install screws (13), seal washers (16) and nuts machined pad is at the bottom.
(17) in two locations in the brake cylinder (14). Check that 31. Set brake springs (5) into holes provided in the brake piston
screws (13) are slightly below the cylinder surface on the (7).
brake piston (7) side. Screws should extend 1/2 in. (12.7 mm) 32. Install oil seal (3) in motor adapter (2) so lip of seal (3) is
from the face of the brake cylinder (14). Adjust both screws toward the brake. Lubricate and install O ring (4) in
evenly. Refer to Dwg. MHP0397 below. Newer hoists are not recessed groove in motor adapter (2).
equipped with and do not require screws (13). 33. Install motor adapter (2) on brake cylinder (14) so the
threaded hole, which is located dead center between the
counterbored mounting bolt holes, is located at the bottom (6
oclock position.)
Adjustment of screws (13) may disengage brake. Load can 34. Secure motor adapter (2) with capscrews (1) and torque to 33
drop without warning. Refer to Dwg. MHP0397 on page 34. ft.-lb (45 Nm). Pull motor adapter down evenly to compress
the brake springs (5). Tighten capscrews 4 to 5 turns each
Older style hoists only progressively round the adapter (2). Do not allow motor
adapter (2) to become cocked.
1/2 in.
35. Install gasket (470) on motor adapter (2). Install motor
(12.7 mm) assembly (450) so spline on shaft (12) engages motor.
Position motor so drain plug (486) is located at the bottom.
Secure with capscrews (468), lockwashers (54). Torque
capscrews (468) to 36 ft.-lb (49 Nm).
Screw 36. On trolley mounted hoists a cover plate is used instead of the
(13) top hook assembly. Install plate (80) with gasket sealant
Loctite 515 and capscrews (81).
37. Install bushings (50) for limit paddle (52) in frames (36) and
(45). Tap bushings (50) in until flush.
38. Install limit paddle (52) with capscrew (48), bushing (50),
spacer (87), washers (49) and nut (56).
Installing Valve Assembly

1. Pre-assemble valve and manifold assembly and install on the
underside of brake housing (27) with capscrews (505) and
washers (309). Capscrews must be finger-tight only.
(Dwg. MHP0397) 2. Ensure rotary bushing (466) is installed in manifold (504)
and slides freely in the bore. Maximum allowable clearance
28. Lubricate and install seals (6) and (8) on brake piston (7). of rotary valve is 0.010 in. (0.254 mm). Install valve cap
Seal lips must face each other. Refer to Dwg. MHP0139. (502) in manifold (504).
Install O ring (15) in recessed groove in brake cylinder (14). 3. Install capscrews (500) and washers (501) that attach
manifold (504) to motor assembly (450). Torque manifold
capscrews to 29 ft.-lb (39 Nm) before finally tightening valve
to brake capscrews.
Hoists with serial numbers lower than HL0510992 used O
rings on brake piston (7). Parts are not interchangeable. If Power Head Piston Motor Assembly
brake piston requires replacement refer to parts section for
upgrade kit. Refer to Dwg. MHP0359 on page 42.
1. Press bearing (465) onto crankshaft counterbalance. Place the
connecting rods (459) on the bushing (476) and hold them in
place with the two connecting rod rings (474). Install
connecting rod rings (474) so the chamfered side is next to
the connecting rod (459).
2. Place the sleeve (475) on the crankshaft (473), then install the
connecting rod (459) assembly on the crankshaft (473).
3. Secure the crankshaft counterbalance to the crankshaft with
taper pin (479) and tighten capscrew (166).
4. Align bearing (465) in the bore of the motor housing (463)
and tap crankshaft assembly in place until each connecting
rod (459) end aligns with a cylinder hole.
5. Check the fit of each compression (454) and oil ring (458) by
placing one ring at a time in the cylinder (453), making sure
it is not canted or tilted in relation to the cylinder wall. With a
(Dwg. MHP0139) feeler gauge, measure the ring gap. Ring gap should be 0.003
to 0.004 in. (0.75 to 0.1 mm).
29. Apply a thin film of grease to bore of brake cylinder (14) and 6. Make sure that compression rings (454), oil rings (458), and
install brake piston (7). pistons (455) are perfectly clean. Carefully place oil rings
(458) and compression rings (454) in their respective grooves bearings in housing (212). Tap or press second bearing cup
on the pistons (455). The plain compression ring (454) must (218) into housing bore.
be placed nearest the head of the piston (455). The oil ring 5. Tap or press bearing cup (204) into cover (202). Place gaskets
(458) with several oil channels must be placed nearest the (203) on shoulder of cover (202).
skirt of the piston (455). 6. Install cover (202) and gaskets on housing (212). Secure with
six screws (200).
Do not interchange the compression and oil rings.

Rotate cover (202) so oil level hole is just below the 3 oclock
7. Compression and oil ring joints (gaps) should be staggered position before installing.
and positioned so that joints (gaps) do not coincide with wrist
pin (457) openings. Refer to Dwg. MHP0224 on page 35. 7. Install keys (207) in shaft (208) and press worm gear (226)
onto shaft making sure it aligns with and fits over the keys
Piston Head (207).
8. Install spacers (206) and (227) on shaft. Press bearing cones
(205) on shaft (208) until they contact the spacers.
9. Install shaft and worm gear assembly in gear housing (212)
Compression Ring Groove so worm gear teeth mesh with worm.
10. Tap or press bearing cup (204) into reducer adapter (232).
11. Install reducer adapter (232) and gaskets (203) on housing
(212). Secure with capscrews (234) and lockwashers (233).
Check to see if shaft (208) turns freely without binding or
Ends of compression rings moving from side to side.
must be staggered to avoid
alignment with wrist pin
opening and ends of oil ring
Wrist pin opening Adjust gaskets (203) to provide zero side to side motion of the
worm gear assembly.
Colored ends of oil ring 12. Install oil seal (219) in motor adapter (220) so oil seal lip
must butt together, faces into the housing.
and must not overlap 13. Install oil seal (228) in reducer adapter (232) so lip faces into
the housing.
14. Install motor adapter (220) on housing (212) and secure with
capscrews (200) (piston motor) or capscrews (234) (vane
Install one compression
motor).
ring on either side of oil ring
15. Install spacer (230) on shaft (208). Take care not to damage
the lip of oil seal (228).
(Dwg. MHP0224) 16. Install key (183) in shaft (208). Slide drive gear (182) onto
shaft (208) so it aligns with and fits over key (183).
8. Rotate the crankshaft so each connecting rod (459) in
succession will project enough beyond the motor housing
(463) to permit inserting the wrist pin (457) through the
On 12 and 25 ton hoists, drive gear (182) is positioned with its
piston (455) and connecting rod (459).
recessed surface toward the reducer adapter (232). On 37.5
9. After each piston (455) is assembled to its connecting rod
and 50 ton hoists, the drive gears flat surface is positioned
(459), install a gasket (460) and cylinder (453).
toward the reducer adapter. Refer to Dwg. MHP1389 on page
10. Slide each cylinder (453) over the piston (455), guiding it
36.
carefully over the compression and oil rings. Note that the
cylinder has four tapered ears around the skirt of the piston
17. Install retainer ring (180).
which serve as ring compressors to aid in installation. The
cylinder should fit into place by tapping lightly. If force is
required, there may be an alignment problem which must be
corrected before continuing. The first bearing cup (218) must be flush against cover (225)
11. Secure cylinders (453) to the motor housing (463) with for accurate backlash reading.
capscrews (55) and lockwashers (452) and tighten uniformly.
18. Rotate worm to check for tight spots and to see if backlash is
Trolley Drive Assembly between 0.004 to 0.008 in. (0.10 to 0.20 mm). Adjust shims
(222, 223 or 224) until correct backlash is achieved.
1. Press or tap bearing cup (218) into housing (212) on cover
(225) side.
2. Place gaskets (222, 223 and 224) on shoulder of cover (225).
3. Install cover (225) and gaskets on housing (212). Secure with
four countersunk screws (200).
4. Press bearing cones (217) onto worm (214). Ensure bearings
are fully seated against worm shoulder. Install worm and
7. Assemble the connecting rods (381 and 382) to the pistons
(373). Ensure retainer rings (378) are fully seated in the
grooves on wrist pins (377). Install the oil rings (370) and
compression rings (372) on the pistons (373). Check gap on
rings is 0.003 to 0.004 ins. (0.076 to 0.1 mm). Note: The
upper compression ring (372) is plain and the lower oil ring
(370) acts as an oil control.
8. Carefully install the cylinders (375) on pistons. Do not use
force during this procedure and avoid damaging oil rings
(370) and compression rings (372).
9. Install a gasket (374) on each cylinder. Insert the piston
assemblies into the motor housing (369) bores, with the
connecting rod (349) positioned correctly to seat on the
needle bearing (352). When the slipper end is seated on the
bearing (352), slide the connecting rod (349) inward to enter
the ring (351). Install capscrews (334) so they are finger tight.
When all cylinders have been installed tighten capscrews
(334) evenly.
10. Install second ring (351) with the radius of the bore
innermost. Install spacer (347). Rotate crankshaft 360 to
ensure parts are correctly fitted.
11. Install rotary valve (337) in rotary valve housing (332). Press
bearings (336) and (338) into rotary valve housing (332).
Install retainer ring (335).
12. Install balance weight (345). Secure balance weight with
setscrew (346).
13. Rotate the crankshaft (354) until the balance weight is at the
bottom dead center position, rotate the rotary valve (337)
until the balance weight is at the bottom position.
Follow assembly instruction 1 through 12 and 17 through 19

for hoist with serial numbers below HL019300.
14. Install gasket (331) on rotary valve housing then assembly to

motor housing and secure with capscrews (334). Rotate the
output shaft in both directions and viewing the rotary valve
(337) through the exhaust cover (339) opening ensure that the
valve is correctly following the output shaft direction. This
checks that both crank and valve slot are correctly engaged.
15. Install cover (339) and secure with capscrews (340).
Trolley Drive Vane Motor Assembly

1. Install seal (252) in cover (253) so seal (252) is flush with
(Dwg. MHP1389) cover face. Seal lip must face towards motor.
2. Install seal (254) in cover (253) so seal lip faces towards the
Trolley Drive Piston Motor Assembly motor.
3. Install bearings (251) in covers (253) and (260) using a small
Refer to Dwg. MHP0381 on page 58. amount of Loctite 609 on the outside bearing diameter. Pack
1. Install oil seal (358) and bearings (356) on crankshaft (354). grease between seal (252) and bearing (251) in cover (253)
Lip of oil seal (358) must face into motor housing (369). Tap filling the cavity.
assembled parts into position in flange plate (363). 4. Install cap (263) on cover (260) with capscrews (264).
2. Install shims (365), spacer (367) and retainer ring (366) on 5. Apply gasket sealant to the motor cylinder (256) surface for
the end of crankshaft (354). cover (253). Use a minimal amount but enough to create a
3. Lubricate and install O ring (368) on flange plate (363). total seal. Install cover (253) to motor cylinder (256).
Align oil-thrower on crankshaft (354) with opening in motor 6. Install dowels (255) to align cover (253) with motor cylinder
housing (369) and assemble flange plate to motor housing (256).
(369) with capscrews (364).
4. Clamp the crankshaft vertically in a soft-jawed vice, shaft
down.
Replacement rotors and cylinders must be supplied as
5. Install spacer (353) so radius on inside bore of spacer is
matched sets in order to maintain the proper end running
toward the crank pin shoulder.
clearance of 0.002 to 0.004 in. (0.05 to 0.1 mm).
6. Install ring (351) and bearing (352). Radius on inside bore of
ring (351) must face outward.
7. Apply a film of ISO VG 32 (10W) oil to the cylinder wall. On 25, 37-1/2 and 50 ton hoists it is suggested that a short length
Install shaft and rotor (259) in cylinder (256). Place one vane of 22 mm chain be available when assembling the bottom block
(258) in each rotor slot so that the long straight vane edge is assembly. The chain should be installed around the sheave prior to
towards the cylinder wall. final assembly of the block sections. If this procedure is followed
8. Apply gasket sealant to the motor cylinder (256) surface for it will simplify the installation of the load chain later.
cover (260). Use a minimal amount but enough to create a
total seal. Install motor cover (260) to motor cylinder (256). HA2-025 Hoist
Align cover with dowel pin (255) holes and carefully tap Refer to Dwg. MHP0315 on page 69.
cover (260) into position until flush with the cylinder (256). 1. Pack bearing (407) with grease and install bearing (407) on
9. Install dowel pins (255) in cover (260) and cylinder (256). hook (408). Screw nut (405) onto threaded shank of hook
The relationship of the motor end covers (253) and (260) (408).
with motor cylinder (256) is very critical. In order to provide 2. Place hook with bearing and nut in one half of hook block
proper running clearance for the rotor, the rotor has to run (400) and tighten nut until parts clamp hook block. Back nut
exactly parallel with the cylinder (256) and perpendicular to off until first dowel pin (406) hole is lined up. Install pin
the covers. Dowel pins (255) are used to locate these parts (406). Do not attempt to drive dowel pin (406) into nut until
within 0.007 in. (0.18 mm) of correct alignment. holes are aligned or threads on hook (408) will be damaged.
10. Install capscrews (265). The correct alignment is established 3. Lubricate and install quad seals (34) on sheave (41) in
by snugging down the capscrews (265) which retain the grooves provided. Using a press against the inner race of
covers to the cylinder and checking the motor for free bearing (32) press bearings (32) onto sheave (41). Repeat the
turning. If any drag is noted, tap around the edges of the process for the opposite side.
motor covers until the shaft turns freely. Tighten capscrews to 4. Install the assembled sheave in the bottom block. Pack
30 in-lbs. (3.3 Nm). cavities in hook blocks (400) with grease and place hook
11. Tap shaft key (257) into the keyway on shaft and rotor (259). blocks together.
12. Install valve manifold (267) on cylinder (256) with capscrews 5. Check dowel holes are lined up. Tap dowels (412) into
(268). position. Secure hook blocks (400) with capscrews (402) and
13. Lubricate and install O rings (269) in recesses in pilot nuts (403) using Loctite 242. Torque capscrews (402) to
control valve (270). Install pilot control valve (270) on valve 310 lb-ft. (420 Nm).
manifold (267) secure with capscrews (273) and (274). 6. Install grease fittings (172) and fill block with grease. Refer
14. Install mufflers (266) in valve manifold (267). to LUBRICATION section on page 21.
Top Hook Assembly HA2-037 Hoist

Refer to Dwgs. MHP0344, MHP0345, MHP0346 and MHP0347 1. Pack bearing (407) with grease and position bearing (407) in
on page 66. hook center block (413) cavity.
1. Install hook (408) and bearing (407) in hook plate (280). 2. Install threaded hook end into hook center block (413) and
2. Install nut (405) on threaded hook end until snug. Back nut through bearing (407).
(405) off until first dowel pin (406) hole is lined up. Install 3. Install nut (405) being careful that threads are not crossed.
pin (406). Do not attempt to drive dowel pin (406) into nut Tighten nut (405) until snug then back nut (405) off until first
until holes are aligned or threads on hook (408) will be dowel pin (406) hole is lined up. Install dowel (406) until
damaged. flush with nut (405) diameter. Do not attempt to drive dowel
3. Install hook plate assembly on power head with capscrews pin (406) into nut until holes are aligned or threads on hook
(178) or (283). On HA2-012 hoists also install capscrew (408) will be damaged
(178). Torque to 115 ft.-lb (156 Nm). 4. Lubricate and install O rings (34) on sheave (41) in grooves
4. Install hoist on mounting structure. provided. Using a press against the inner race of bearing (32)
press bearings (32) onto sheave (41). Repeat the process for
the opposite side.
Bottom Block Assembly 5. Install the assembled sheave in the hook center block (413).
Pack cavities in hook center block (413) and hook block
HA2-012 Hoist (400) with grease.
Refer to Dwg. MHP0314 on page 69. 6. Install hook block (400) and side plate (415) over bearings
1. Pack bearing (407) with grease and install bearing (407) on (32) and sheave (41) making sure dowel holes are lined up.
hook (408). Screw nut (405) onto threaded shank of hook Tap dowels (412) into position. Secure hook block and side
(408). plate with capscrews (402) using Loctite 242. Torque
2. Place hook with bearing and nut in one half of hook block capscrews (402) to 310 ft.-lb (420 Nm).
(400) and tighten nut until parts clamp hook block. Back nut 7. Install grease fittings (172) and fill block with grease. Refer
off until first dowel pin (406) hole is lined up. Install pin to LUBRICATION section on page 21.
(406). Do not attempt to drive dowel pin (406) into nut until
holes are aligned or threads on hook (408) will be damaged. HA2-050 Hoist
3. Install pin (414). Refer to Dwg. MHP0317 on page 68.
4. Pack cavities in hook blocks (400) with grease and place 1. Pack bearing (407) with grease and position bearing (407) in
hook blocks (400) together. Apply a small amount of hook center block (413) cavity.
Loctite 242 to capscrews threads and install capscrews 2. Install threaded hook end into hook center block (413) and
(402) and nuts (403) to clamp parts. Torque capscrews to 205 through bearing (407).
lb-ft. (278 Nm). Check that hook swivels freely. 3. Install nut (405) being careful that threads are not crossed.
5. Install grease fitting (172) and fill block with grease. Refer to Tighten nut (405) until snug then back nut (405) off until first
LUBRICATION section on page 21. dowel pin (406) hole is lined up. Install dowel (406) until
flush with nut (405) diameter. Do not attempt to drive dowel
pin (406) into nut until holes are aligned or threads on hook
Load Test
(408) will be damaged
4. Lubricate and install quad seals (34) on sheaves (41) in Prior to initial use, all new, extensively repaired, or altered hoists
grooves provided. Using a press against the inner race of shall be load tested by or under the direction of personnel
bearing (32) press bearings (32) onto both sides of instructed in safety, maintenance and operation of this hoist. A
sheaves (41). written report must be maintained on record confirming the rating
5. Install the assembled sheaves in the hook center block (413). of the hoist.
Pack cavities in hook center block (413) and hook blocks 1. Operate the hoist fully in both directions without a load.
(400) with grease. Hoist must operate smoothly, without evidence of binding.
6. Install hook blocks (400) over bearings (32) and sheaves (41) Response to operating controls must be quick and accurate.
making sure dowel holes are lined up. Tap dowels (412) into 2. Place a 10% load on hoist and operate hoist fully in both
position. Secure hook blocks(400) with capscrews (402) directions. Hoist must operate smoothly, without evidence of
using Loctite 242. Torque capscrews (402) to 310 ft.-lb (420 binding. Response to operating controls must be quick and
Nm). accurate.
7. Install grease fittings (172) and fill block with grease. Refer 3. Dynamically load test hoist to 100% of its rated capacity in
to LUBRICATION section on page 21. accordance with ASME B30.16 standards. Hoist must
operate smoothly, without evidence of binding. Response to
operating controls must be quick and accurate.
Testing to more than 100% may be necessary to comply with

standards and regulations set forth in areas outside of the
USA.
HA2 HOIST DESCRIPTION DRAWING
(Dwg. MHP0422)
HA2 HOIST DRAWINGS AND PARTS TABLE OF CONTENTS
Description Page No.
Power Head Assembly Drawing (MHP0353) ...................................................................................................................................................40

Power Head Piston Motor Assembly Drawing (MHP0359) .............................................................................................................................42
Power Head Piston Motor Valve Assembly Drawing (MHP0382)...................................................................................................................44
Two Lever Pendant Assembly Drawing (MHP2235 and MHP2236) ..............................................................................................................46
Four Lever Pendant and Emergency Stop Assembly Drawing (MHP2237 and MHP2238)............................................................................48
Old Style Pendant with Emergency Stop Assembly Drawing (MHP0396)......................................................................................................50
Old Style Pendant without Emergency Stop Assembly Drawing (MHP1706).................................................................................................52
Trolley Piston Motor Valve Assembly Drawing (MHP0415)...........................................................................................................................54
Vane Motor Valve Assembly Drawing (MHP0407) .........................................................................................................................................55
Trolley Drive Vane Motor Assembly Drawing (MHP0379) .............................................................................................................................56
Trolley Drive Piston Motor Assembly Drawing (MHP0381) ...........................................................................................................................58
12 Ton Trolley Assembly Drawing (MHP1525)...............................................................................................................................................60
25 Ton and Larger Trolley Assembly Drawing (MHP0282) ............................................................................................................................62
Trolley Drive Assemby Drawing (MHP0306) ..................................................................................................................................................64
Top Hook Assemby Drawings (MHP0344, MHP0345, MHP0346 and MHP0347) ......................................................................................66
50 ton and 37-1/2 ton Bottom Block Assembly Drawings (MHP0317 and MHP0316)..................................................................................68
12-1/2 ton and 25 ton Bottom Block Assembly Drawings (MHP0314 and MHP0315)..................................................................................69
Chain Bucket Assembly Drawing (MHP1524).................................................................................................................................................70
Load Chain and Chain Stopper Drawing (MHP0399) ......................................................................................................................................71
Hose Assembly Drawings (MHP0425).............................................................................................................................................................72
Hull Bumper Assembly Drawings (MHP0431 and MHP0433).......................................................................................................................73
Rope Control Assembly Drawing (MHP1515).................................................................................................................................................74
Trolley Mount Piping Assembly Drawing (MHP1514)....................................................................................................................................76
Hook-Mount Lubricator-Filter Piping Assembly Drawing (MHP0601) ..........................................................................................................78
Mufflers Drawing (MHP1526)..........................................................................................................................................................................79
Label and Tag Parts Drawing (MHP1496)........................................................................................................................................................80
HOIST POWER HEAD ASSEMBLY PARTS DRAWING
Stamped 3
TOP 5 Old Style
6
7
8 13
1 9
12 17
2 14
4 16
14
18 86
10
BRAKE 20
32 PORT 22
23 26
33 15 25
34 35
36 86 19 27
18
37 38 29
24
39 26
41 4
50 34 28
52 33 26
32 82
56
37 37
38
50
39 32
(37.5 - 50 ton 33
87 49 ONLY) 34
25 51
37
50
48
40
34
33 81
32
38
39
80
57
45 58
57
60
63 44
62 421
64 65 25
71 142 43
66 68
50
69 68 48 59
72 47
62 46
73
67
76 68
77
68
67
78
30
79
75
74 83
(Dwg. MHP0353)
HOIST POWER HEAD ASSEMBLY PARTS LIST
Item Description Qty Part Item Description Qty Part

No. of Part Total Number No. of Part Total Number
1 Capscrew 8 71059901 48 Capscrew 1 71322143
2 Adapter 1 11954 49 Washer 2 52915
3 Oil Seal 1 50541 50 Bushing 2 (3) 52675
4 O Ring 2 52670 51 Stripper (37-1/2 and 50 ton) 1 13001
5 Spring 6 50751 Limit Arm Assembly
6 Seal 1 71107726 (includes items, 49-50, 56, 16219
7 Brake Piston * 1 22177 and 87 for 12-1/2 and 25 ton)
52 1
8 Seal 1 71107718 Limit Arm Assembly
(includes items, 49-50, 56, 17290
9 Retainer Ring 1 50810
and 87 for 37-1/2 and 50 ton)
10 Washer 1 50528
56 Nut 1 54661
12 Shaft 1 12009
57 O Ring 2 71106728
13 Capscrew** 2 71337505
58 Ring Gear 1 71068639
14 Cylinder 1 11951
59 Pin 3 71106710
15 O Ring 1 52730
60 Planetary Assembly 1 71068621
16 Seal** 2 54655
62 Thrust Washer 2 71068647
17 Nut** 2 71328355
63 Sun Gear 1 71068613
18 Bushing 2 12011
19 Sprag Clutch 1 52666
65 Input Housing 1 71068589
20 Brake Hub 1 12010
66 Capscrew 12 71267405
22 Friction Disc 5 12013
67 Plug 3 71068571
23 Brake Disc 4 12012
68 O Ring 4 52149
24 Bearing 1 52665
69 Ring Gear 1 71068548
25 Capscrew 4 71316525
71 Fitting, Bushing 1 54659
26 Plug 4 54912
72 Sun Gear 1 71068530
27 Brake Housing 1 11953
28 Plug 1 54292
74 Thrust Washer 1 52950
29 Motor Coupling 1 11999
75 Spacer 1 71068522
30 Drive Shaft 1 11998
76 Pin 2 71068472
32 Bearing 2 (4) 54483
77 Ring Gear 1 71068514
33 O Ring 2 (4) 54341
78 Cover 1 71068654
34 Seal 2 (4) 71007405
79 Capscrew 8 71106736
Capscrew (12-1/2 and 25 ton) 4 71322085
35 Plate (12-1/2 and 25 ton) 12844
Capscrew (37-1/2 and 50 ton) 5 71328769 80 1
Plate (37-1/2 and 50 ton) 17098
Frame (12-1/2 and 25 ton) 11844
36 1 81 Capscrew 4 71322184
Frame (37-1/2 and 50 ton) 11848
82 Frame (37-1/2 and 50 ton) 1 11850
37 Pin 2 (4) 71328777
83 Pin 2 71068464
38 Insert 1 (2) 9147-1
86 O Ring** 1 52662
39 Capscrew 2 (4) 71322101
87 Spacer 1 23431-046
40 Sheave, Drive 1 11980
142 Lockwasher 12 50181
Sheave, Idle (37-1/2 and 50
41 ton) 1 11979 421 Breather 1 52024
Reducer Assembly (includes
43 Stripper 1 12008 items 57 through 79, 83 and
490 --- 52659
44 Spacer 1 12007 421)
45 Frame (Reducer Side) 1 11846
46 Pin (Chain Anchor - 50 ton) 1 16046
47 Pin, Cotter 1 51021
Recommended Spare for one hoist, 2 years of normal operation.

* Refer to BRAKE UPGRADE NOTICE on page 81.
** Only required on older style hoists
POWER HEAD PISTON MOTOR ASSEMBLY PARTS DRAWING
55
452
458
453
454 459
455 460
456
457
462
463
465
486
466
54
467
468
483
487
484
485
465
470
473 474 166

479
475
54
476
474
473
486
(Dwg. MHP0359)
POWER HEAD PISTON MOTOR ASSEMBLY PARTS LIST
Item Description Qty Part

No. of Part Total Number
450 Motor Assembly (incls items 54, 55, 166, 452-465 and 467-479) 1 50259-2
55 Capscrew 20 71328371
166 Capscrew 1 51712
452 Washer (copper) 20 94-027-20
453 Cylinder 5 94-024
454 Compression Ring 5 Order Kit 71032932
455 Piston Assembly (incls items 454, 457 and 458) 5 94-010A
456 Plug 10 Order Item 457
457 Wrist Pin Assembly (incls item 456) 5 94-011-1A
458 Oil Ring 5 Order Kit 71032932
459 Connecting Rod 5 94-009
460 Gasket 5 94-025-5
462 Vent Cap Assembly 1 26604
463 Motor Housing 1 Not Sold Separately
465 Bearing 2 50944
466 Rotary Bushing 1 20-2
467 Rotary Valve 1 94-019
468 Capscrew 5 71328389
470 Gasket 1 94-029
473 Crankshaft Assembly (incls items 54, 166, 473-476, 479, 486) 1 94-001
474 Connecting Rod Ring 2 94-008
475 Sleeve 1 94-007
476 Bushing 1 94-006
479 Pin 1 94-004
483 Fitting, Elbow 2 71127815
484 Fitting, Nipple 1 50859
485 Pipe Coupling 2 53876
486 Plug 3 51599
801 Service Kit (includes items 452, 454, 458, 460 and 470) 1 71032932
Recommended spare for one hoist, 2 years of normal service.
VALVE ASSEMBLY PARTS DRAWING
536
537
538 536 532
86 529
520 533 533
504 539
500 543
466 86
54 540 542 535
530
502
100 528
527
505
524 547
54 523
505 522 516 548
506 501 525 549
550
507
552 544
510
526 553
508
509
512 518
545
513
519 546
514
511
515 309
520
516 554
517 505
556
567
557 555
558 568
559
569
Notice
Align passage in brake manifold (552) 570
to cover one port only in control valve.
Brake Air
Ports 572
560
562 Brake Manifold 573
Passage
574
541
250
566
565
542 563
564
(Dwg. MHP0382)
VALVE ASSEMBLY PARTS LIST

28 Plug 1 54292 536 Bushing 2 50498
54 Lockwasher 10 50200 537 Cap (incls item 536) 1 11763
86 O Ring 2 52662 538 Setscrew 1 71069066
100 Fitting, Elbow 1 53030 539 Link 1 11768
250 Capscrew 8 51095 540 Push Rod 1 11767
309 Washer 4 71055206 541 Capscrew 2 71128938
466 Rotary Bushing 1 20-2 542 Lockwasher 8 71146625
501 Lockwasher 4 71268908 544 Gasket 1 12023
502 Valve Cap 1 15031 545 Spacer 1 12022
504 Manifold Section* 1 Order B-10064 546 Housing 1 11962
505 Capscrew 6 51766 547 Fitting, Nipple 1 54623
506 Gasket 1 15037B 548 Fitting, Pipe Elbow 1 54624
507 Dowel 2 71328363 549 Fitting, Nipple 1 52809
508 Plug 4 54247 550 Fitting, Elbow 1 54611
509 Plug 1 552 Manifold (Brake) 1 13372
510 Manifold Section* 1 Order B-10064 553 Gasket 1 13373
511 Lockwasher 8 71268890 554 Gasket 1 12024
512 Gasket 1 9853 555 Sleeve** 1 21139
513 Block 1 9426 556 O Ring 10 51553
514 Capscrew 4 71069033 557 Spool** 1 21139
515 Bracket 1 8909 558 Stop 1 12019
516 Fitting 4 52092 559 Spring 1 71798
517 Fitting, Vented 4 18647 560 Spring Holder 1 12018
518 Gasket 1 9857 562 Shoulder Screw 1 53845
519 Cover Plate 1 20250 563 End Cap 1 11981
522 Gasket 1 9856 565 Fitting, Nipple 1 51704
523 Manifold (Trolley) 1 9439 566 Muffler, 1-1/4 in. 1 52465
525 Capscrew 4 71146617 568 Washer 1 9438-B
526 Gasket 1 9855 569 Piston Spacer 1 9438-A
527 Shoulder Bolt 1 71085179 570 O Ring 1 51554
528 Link 1 21289 572 Piston 1 9403
529 Pin 1 51974 573 O Ring 1 5155
530 Clevis 1 11220 574 Housing 1 10063
532 Pin 1 71146633 800 Control Valve Assembly 1 12354
533 Retainer Ring 2 52663 Control Valve Service Kit
535 Shaft 1 11769 802 (incls items 86, 526, 544, 1 71034573
553, 554, 556, and 559

* Manifold includes items 504 through 510 and 4 of item 54.
** Not available separately. Order kit number 21139 for one each of sleeve (item 555) and spool (item 557).
TWO LEVER PENDANT ASSEMBLY PARTS DRAWINGS
Pendant without Emergency

916
901
905
914 909
908
906
907
910
917
912
920
911
915
904
913
918
919
(Dwg. MHP2235)
Pendant with Emergency Stop

916
903 901
905 904
914 909
907 908
906
907
910 917
912 902
911
915 910
904
904
913
912
913
918
919
(Dwg. MHP2236)
TWO LEVER PENDANT ASSEMBLY PARTS LIST
Item Description Qty Part Number

No. of Part Total Without E-Stop With E-Stop
820 Pendant Assembly 1 PHS2E PHS2E-U
901 Lifting Eye 1 64222332
902 Emergency Stop Valve 1 --- 95790108
903 Plug 1 --- 95790106
904 O Ring 2(5) 58209229
905 Plug 2(4) 65107741
906 Spring 2(4) 69128541
907 Ball 2(5) 69401625
908 Pin 1 95790040
909 Setscrew 2 42008607
910 O Ring 2(3) 58235329
911 Setscrew 2(3) 42008307
912 Protector 2(3) 95790107
913 Valve 2(3) 95790104
914 Lever 2 95790122
915 Pendant Handle* 1 Order item 820
916 Fitting, Nipple 3(5) 71078158
917 Label Kit 1 95790111
918 Exhaust Washer 1 95790114
920 Plug 1 65129541 ---
** Label: Read the Manual 1 96180098
** Label: Do Not Use for Lifting Personnel 1 96180100
Recommended spares for one hoist, 2 years of normal service.

* Not sold separately. Order new Pendant.
** Not Illustrated
() Quantity Required for Pendants with Emergency Stop
FOUR LEVER PENDANT AND EMERGENCY STOP DRAWING
916
928
901
904
903 923 925

907 910
905 904
906 912
907 913
908 909
902
917
922
924
926
911
917
925
921 927 914
918
915
919
(Dwg. MHP2237)
928
911
916
901 925
923
910
904
905
906 912
907 913
908 909
926
920
922
924
911 917
921 925
927 914
918
915
919
(Dwg. MHP2238)
FOUR LEVER PENDANT CONTROL ASSEMBLY PARTS LIST

820 Pendant Assembly 1 PHS4E PHS4E-U
901 Lifting Eye 1 64222332
902 Emergency Stop Valve 1 --- 95790108
903 Plug 1 --- 95790106
904 O Ring 4(7) 58209229
905 Plug 4(6) 65107741
906 Spring 4(6) 69128541
907 Ball 4(7) 69401625
908 Pin 1 95790040
909 Setscrew 4 42008607
910 O Ring 4(5) 58235329
911 Setscrew 4(5) 42008307
912 Protector 4(5) 95790107
913 Valve 4(5) 95790104
914 Lever 2 95790122
915 Pendant Handle* 1 Order item 820
916 Fitting, Nipple 5(7) 71078158
917 Label Kit 1 95790111
918 Exhaust Washer 1 67600303
920 Plug 1 95790097 ---
921 Capscrew 2 41322106
922 Washer 4 45201005
923 O Ring 4 58218229
924 Screw 2 41330506
925 Pin 2 95790127
926 Lever 2 95790128
927 Attachment (Left) 1 95790125
928 Attachment (Right) 1 95790126
** Label: Do Not Use for Lifting Personnel 1 65129541 ---
** Label: Read the Manual 1 96180098

* Not sold separately. Order new Pendant.
** Not illustrated
() Quantity Required for Pendants with Emergency Stop
OLD STYLE PENDANT (WITH EMERGENCY STOP) ASSEMBLY PARTS DRAWING
422
419 423
428 424
420 516
430
515
426
28
427
429
433
437
432
434
440
426
427 436
438
428 439
429
442
448
432
443
444
426
427
428
429
445
448
432
447
446
(Dwg. MHP0396)
OLD STYLE PENDANT (WITH EMERGENCY STOP) ASSEMBLY PARTS LIST
Part Number
Item Description Qty 2 Lever 4 Lever
No. of Part Total
Without With Without With
E-stop E-stop E-stop E-stop
28 Plug 3 54292
Pendant Assembly (Standard) --- 18952 51412 18956
417 1
Pendant Assembly Marine (Anodized) 21685 15003-1 19755 15002-1
419 Capscrew 2 51675 51679
420 Washer 2 51676
422 Plug 1 --- 51674 51674
423 Spring 1 51414 --- 51414
424 Ball 1 51552 51552
426 Cap See ( ) 9486 (2) 9486 (4) 51233 (4) 9486 (6)
427 O Ring See ( ) 51233 (2) 51233 (4) 51233 (6)
428 Spring See ( ) 51235 (2) 51235 (3) 51235 (4) 51235 (5)
429 O Ring See ( ) 50846 (2) 50846 (4) 50846 (6)
430 Spool (Emergency Stop) 1 --- 9071-4
432 O Ring See ( ) 51234 (2) 51234 (4) 51234 (4) 51234 (6)
433 Spool (Emergency Stop) 1 9071-2 9071-2
--- ---
434 Block (Emergency Stop) 1 9984 9424
435 Spool (Trolley) 2 --- 9071-3
436 Nameplate 1 9436 9436
437 Drive Screw 4 51673 51673
--- ---
438 Emergency Stop Button 1 9414 9414
439 Capscrew 1 53869 53869
440 Gasket 1 9854
442 Block (Trolley) 1 51678
---
443 Button (Trolley) 2 9414-1
444 Gasket 1 9852
445 Pin 1(2) 51671
446 Lever See ( ) 51413 (2) 51413 (4)
Pendant Handle (Standard)
447 1 Order item 417
Pendant Handle Marine (Anodized)
448 Spool (Hoist) 2 9071-1
515 Bracket 1 8909
516 Fitting See ( ) 52092 (4) 52092 (5) 52092 (6)
Pendant Service Kit (includes items 423, 424,
803 1 --- 9750-4
427429, 432, 440 and 444)
OLD STYLE PENDANT (WITHOUT EMERGENCY STOP) ASSEMBLY DRAWING
To Pilot Air Regulator
137
194
203 203A 210 192
209 193
204
208 210
202 508
207
201
206
215
216
217
200
205
(Dwg. MHP1706)
OLD STYLE PENDANT (WITHOUT EMERGENCY STOP) PARTS LIST

482 Pendant Body Assembly (incls items 200-210, and 220) 1 MLK-A269C
189* Tie Wrap As reqd every 3-5 feet 54235
192 Fitting, Hose End 6 51029
194 Hose (Bulk) Specify Length 50923
200 Pendant Handle 1 Order item 482
201 Pendant Throttle Valve 2 MLK-K264B
202 Throttle Valve Face 2 R000BR1C-283
203 Pendant Throttle Valve Cap 2 MLK-K266A
203A Valve Cap Gasket 2 MLK-239
204 Pendant Throttle Valve Spring 4 MLK-51A
205 Pendant Throttle Lever 2 MLK-273
206 Throttle Lever Pin 1 DLC-120A
207 Lockwasher 2 D02-138
208 Strain Relief Support 1 MLK-540
209 Relief Support Lockwasher 2 H54U-352-10
210 Screw 4 MF-31
215 Strain Relief Cable Specify Length BWR3A
216 Clamping Sleeve 2 MLK-521
217 Clamping Thimble 2 MLK-602
508 Plug 1 54247
--- Strain Relief Assembly (incls items 215 through 217) 1 MLK-LWR3A

* Refer to Dwg. MHP0425 on page 72.
TROLLEY PISTON MOTOR VALVE ASSEMBLY DRAWING AND PARTS LIST
631
638
626
634
629
626
630
632
631
637
636
635
633
628
627
(Dwg. MHP0415)
625 Valve Assembly (incls items 626 thru 638) 1 51700
626 End Cap Gasket 2 51978
627 Valve Spool 1
Order item 625
628 Valve Sleeve 1
629 Shoulder Screw 1 9640-4
630 Centering Shaft Guide 1 9640-5
631 Bolt 8 9640-6
632 End Cap 1 9640-7
633 O Ring 6 51632
634 Valve Body 1 Order item 625
635 Spacer 1 9640-10
636 Washer 1 9640-11
637 Spring 1 54925
638 End Cap 1 9640-13
804 Valve Service Kit (includes items 626 and 633) 1 9750-13
VANE MOTOR VALVE ASSEMBLY DRAWING AND PARTS LIST
588
587
585 269
584
589
114
583 580
581
582 598 592
583
585 585
269 269
600
588 593
584 597
595 596
587
594
593
581
590
(Dwg. MHP0407)
Pilot Control Valve (incls 587 Retainer 2 4502-43
270 items 114, 269 and 580 thru 1 50431 588 O Ring 2 P-1000-19
600) 589 Capscrew 1 8325-93
114 Fitting, Elbow 2 51281 590 Cap Assembly* 1 SA-4302-83
269 O Ring 7 P-1100-13 592 Pilot Cap 2 4302-11
Order item 593 Washer 4 4302-02
580 Body 1
270 594 Spring 2 71060206
581 Plunger 1 71060198 595 Spring Cap 2 4302-14
582 O Ring 2 P-1100-10 596 Pin 2 4302-22
583 O Ring 2 P-1000-10 597 Pilot Spacer 2 4302-32
584 Bushing 2 4502-04 598 Piston 2 4302-38
585 O Ring 5 P-1000-17 600 Screw 8 PFS-1032-36

* Item 590 includes items 592 to 598 and 585.
TROLLEY DRIVE VANE MOTOR ASSEMBLY PARTS DRAWING
270
273 269
267
274 268
256 255
114
266
275
257 258
265
259
220
251 260
268
264
262
263
251
252
253
254
(Dwg. MHP0379)
TROLLEY DRIVE VANE MOTOR ASSEMBLY PARTS LIST

199 Motor Assembly (incls items 251 thru 265) 1 4864
220 Motor Adapter 1 6553
251 Bearing 2 51074
252 Seal 1 50840
253 Cover 1 6554
254 Seal 1 51591
255 Dowel 4 51084
256 Cylinder 1 3131
257 Shaft Key 1 50273
258 Vane 6 4335-6
259 Shaft and Rotor 1 4333-A
260 Cover 1 3761
263 Cap 1 4334
264 Capscrew 3 71328751
266 Muffler 2 50593
267 Valve Manifold 1 8466
268 Capscrew 6 71328512
269 O Ring 5 P-1100-13
270 Pilot Control Valve 1 50431
273 Capscrew 1 71319057
274 Capscrew 2
275 Fitting, Reducer 1 54913
805 Repair Kit (incls items 251, 252, 254, 255, 258, 262, 264 and 265) 1 1000P60-VMK
TROLLEY DRIVE PISTON MOTOR ASSEMBLY PARTS DRAWING
352 330
Old Style
353
331
351
349
334
351
347
335
345 336
346
337 332
338
339
334
340 343
360
333
364
362
368
380 366
384
381
367
382 365
383 369
363
370
380 373
356
358 372
355 378
379
372
375
354
378 377
374
334
(Dwg. MHP0381)
TROLLEY DRIVE PISTON MOTOR ASSEMBLY PARTS LIST

Motor Assembly (incls items 363 Flange Plate 1 71029680
329 1 52151
330 thru 379) 364 Capscrew 4 71029870
330 Gasket 1 71018386 365 Shim 5 71029631
331 Gasket 1 71018394 366 Retainer Ring 1 71029599
332 Rotary Valve Housing 1 71028252 367 Spacer 1 71029615
Plug (Steel) 54658 368 O Ring 1 71029706
333 1
Plug (Brass) 71112247 369 Motor Housing 1 Order item 329
334 Capscrew 24 71030084 370 Oil Ring 4 71018428
335 Retainer Ring 1 71028328 372 Compression Ring 8 71018410
336 Bearing 1 71028310 Piston Assembly (incls items
373 4 71029557
337 Rotary Valve 1 71028245 370, 372, 377 and 378)
338 Bearing 1 71028237 374 Gasket 4 71018402
339 Cover 1 71029854 375 Cylinder 4 71028336
340 Capscrew 2 71030134 377 Wrist Pin 4 Order item 373
343 Key 1 71030068 378 Retaining Ring 8 Order item 373
345 Balance Weight 379 Plug 1 71029722
346 Setscrew Spacer 0.069 in (1.75 mm) 71378632
Spacer 0.060 in. (1.5 mm) Spacer 0.077 in (1.96 mm) As 71378640
380
Spacer 0.010 in. (0.25 mm) Spacer 0.089 in (2.26 mm) Reqd 71378657
347
Spacer 0.060 in. (1.5 mm) Not Order Kit Spacer 0.100 in (2.54 mm) 71378665
Spacer 0.060 in. (1.5 mm) available 149-081 381 Connecting Rod 1 71378574
349 Connecting Rod 382 Connecting Rod 3 71378582
351 Spacer 383 Bearing 1 71378590
352 Bearing 384 Pin 3 71378608
353 Spacer 385 Spacer 1 71378616
354 Crankshaft 1 71029664 Motor Repair Kit (incls items
806 330, 331, 358, 368, 370, 372 1 71028120
355 Key 1 71030225
and 374
356 Bearing 2 71029904
Complete Motor Retrofit Kit
358 Seal 1 71018444 (incls complete motor assy 71388672
360 O Ring (shipping only) 1 71030167 and associated mounting)
362 Breather Plug 1 71030175

Note: Hoists with serial numbers above HL0190300 will have new style connecting rod assembly.
12.5 TON TROLLEY ASSEMBLY DRAWING
184
156
179
155
183
160 151
180
182 154 153
172 150
162 152
165
163
164
168
158
167
157
166
653
186
173 160
170
174 156
189
176
188
(Dwg. MHP1525)
12.5 TON TROLLEY ASSEMBLY PARTS LIST

150 Side Plate (Plain) 2 22898
151 Wheel (Plain) 8212
Wheel (Copper Plate)
2
Wheel (Zinc Plate) Contact Factory
Wheel (Bronze)
152 Oil Seal 4 50539
153 Retaining Ring 4 51069
154 Bearing 4 51066
155 Retaining Ring 4 52355
156 Spacer 36 8424-6
157 Capscrew
4 Order Kit 24111-1
158 Lockwasher
160 Bushing 4 28476-1
162 Pin
163 Spacer
4 Order Kit 24111-1
164 Guide Roller Holder
165 Guide Roller
167 Washer 4 50177
168 Bumper 4 51722
170 Suspension Yoke (6-8 in. Std.) 22901
Suspension Yoke (8-10 in.)
2
Suspension Yoke (10-12- in.) Contact Factory
Suspension Yoke (14-16 in.)
172 Fitting, Grease 10 53095
173 Pin, Cotter 8 51996
174 Pin 4 22933
176 Bushing 2 21833
179 Geared Wheel (Plain) 8234
Geared Wheel (Copper Plate) 8234-CP
1
Geared Wheel (Zinc Plate) Contact Factory
Geared Wheel (Bronze) 8234-3
180 Retaining Ring (Piston Motor) 52645
1
Retaining Ring (Vane Motor) 51192
182 Drive Gear 1 17690
183 Key 1 19523-075
184 Side Plate (Geared) 1 22897
186 Drive Screw 4 50915
188 Suspension Bar 1 22899
189 Capscrew 4 71124804
653 Nameplate 1 71070098-R
* Geared Trolleys require Quantity (1) Plain Side Plate.
25 TON AND LARGER TROLLEY ASSEMBLY PARTS DRAWING
179
182
180
152
183
153
154
151
184 161 150
157
158 155
159
172
156
161
156
162
165
163 653 170
164 157
158
158
157 175
167 168
166 173
170
158 186 172
157 174
172
169 176
177
176
177
178
(Dwg. MHP0282)
25 TON AND LARGER TROLLEY ASSEMBLY PARTS LIST

No. of Part Total 25 Ton 37.5 Ton 50 Ton
Side Plate (Plain) Right Hand 8326 (3) 17525 (2) 16760 (2)
150 See ( )
Side Plate (Plain) Left Hand 8327 (1) 17527 (2) 16240 (2)
Wheel (Plain) 8212 8402
Wheel (Copper Plate) 18485 8402-CP
151 8*
Wheel (Zinc Plate) 18486 Contact Factory
Wheel (Bronze) 8212-1 Contact Factory
152 Oil Seal 8 50539 50540
153 Retaining Ring 8 51069 51046
154 Bearing 8 51066 50455
156 Spacer See ( ) 8424-2 (36) 8424 (20)
157 Capscrew Order Kit
20(16) Order Kit 24111-2S
158 Lockwasher 24111-1S
159 Connecting Plate See ( ) 8329-12 (4) 16402-1 (2)
161 Bushing 8 28476-3 28476-2
162 Pin
163 Spacer Order Kit
4 Order Kit 24111-2S
164 Guide Roller Holder 24111-1S
165 Guide Roller
166 Capscrew 4 51712 52008
167 Washer 4 50177 50182
168 Bumper 4 51722 71756
169 Cap 1 16185 16188
Suspension Yoke (6-8 in. Std.) 16184 Contact Factory
Suspension Yoke (8-10 in.) 18815 18026 16166
170 2
Suspension Yoke (10-12- in.) 21054 16639
Suspension Yoke (14-16 in.) --- ---- 16166-D
173 Pin, Cotter 8 51996 54447
174 Pin 4 16291 16292
175 Bracket 1 16186 17706
176 Bushing 2 16187 16190
177 Trolley Bracket 2 11852 17133 11854
178 Capscrew 8 71322192
Geared Wheel (Plain) 8234 8403
Geared Wheel (Copper Plate) 18483 8403-CP
179 2
Geared Wheel (Zinc Plate) 18484 Contact Factory
Geared Wheel (Bronze) 8234-1 Contact Factory
Retaining Ring (Piston Motor) 52645
180 1
Retaining Ring (Vane Motor) 51192
182 Drive Gear 1 17690
183 Key 1 19523-100
184 Side Plate (Geared) 1 8327 17528 16650
186 Drive Screw 4 50915
653 Nameplate 1 71070098-R
* Geared Trolleys require Quantity (6) Plain Wheels.
TROLLEY DRIVE ASSEMBLY PARTS DRAWING
200
202
486
203
204
200
224
212 210
222
183
217
205
206 225
207
223
208 218
486
226
214 205
216 204
228
227
213
486
233
217
200 218 234

229
219
230
220 232
234 203
236
182
142
180
(Dwg. MHP0306)
TROLLEY DRIVE ASSEMBLY PARTS LIST

No. of Part Total Piston Motor Vane Motor
808 Trolley Drive Assembly 1 18798-2 17492
182 Drive Gear** 1 17690
Key (25 ton)** 19523-100
183 1
Key (37.5 and 50 ton)** 19523-075
200 Screw 14 71328512
202 Cover 1 3117
203 Gasket (Set) 2 3118
204 Bearing (Cup)
2 Order Bearing Assembly 71073407
205 Bearing (Cone)
206 Spacer 1 4147
207 Key 2 3667
208 Shaft** 1 3112-2B
210 Plug (Vented) 1 51803
212 Housing 1 B-5060
213 Plug 1 52701
214 Worm 1 11291 3829
216 Key** 1 7285-41
217 Bearing (Cup)
2 Order Bearing Assembly 71073415
218 Bearing (Cone)
219 Oil Seal 1 51283
220 Motor Adapter 1 11252 6553
222 Shim 0.007 in. (0.178 mm)
223 Shim 0.005 in. (0.127 mm) 1 Order Shim Kit 6550-50
224 Shim 0.020 in. (0.508 mm)
225 Cover 1 3115
226 Worm Gear 1 3830
227 Spacer** 1 4147-1
228 Oil Seal 1 51578
229 Sleeve 1 3114
230 Spacer** 1 4147-9
232 Reducer Adapter** 1 8333-2
234 Capscrew See ( ) 71125454 (6) 51780 (10)
486 Plug 3 51599
Gear Box Service Kit incls items 182, 183, 208,
807 1 9750-17
216, 227, 230 & 232
* Spacer Plate 1 Contact Factory

* Not illustrated **Rack drive only
TOP HOOK ASSEMBLY PARTS DRAWINGS
12-1/2 ton 25 ton
408 408
418
418
178
178
172
283 172 178
280
280 285
287
285 407
407 405
405 287 406

285 285
406
284 178
(Dwg. MHP0344) (Dwg. MHP0345)
37-1/2 ton 50 ton
408 408
418
418
283
283
285 178
285 178
280
280
287 287 287

287
172 285 172
285 407
407
178 405
405
406
406 178
(Dwg. MHP0347)
(Dwg. MHP0346)
TOP HOOK ASSEMBLY PARTS LIST

No. of Part Total 12.5 Ton 25 Ton 37.5 Ton 50 Ton
149 Top Hook Assembly 1 17896 12027 14769 14772
178 Capscrew See ( ) 71322788 (2) 71322192 (6) 71322192 (2)
280 Hook Plate 1 17897 12058 14768 14773
283 Capscrew See ( ) 71322770 (2) --- 71352090 (8) 54322 (8)
284 Capscrew 1 71322796 ---
285 Lifting Eye * 2 9575F
287 Spacer * 2 --- 16755-4
405 Nut 1 8476 8316 8516
406 Pin 1 50917 50958 50974
407 Bearing 1 50144 50394 50331
Hook (incls item 418) 8474-3 11030 8414-3 8515-2
408 1
Hook Copper Plate (incls item 418) Contact Factory 18479 8414-3-CP Contact Factory
418 Hook Latch Kit 1 50597 52173 51237 50230B
* Items 285 and 287 attach to Frame, item 36 or 82. Refer to Dwg. MHP0353 on page 40. Refer to Dwg. MHP0344-MHP0347 attachment
capscrews.
BOTTOM BLOCK ASSEMBLY PARTS DRAWINGS
50 ton
34
421
34
413
412
34 402
32
34 172
41
32
400 32 400
41
32
172
408
405
407
406
402
418
172
(Dwg. MHP0317)
37-1/2 ton
414 415
416
413 412
34
32
34
41
32
400 402
421
408
405
407
172
406 418
172
402
(Dwg. MHP0316)
BOTTOM BLOCK ASSEMBLY PARTS DRAWINGS AND PARTS LIST
12-1/2 ton 25 ton
400 403 400 172

402
414
34 32
400 41
34
402 400 32
412
405
406 421 408
405
172 407
407 406
418
403 172
408
418 (Dwg. MHP0315)
(Dwg. MHP0314)

Bottom Block Assembly 16998 12004 12928 14771
11 1
Bottom Block Assembly (copper plate) 16998-CP 12004-2 12928-CP Contact Factory
32 Bearing See ( ) 54483 (2) 54483 (4)
34 Seal See ( ) --- 71007405 (2) 71007405 (4)
41 Sheave, Idle See ( ) 11979 (1) 11979 (1) 11979 (2)
172 Fitting, Grease See ( ) 53095 (1) 53095 (2) 53095 (2) 53095 (3)
400 Hook Block See ( ) 19794 (1) 12014 (2) 12268 (1) 12267 (2)
402 Capscrew See ( ) 71028559 (2) 71264675 (4) 71264675 (8)
403 Nut See ( ) 53783 (2) 51752 (4) ---
405 Nut 1 8476 8316 8516
406 Pin 1 50960 50958 50974
407 Bearing 1 50144 50394 50331
Hook (incls item 418) 8474-3 20504 8414-3 8515-2
408 Hook Copper Plate (incls item 418) 1 18889-CP 18479 Contact Factory 20506
Hook with Bullard Latch Contact Factory 13725 Contact Factory
412 Pin See ( ) --- 54205 (2) 54205 (4)
413 Hook Center Block 1 --- 13000 12264
414 Cotter Pin 1 22280 --- 22280
415 Side Plate 1 12999 ---
---
416 Capscrew 1 71328744
418 Hook Latch Kit 1 71341663 52173 51237 50230
421 Breather 1 --- 52024
CHAIN BUCKET ASSEMBLY DRAWING AND PARTS LIST
302
320
301
304
175
284 157
307
300 306
307 305
316 316
306 317
319 317 306
307 313
306
313
167 167
167 167
315 315
312 312
(Dwg. MHP1524)
167 Washer 4 50177 304 Capscrew 1 71098073
Capscrew (25 ton) Order Kit 305 Bracket 1 21619
24111-18
157 2 306 Clevis Assembly 4 54645
Capscrew (37.5 and 50 ton) Order Kit
24111-2S Specify
307 Chain (bulk) 50962
Length
Bracket (25 ton) 161B6
175 1 Contact
Bracket (37.5 and 50 ton) 17706 312 Chain Bucket 1
Factory
284 Capscrew 3 54727 313 Nut 2 71061584
300 Nut 1 51750 315 Capscrew 2 54240
301 Spacer 2 23435-188 316 Chain Guide 1 17575
Tension Link (12-1/2 ton) 2 317 Capscrew 1 54202
Tension Link (25 ton) 3 319 Shackle 1 71098099
302 21620
Tension Link 320 Hook 1 71098081
4
(37-1/2 and 50 ton)
* Specify Load Chain Length in feet
LOAD CHAIN AND CHAIN STOPPER DRAWING AND PARTS LIST
(Dwg. MHP0399)

240 Load Chain (Zinc Plated) Specify Length 16756
241 Chain Stopper 1 16246
316 Chain Guide 1 17575
HOSE ASSEMBLY DRAWING AND PARTS LIST

192 No. of Part Total Number
188 Chain, Zinc Plated 50041
189 Tie Wrap As reqd 54235
190 Tie Wrap 71308746
191 S Hook 2 D02-421
192 Hose Fitting 51029
193 Fitting, Nipple As reqd 71048268
196 194 Hose (bulk) 50923
195 195 Exhaust Valve As reqd 71372890
Exhaust Valve Kit (incls
As reqd 20417
193 items 192, 193 and 196)
196 Fitting As reqd 71048284
Recommended spare or one hoist, 2 years of normal
service.
190 Hose Assembly

188 Pendant without Emergency Stop
189 Length Part Number
Feet Meters 2 Lever 4 Lever 6 Lever
10 3 21653-10 21654-10 21655-10
194
15 4.5 21653-15 21654-15 21655-15
20 6 21653-20 21654-20 21655-20
25 7.6 21653-25 21654-25 21655-25
191 30 9 21653-30 21654-30 21655-30
192 35 10.7 21653-35 21654-35 21655-35
40 12 21653-40 21654-40 21655-40
45 13.7 21653-45 21654-45 21655-45
50 15.25 21653-50 21654-50 21655-50
Pendant with Emergency Stop
10 3 21656-10 21657-10 21658-10
15 4.5 21656-15 21657-15 21658-15
20 6 21656-20 21657-20 21658-20
25 7.6 21656-25 21657-25 21658-25
30 9 21656-30 21657-30 21658-30
35 10.7 21656-35 21657-35 21658-35
Optional New Style 40 12 21656-40 21657-40 21658-40
Pendant
45 13.7 21656-45 21657-45 21658-45
(Dwg. MHP0425) 50 15.25 21656-50 21657-50 21658-50

Notes: 1. Dump valves included on lengths of 10 ft. (3 m)
and greater.
2. For hose bundles longer than 50 ft. (15.25 m)
contact Technical Sales for control acceptability.
3. Exhaust valve assembly not required when using
new style pendants.
HULL BUMPER ASSEMBLY DRAWING AND PARTS LIST
12.5 and 25 ton Hoists 37.5 and 50 ton Hoists
140
135 167
285
138
284
136 178
167
144
158 139 142
168 143
282
(Dwg. MHP0431)
141 167
(Dwg. MHP0433)

120 Bumper Assembly 1 16178 16180
135 Spacer 2 16640-10 ---
136 Nut 2 52919 ---
138 Bracket 1 9596-1 ---
139 Capscrew 2 53997 ---
140 Mounting Plate 1 --- 19406
141 Bumper 1 --- 54739
142 Lockwasher 2 --- 50181
143 Capscrew 2 --- 54662
144 Spacer 1 --- 16755-3
158 Lockwasher 2 50203 ---
167 Washer 4(2) 52914
168 Bumper 2 71756 ---
178 Capscrew 1 --- 54319
282 Capscrew 2 50197 ---
284 Capscrew 3 --- 54727
285 Lifting Eye 1 --- 9575F
() Quantity required for 37.5 and 50 ton models only.
ROPE CONTROL ASSEMBLY DRAWING
127
128
514
518
48
50 519
49
87 511
520
Hoist Manifold -
viewed from below
508
131
420
527
528 133
56
52
134
514
133 Old Style Limit Paddle
191 for replacement order New Style
135
56
52
136 49
138
(Dwg. MHP1515)
ROPE CONTROL ASSEMBLY PARTS LIST

125 Rope Control Assembly (incls items 127-134, 191, 420, 508 and 514) 1 14874
48 Capscrew 1 71322143
49 Washer 2 52915
50 Bushing 2 52675
Limit Arm Assembly (includes items, 49-50, 55-56, 84-85 for 12-1/2 and 25 ton) 16219
52 1
Limit Arm Assembly (includes items, 49-50, 55-56, 84-85 for 37-1/2 and 50 ton) 17290
56 Nut 1 54661
87 Spacer 1 23431-046
126 Plug, Vented 1 14895
127 Gasket 1 21555
128 Cover Plate 1 14879
131 Nut 2 50852
133 Eyebolt 2 54753
134 Rope Control Arm 1 21199
135 Nylon Cord As reqd 51777
136 Knob 2 4868
138 Control Handle 1 8273
191 S Hook 2 52120
420 Washer 2 51676
508 Plug 3 54247
518 Gasket 1 9857
519 Cover Plate 1 20250
527 Shoulder Bolt 1 71085179
528 Link 1 21289
TROLLEY MOUNT PIPING ASSEMBLY PARTS DRAWING
Trolley
Sideplate
98
91
92
102
93 99 97
108
640
106 96
113
97
90 95
112 97
105 94
107
Trolley Drive
Motor Hoist Motor Brake
112 115
114
116
113
516
523 104
524 114
103 118
522
114
119 100 90
547 549
550
548
To Pendant 114
Hoist Control
Valve
566
565
(Dwg. MHP1514)
TROLLEY MOUNT PIPING ASSEMBLY PARTS LIST

90 Hose Assembly 1 --- 17550-1
91 Fitting, Elbow 1 54244 54259
92 Lubricator (optional) 1 L30-08-000
93 Fitting, Nipple 1 --- 51018
94 Filter (optional) 1 F30-08-000
95 Fitting, Nipple 2(1) 71077093 54267
96 Fitting, Coupling 1 52318
97 U-Bolt (with Nut) 1(2) 51681
98 Bracket 1(2) 14878 8551-5
99 Capscrew 1(2) 50856
100 Fitting, Elbow 1 --- 53030
102 Hose Assembly 1 --- 17549-1 or -2
104 Fitting, Nipple 1(2) 52191
106 Hose Assembly 1 --- 17073-3
107 Muffler 3/4 in. 2 --- 52104
112 Fitting, Elbow 2 --- 71108781
113 Hose Assembly 1 --- 17073-4
115 Hose Assembly 1 17073-1
116 Valve 1 --- 51756
118 Dump Valve 1 50275
119 Hose Assembly 1 17073-2
516 Fitting 2 --- 52092
522 Gasket 1 9856
523 Manifold (Trolley) 1 9439
566 Muffler 1-1/4 in. 1 52465
640 Fitting, Elbow 1 53029 ---
HOOK-MOUNT LUBRICATOR-FILTER PIPING ASSEMBLY
115 114
104 118 116
103 114
119
104
114
641
642
97
650 508
641
643
649 98 95
353
648
114
508
647 640 91
97 94
96 95
92
(Dwg. MHP0601)
No. of Part Total With Emergency Stop Without Emergency Stop
92 Lubricator (Optional) 1 L30-08-000
94 Filter (Optional) 1 F30-08-000
96 Fitting, Coupling 1 52318
97 U Bolt (w/ Nut) 1 51681
98 Bracket 1 14878
104 Fitting, Nipple See ( ) 52191 (1) 52191 (2)
114 Fitting, Elbow See ( ) 51281 (2) 51281 (4)
115 Hose Assembly 1 17073-1 17073-2
116 Valve 1 --- 51756
118 Dump Valve 1 50275
119 Hose assembly 1 17073-2
333 Plug 1 54658 ---
508 Plug 3 54247
641
649 Washer 2 53540
650 Washer 2 53516
MUFFLERS DRAWING AND PARTS LIST
Hoist Motor Trolley Motor
112
561
107
565
566
(Dwg. MHP1526)
107 Muffler, 3/4 in. 2 52104
566 Muffler, 1-1/4 in. 1 52465
LABEL AND TAG PARTS LIST
658 666 667

651 662 651
666 657 663
659 665 661
658 658
658
666
667
656
655
657
185 650
657
654 660
660 660
661
659 652
661 654
25t
661 664
Note: Exact location of Tags and Labels may vary, depending on unit configuration, options and accessories.
(Dwg. MHP1496)
Item Description Qty Total Part

No. of Part Hook Mount Trolley Mount Number
Label Kit (Hook Mounted Hoist) As reqd --- 18916-R
---
Label Kit (Trolley Mounted Hoist) --- As reqd 18917-R
185
650 Tag, Supply Line Notice 1 71042121
651 Label, Hercu-Link Logo 2 3 71046387
652 Tag, Oil Fill Notice 1 71042147
653 Nameplate 1 71070098-R
654 Label, Drain 2 71043632
655 Label, Air Supply 1 71046395
656 Tag, Oil Level Caution 1 3 71107148
657 Label, Oil Level 4 6 71043616
658 Label, Oil Fill 3 5 71042204
659 Label, Exhaust 1 3 71042196
660 Label, Oil Drain 3 5 71042188
661 Label, Lube 5 13 71042170
662 Label, Ingersoll-Rand Name and Logo 2 1 71106231
663 Label, Ingersoll-Rand Name and Logo --- 2 71106256
664 Tag, Operating Warning 1 71059612
12-1/2 Ton - 0
665 Label, May be Removed after Installation --- 25 Ton - 4 71042154
37-1/2 Ton - 2
666 Tag, Vent Plug Notice 2 --- 71107155
667 Label, Operating Warning 1 2 71107130
ACCESSORIES AND REPAIR KITS
Description Qty Part

of Part Total Number
Air Supply Hose (Bulk) 1-1/4 in. Specify Length 50766
Chain Lubricant As reqd LUBRI-LINK-GREEN
Control Valve (item 800) Service Kit 1 71034573
Filter (1 in. FNPT) 1 F30-08-000
Hoist Piston Motor (item 450) Service Kit (incls items 452, 454, 458, 460 and 470) 1 71032932
Label Kit (Hook Mount Hoist) 1 18916-R
Label Kit (Trolley Mount Hoist) 1 18917-R
Liquidator 1 8848-LU1-150
Lubricator (1 in. FNPT) 1 L30-08-000
Manifold Seal Kit (incls items -) 1 71034599
Old Style Pendant Assembly Service Kit 1 9750-4
Regulator (1 in. FNPT) 1 R30-08-000
Regulator Gauge 1 GRP-95-229
Flat Gear Rack Section (6 ft.) 1 10953
Strainer 1 JU-A267AT
Trolley Control Valve (item 804) Service Kit 1 9750-13
Trolley Drive Vane Motor Repair Kit (incls items 251, 252, 254, 255, 258, 262, 264
1 1000P60-VMK
and 265)
Trolley Gearbox Service Kit (incls items 182, 183, 208, 216, 227, 230 and 232) 1 9750-17
Trolley Piston Motor Repair Kit (incls items 330, 331, 358, 368, 370, 372 and 374) 1 71028120
HOIST UPGRADES
The brake piston and seal design on all HA2 hoists were revised as When replacing brake piston on hoists with serial numbers prior to
part of Ingersoll-Rand's continuing product improvement HL0510992 (approximate manufacture date Sept. 1992) order
program. Refer to Table 10 for description of change. retrofit kit part number 22181.
Table 10Brake Upgrade Parts List
Old Parts New Parts Parts are not interchangeable. O rings cannot be used with
new brake piston and seals cannot be used with old brake
Description Part Description Part
of Part No. of Part No. piston.
O Ring 52672 Seal 71107726

O Ring 52671 Seal 71107718
Brake Piston 11949 Brake Piston 22177
PARTS ORDERING INFORMATION
Hercu-Link hoists are designed and constructed to provide long,

Return Goods Policy
trouble-free service. In time it may become necessary to order and
install new parts to replace those that have been subjected to wear. If it becomes necessary to return the complete hoist or certain
parts to the factory, contact the Distributor from whom you
The use of replacement parts other than Ingersoll-Rand may purchased the hoist, or the nearest Ingersoll-Rand Distributor in
result in decreased hoist performance, and may, at the company's your locality. Ingersoll-Rand will not accept any returned goods
option invalidate the warranty. for warranty or service work unless prior arrangements have been
made and written authorization has been provided from the
For your convenience and future reference it is recommended that location where the goods were purchased.
the following information be recorded.
Model Number ______________________________________ Disposal
Serial Number _______________________________________ When the life of the hoist has expired, it is recommended that the
hoist be disassembled, degreased and parts separated as to
Date Purchased ______________________________________ materials so that they may be recycled.
When ordering replacement parts, please specify the following:

1. Complete hoist model number as it appears on the nameplate.
Mineral-based oils can be recycled, however, some oils such
2. Part number(s) and part description as shown in this manual.
as glycols may be extremely toxic and must be identified and
3. Quantity required.
disposed of in accordance with local, state and national
regulations.
On hook-mounted hoists, the model and serial number plate is
located on the top hook block.
For additional information contact:
Ingersoll-Rand
On trolley-mounted hoists, the model and serial number plate is
P.O. Box 24046
located on the trolley side plate.
2724 Sixth Avenue South
Seattle, WA 98124-0046 USA
Phone: (206) 624-0466
Continuing improvement and advancement of design may Fax: (206) 624-6265
produce changes to this hoist which are not included in this
manual. Manuals are periodically revised to incorporate or
changes. Always check the manual edition number on the
front cover for the latest issue. Ingersoll-Rand
Douai Operations
111, avenue Roger Salengro
59450 Sin Le Noble, France
Phone: (33) 3-27-93-08-08
Fax: (33) 3-27-93-08-00
For additional information on the following products order the publication by the reference Part/Document number listed:
Publication Part/Document Number
Accu-trol Manual Supplement MHD56014
WARRANTY
Limited Warranty
Ingersoll-Rand Company (I-R) warrants to the original user its maintained by the user, or where the malfunction or defect can be
Hoists and Winches (Products) to be free of defects in material attributed to the use of non-genuine I-R parts.
and workmanship for a period of one year from the date of
purchase. I-R makes no other warranty, and all implied warranties including
I-R will repair, without cost, any Product found to be defective, any warranty of merchantability or fitness for a particular purpose
including parts and labor charges, or at its option, will replace are limited to the duration of the expressed warranty period as set
such Products or refund the purchase price, less a reasonable forth above. I-R's maximum liability is limited to the purchase
allowance for depreciation, in exchange for the Product. Repairs price of the Product and in no event shall I-R be liable for any
or replacements are warranted for the remainder of the original consequential, indirect, incidental, or special damages of any
warranty period. nature rising from the sale or use of the Product, whether based on
contract, tort, or otherwise.
If any Product proves defective within its original one year
warranty period, it should be returned to any Authorized Hoist and Note: Some states do not allow limitations on incidental or
Winch Service Distributor, transportation prepaid with proof of consequential damages or how long an implied warranty lasts so
purchase or warranty card. that the above limitations may not apply to you.
This warranty does not apply to Products which I-R has This warranty gives you specific legal rights and you may also
determined to have been misused or abused, improperly have other rights which may vary from state to state.
Important Notice
It is our policy to promote safe delivery of all orders. Damage Claims
You must file claims for damage with the carrier. It is the
This shipment has been thoroughly checked, packed and inspected transportation company's responsibility to reimburse you for
before leaving our plant and receipt for it in good condition has repair or replacement of goods damaged in shipment. Claims for
been received from the carrier. Any loss or damage which occurs loss or damage in shipment must not be deducted from the
to this shipment while end route is not due to any action or Ingersoll-Rand invoice, nor should payment of Ingersoll-Rand
conduct of the manufacturer. invoice be withheld awaiting adjustment of such claims as the
carrier guarantees safe delivery.
Visible Loss or Damage
If any of the goods called for on the bill of lading or express You may return products damaged in shipment to us for repair,
receipt are damaged or the quantity is short, do not accept them which services will be for your account and form your basis for
until the freight or express agent makes an appropriate notation on claim against the carrier.
your freight bill or express receipt.
Concealed Loss or Damage

When a shipment has been delivered to you in apparent good
condition, but upon opening the crate or container, loss or damage
has taken place while in transit, notify the carrier's agent
immediately.
United States Office Locations International Office Locations
For Order Entry, Regional Sales Offices Offices and distributors in Latin America Operations
Order Status and principal cities throughout the Ingersoll-Rand
Technical Support Chicago, IL world. Contact the nearest Production Equipment Group
131 W. Diversey Avenue Ingersoll-Rand office for the 730 N.W. 107 Avenue
Ingersoll-Rand Elmhurst, IL 60126-1102 name and address of the Suite 300, Miami, FL
P.O. Box 24046 Phone: (630) 530-3800 distributor in your country or 33172-3107 USA
2724 Sixth Avenue South Fax: (630) 530-3891 write/fax to: Phone: (305) 559-0500
Seattle, WA 98124-0046 USA Fax: (305) 222-0864
Phone: (206) 624-0466 Detroit, MI Canada
Fax: (206) 624-6265 1872 Enterprise Drive National Sales Office Europe, Middle East and
Rochester, MI 48309 Regional Warehouse Africa
Ingersoll-Rand Phone: (248) 293-5700 Toronto, Ontario Ingersoll-Rand
Distribution Center Fax: (248) 293-5800 51 Worcester Road Douai Operations
P.O. Box 618 Rexdale, Ontario 111, avenue Roger Salengro
510 Hester Drive Houston, TX M9W 4K2 59450 Sin Le Noble, France
White House, TN 37188 450 Gears Road Phone: (416) 213-4500 Phone: (33) 3-27-93-08-08
Phone: (615) 672-0321 Suite 210 Fax: (416) 213-4510 Fax: (33) 3-27-93-08-00
Fax: (615) 672-0801 Houston, TX 77067-4516 Order Desk
Phone: (281) 872-6800 Fax: (416) 213-4506 Asia Pacific Operations
Web Site: Fax: (281) 872-6807 Ingersoll-Rand
www.irco.com Regional Sales Offices 42 Benoi Road
Los Angeles, CA Edmonton, Alberta Jurong, Singapore 629903
13107 Lakeland Road Phone: (780) 438-5039 Phone: 65-861-1555
Santa Fe Springs, CA 90670 Fax: (780) 430-4300 Fax: 65-861-0317
Phone: (562) 777-0808
Fax: (562) 777-0818 Montreal, Quebec Russia
3501 St. Charles Blvd. Ingersoll-Rand
Philadelphia, PA Kirkland, Quebec Kuznetsky Most 21/5
P.O. Box 425 H9H 4S3 Entrance 3
900 E. 8th Ave., Suite 103 Phone: (514) 695-9040 Moscow 103895 Russia
King of Prussia, PA 19406 Fax: (514) 695-0963 Phone: 7-501-923-91-34
Phone: (610) 337-5930 Fax: 7-501-924-46-25
Fax: (610) 337-5912 British Columbia
1200 Cliveden Avenue Australia
Delta, B. C. Ingersoll-Rand
V3M 6G4 1 Hartnett Drive
Phone: (604) 523-0803 Seaford, Vic 3198
Fax: (604) 523-0801 Australia
Phone: 613 95541642
Fax: 613 95541607
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Form MHD56298

LS500HLP/ LS150HLP SAM0222

PARTS, INSTALLATION AND MAINTENANCE MANUAL

READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual

Description Page No.

Label part number 71107130 is attached to trolley side plate.

Tag part number 71042147 is attached to lubricator in inlet air

Tag part number 71107155 is attached to power head reduction

Tag part number 71059612 is attached to pendant assembly.

Example: HA2-025MA3-10-6PA HA 2 - 025 M A 3 - 10 - 6 P A

Motor-driven brake shaft is connected to brake through a sprag

Hoist Model HA2-012 HA2-025 HA2-037 HA2-050

Traceability M1Material Traceability certificates according to EN 10204 (Ex

Prior to installing hoist, carefully inspect it for possible shipping

Hook Mounted Hoist

Installing Trolley Over End of Beam

Item numbers on Dwg. MHP0352 reference items numbers

Rack Drive (optional feature)

Refer to Dwg. MHP1177 on page 9.

(Dwg. MHP0340) If a larger adjustment is required.

Maintain clearance between rack and

0.06 to 0.10 inch

(Dwg. MHP0352) (Dwg. MHP1177)

Normal trolley drive mounted

Converting from normal trolley drive to Rack Drive requires

Adjust container support so that chain container does not

1. Check chain container size to make sure length of load chain

Shipping Plug Removal

Failure to remove shipping plugs in brake housing can result

Refer to Dwg. MHP0191 on page 11.

Two Motor Pendant PHS4E(-U)

E Pendant control block shown is for standard pendant assembly

Pendant (Optional Style)

To avoid damaging pendant hose, make sure strain relief

Check strain relief chain (188) is properly connected to hoist and

Emergency Air Shutoff

If supply air is wet and unfiltered, and/or hoist is operated in a

If it is necessary to use emergency air shut off valve, then

Trolley Drive Assembly Run-In Period

Maximum efficiency of trolley drive worm gear is obtained after a

Overloading will not decrease run-in time and it may damage

During run-in higher than normal temperature rise and lower

Hoist without air powered trolley

Brake Release Hoist

Hoist with air powered vane or piston motor trolley

Lubricator Main Air

The four most important aspects of hoist operation are:

Operators must be physically competent. Operators should have

Initial Operating Checks Raise Load

Pendant Hoist Control

Pilot Pendant Throttle with Emergency Stop

Refer to Dwg. MHP0395 on page 16.

(Dwg. MHP1649) Accu-Trol Pendant (Push Button Type)

The optional Accu-Trol Pendant is available with 2, 4 or 6

Pull Rope Operation

The hoist can be supplied with an optional manual pull rope

Deficiencies revealed through inspection, or noted during

Hoist Hook Throat Width Discard Width

The full extent of load chain wear cannot be determined by

8. LOAD CHAIN REEVING. Ensure welds on standing links