Ingersoll-Rand 7790-A User's Manual
Contents
1. N U Routine Inspection The type of application for a hoist varies so greatly it is impractical to recommend an exact time table for inspection of the hoist Where hoist is subjected to continuous operation with capacity loads it recommended the unit be inspected twice a week If the application is less demanding the unit should be inspected twice a month In general the frequency of inspection should be determined by the severity of the application The user of a hoist should be guided by any existing federal state or local regulations governing the use testing or inspection of the hoist If any damage or malfunction is evident do not operate hoist until all repairs have been made and hoist tested for proper operation The following points and areas are recommended for inspection Load Chain and Anchor Points Visually check for nicked gouged twisted bent corroded rusted worn or broken links Check ends of chain where chain is anchored to hoist frame and where chain is fastened to lower hook Check anchors and pins Check chain elongation with a vernier caliper as shown IF VISUAL CHECK REVEALS NO DEFECTS PROCEED AS FOLLOWS LAY USED CHAIN ON FLAT SURFACE AND MEASURE BETWEEN FIVE 5 LINKS AS SHOWN MEASUREMENT SHOULD BE TAKEN ON PORTION OF CHAIN WHICH HAS MOST PASSED OVER THE POCKET WHEEL IF MEASUREMENT TAKEN IS SEE TABLE INCHES OR MORE CHAIN SHOULD BE REPLACED2. SI no Description Part SI no Description Part no 74 Cotter Pin Y 15 32 15 Bearing Race 43041 75 Carrier 42965 16 Collar 43032 76 Bearing Race 4 req d 42364 117 Roll Pin Y178 128 77 Gear 2 req d 42971 18 Roll Pin Y178 117 78 Shaft 2 req d 42973 19 Bearing Race 2 req d 37391 79 Spacer 42974 20 Thrust Bearing 37392 80 Bearing 42968 21 Yoke 43037 81 Bearing Y65 12 122 Safety Latch includes bolt nut and spring 420230 82 Retaining Ring Y 147 112 23 Hook 83 Retaining Ring Y145 18 Steel Hook for standard 2 ton models 43031 Gearing Assembly includes items 70 thru includes item 122 73 and 75 thru 83 42976 Bronze Hook for 2400 and 3000 Ib spark 84 Fixed Ring Gear 42966 resistant models includes item 122 43083 85 Roll Pin 2 req d Y178 101 YOKE AND HOOK ASSEMBLY with steel 43047 86 O Ring 6 req d Y325 10 hook for standard 2 ton models includes 87 Wave Washer 40041 41440123 88 Seal 04565511 YOKE AND HOOK ASSEMBLY with 89 Plate Includes item 88 bracket 43118 bronze hook for 2400 and 3000 Ib spark 42980 1 and roll pin Y178 44 not shown resistant models includes items 114 thru END PLATE and RING GEAR 123 43099 ASSEMBLY includes items 84 thru 89 43003 LOWER BLOCK ASSEMBLY for standard 43048 101 and 102 2 ton models includes items 114 thru 129 90 Screw 37701 with steel hook 91 Ball 2 req d Y16 10 LOWER BLOCK ASSEMBLY for spark
3. UP DN TIMING GROOVES l l ON VALVE BODY IDENTIFICATION MARK x ON END OF VALVE BODY STEP 2 WITH BRAKE RELEASE BLOCK ASSEMBLED TO CONTROL ROD INSERT ROD THROUGH BRAKE END OF HOUSING THROUGH CONTROL ARM 68 AND ON THROUGH HOUSING STOPPING BEFORE ROD PROTRUDES FROM HEAD ASSEMBLE GEAR 25 TO HEAD ALIGNING CENTER TOOTH OF GEAR BETWEEN TWO GROOVE MARKINGS ON THE VALVE BODY AS SHOWN ASSEMBLE CONTROL ROD THROUGH GEAR AND SECURE WITH ROLL PIN 26 SECURE CONTROL ARM TO ROD WITH ROLL PIN 69 LS UP DN Ea 25 STEP 3 ASSEMBLE O RINGS 16 VALVES 17 AND 19 AND ASSEMBLE VALVES INTO HEAD AS SHOWN ASSEMBLE O RINGS 18 TO ADAPTERS 29 AND O RINGS 20 TO VALVE CAPS 21 AND ASSEMBLE TO HEAD Form 10590149 Edition 2 NOTE When reassembling head to housing a new Gasket 31 must be installed Tighten Screws 22 to approximately 60 in Ibs torque When tightening these screws it is recommended that an air line be attached to the air inlet and the hoist operated to insure that no binding of the motor occurs Tighten screws alternately and gradually until desired torque is reached without binding of motor Lubricate all O Rings with O Ring lube 36460 before assembling Insure O Ring 32 is properly positioned
4. 107 UN Ma 137 Y 140 142 3 j 9 141 143 5 se 145 147 346 MSs 148 149 8 Form 10590149 Edition 2 2 TON MODELS 123 1 MODELS 149 152 7122 2 MODELS 448 1 TON MODELS E 143 y T 1 TON MODELS ee y anv PART NUMBER THIS SIDE CAUTION TIGHTEN NUTS 25 TO 30 FT LBS TORQUE ONLY ASSEMBLE WITH SPLIT SIDE ONE UP AND ONE DOWN dis ASSEMBLE WITH SPLIT SIDE ONE UP OR DOWN o 16 t gt 4 3 2 4 lt 155 di 2 TON MODELS IS Form 10590149 Edition 2 12 1 i 4 5 7s 8 15 16 17 1819 20 212019 1828 16 DO NOT ATTEMPT ADJUST OR REMOVE THESE VALVES ON SPARK RESISTANT MODELS 157 158 D gt DO 165 166 ITEMS INCLUDED IN SERVICE KIT PART NUMBER 41619 1 w ITEMS INCLUDED IN SERVICE KIT PART NUMBER 41759 Wi ITEMS INCLUDED IN 43004 SHAFT ASSEMBLY Parts List 10 SI no Description Part no SI no Description Part no Head Assembly standard models includes MOTOR ASSEMBLY includes items 36 items 1 thru 21
5. VERNIER CALIPER IE j NEW CHAIN IT IS NOT INFERRED that a chain is safe prior to the occurence of elongation of the chain It is inferred ONLY that when said elongation is evident the chain must be replaced Other factors such as those mentioned as a visual check may render chain unsafe long before replacement due to elongation is necessary NOTE New chain should never be used on a worn pocketwheel replace chain and pocketwheel as a pair Chain should also be replaced when replacing brake shoes IDENTIFICATIONS NEW CHAIN MARKINGS MEASUREMENT REPLACE CHAIN Qo or 4 291 4 366 4 340 4 415 Hooks and Suspension Check upper and lower hooks and related parts for bent worn cracked broken or otherwise damaged parts Ontrolley suspended models check conditions of trolley parts trolley adapter and related parts Check for loose bolts nuts or rivets CORRECT HOOK OPENING 1 1 4 ON 1 TON UPPER amp LOWER HOOKS 1 3 8 ON 2 TON UPPER amp LOWER HOOKS Brake 1 2 Check brake operation see Adjusting Brake page 2 Check brake linings and components NOTE When replacement of brake shoes indicated they must be replaced as a pair Also replace chain at this time Gears Bearings and Pocketwheel Check teeth on gears and motor shaft pinion Check pockets of pocketwheel Check bearings for noisy operation indicating wear Throt
6. 92 Brake Shoe 2 req d 42994 resistant models includes items 114 thru 93 Brake Wheel 4307141 129 with bronze hook 43101 v 794 Brake Spring 42982 124 Bolt Y5 85 C 95 Housing Cap 42979 125 Washer 2 req d Y14 816 96 Cap Screw 2 req d Y154 54 126 Spacer 2 req d 43039 97 Drive Screw 4 req d Y60 43 127 Spacer 2 req d 43042 98 Capacity Plate 128 Shaft 43038 1500 Ib 45278 129 Bolt includes grease fitting 35323 40072 1 ton 41589 130 Shroud 2 req d 2400 Ib 43116 for standard 2 ton models 43043 3000 Ib 43050 for 2400 models includes capacity plate 43121 2 ton 43123 and four drive screws Y60 30 not shown 99 Nut Y12 106 C for 3000 models includes capacity plate 5100 Washer Y 117 616 45281 and four drive screws Y60 30 not 01 Shoulder Screw 4 req d 42993 shown 45282 102 Washer 4 req d Y1 416 C 33 Washer 3 req d Y14 416 03 Screw 4 req d Y99 41 134 Cap Screw 3 req d Y99 49 04 Washer 4 req d 30997 35 Nut 3 req d Y242 12 B 105 Clevis 34987 136 Screw Y99 44 06 Roll Pin Y178 104 37 Chain Stop 2 req d 43127 07 Link Chain 38 Nut Y107 4 Z for 1 ton standard models 10 ft 3 m lift 42988 11 Chain Stop Assembly includes items 136 for 2400 3000 Ib spark resistant thru 138 43128 models 10 ft 3 m lift 43095 22 39 Snap Ring 42999 08 Retaining Ring 2 req d Y145 8 40 Sleeve 42998 09 Anchor Pin 43020 141 Pin 43702 1 110 Retaining Ring 2 req
7. Form 10590149 Edition 2 September 2005 HOISTS Series 7790 A 7792 A Operator s Manual amp Save These Instructions Ingersoll Rand Safety Information Operating Precautions To aid the operator s understanding of proper and safe use of hoists the publication OVERHEAD HOISTS ANSI B30 16 1981 can be purchased from American Standards Institute Inc 1430 Broadway New York New York 10018 Do not use the hoist described in this manual to lift or transport humans Never try to lift a load heavier than the rated capacity of the hoist Operate hoist with caution Operator should have a good attitude toward safety Lubrication Routine Lubrication Requirements Lack of or an excessive amount of lubrication will affect the performance and life of this tool Use only recommended lubricants at below time intervals EVERY 8 HOURS OF TOOL OPERATION fill lubricator reservoir with spindle oil 29665 If an in line or air line lubricator is not used fill oil reservoir of built in oiler of hoist head EVERY 80 HOURS OF HOIST OPERATION Grease fittings in lower BLOCK HOOK ASSEMBLY and TROLLEY WHEELS with NLGI 1 grease 33153 EVERY 160 HOURS OF HOIST OPERATION Fill oil reservoir in GEAR CHAMBER with EP gear oil 40164 Coat load chain of hoist with EP gear oil 40164 Air Supply Requirements For maximum operating efficiency the following air supply specifications should be mainta
8. 24 thru 30 33 and 34 with thru 45 42977 adapter 46211 46126 2 36 Retaining Ring Y145 22 Head Assembly spark resistant models 537 2 req d 42086 includes items 1 thru 19 24 thru 30 33 34 38 End Plate 43076 end 59 withradapter 46212 46126 3 ST Cylinder includes item 40 43130 1 Adapter 40 Roll Pin Y178 73 standard models 46211 41 Rotor 43068 spark resistant models 46212 42 Blade 8 req d 43067 2 Screen 31648 43 End Plate 42958 3 Swivel 46839 544 Key 30934 SWIVEL KIT includes items 1 thru 3 45 Spindle 42959 standrad models includes adapter 46211 46840 y 46 Retaining Ring 2 req d Y 147 200 spark resistant models includes adapter y 47 Bearing 2 req d 92962 ARO 46212 46841 5748 Retaining Ring Y145 25 4 Retaining Ring Y145 28 49 Seal 42149 515 O Ring 2 req d Y325 115 50 Shaft 42960 6 Swivel Body 33314 SHAFT ASSEMBLY includes items 49 57 O Ring Y325 17 and 50 43004 8 Screen 46072 Capacity Label not shown 9 Cap Screw 2 req d 154 53 1000 kg 2200 Ib 46067 3 10 Washer 2 req d Y14 10 2400 Ib 44198 7 11 Exhaust Deflector 42954 2000 kg 4400 Ib 46067 4 12 Screen 42957 1500 Ib 44198 9 13 Muffler Filler 42956 3000 Ib 44198 10 14 Head includes roller bearing 33239 and 51 Housing includes item 52 pipe plug three pipe plugs Y227 3 not shown 46125 Y227 2 L set screw Y29 44 and 15 Body 43079 warning label 43640 not shown 42996 16
9. Handle includes item 185 44806 UPPER HOOK ASSEMBLY for 1500 Ib 83 Sash Chain 2 req d 37657 5 spark resistant models includes items 143 84 Anchor 2 req d 37723 44 and 147 thru 150 with bronze hook 43097 85 Warning Label 24596 UPPER HOOK ASSEMBLY for standard 2 PULL CHAIN CONTROL ASSEMBLY 40004 5 ton models includes items 116 119 120 includes items 180 thru 185 22 123 150 154 and 155 with steel hook 43049 86 Trolley Wheel 4 req d UPPER HOOK ASSEMBLY for 2400 and 43096 or I Bean mounting 3000 Ib spark resistant models includes or standard 1 ton models 41015 items 116 119 120 122 123 150 154 and 155 with bronze hook or spark resistant 1 ton models 41015 1 150 Bracket standard 2 ton models 40149 for 1 ton and 1500 models 42997 spark reistant 2 ton models 40149 1 for 2 ton 2400 and 3000 Ib models 43030 H Beam mounting flat tread wheel 151 Mounting Rod 2 req d 43001 standard 1 ton models 45376 152 Washer 4 req d 46049 standard 2 ton models 45377 153 Nut 4 req d 46049 187 Spacer 8 req d 154 Roll Pin Y178 128 1 ton models 41022 155 Roll Pin Y178 117 2 ton modeles Y13 12 C CYLINDER ASEMBLY 2 req d includes 43017 188 Side Plate 2 req d 43052 items 156 thru 164 189 Lock Washer 8 req d Y 14 750 156 Elbow Y54 23 190 Nut 4 req d Y12 12 157 Cylinder 41064 1 191 Nut 4 req d 46049 158 O Ring Y325 222 192 Shaft 2 req d 43009 159 Piston 410
10. and secure with pin 141 Assemble hook 149 to bucket 145 Apply a liberal amount of grease to groove of collar 143 and assemble eleven balls 144 to collar Assemble collar 143 over shank of hook and secure with roll pin 147 Assemble bucket 145 to connector 142 and secure with pin 146 Slide sleeve 140 over bucket 145 and secure with snap ring 139 2 Ton Models Assemble hook 123 to yoke 121 Apply a liberal amount of grease to thrust bearing 120 and assemble bearing races 119 and thrust bearing to collar 116 Assemble collar 116 over shank of hook and secure with roll pins 117 and 118 Lubricate roller bearing of sheave 114 and assemble bearing race 115 to sheave Assemble spacers 127 sheave 114 and shaft 128 yoke 121 Assemble washers 125 and spacers 126 to bolts 124 and 129 and secure bolts to shaft 128 Feed load chain around sheave with weld of standing inks facing out from sheave and attach end of chain to anchor bracket 112 with pin 111 and retaining rings 110 Position shrouds 130 on lower hook assembly and secure with washers 133 and bolts 134 a CELLELO od 193 191 CAUTION TIGHTEN NUTS 25 TO 30 FT LBS TORQUE ONLY 189 494 189 4 73 76 7 x ER NY
11. d Y145 2 142 Connector 43028 11 Pin 42970 43 Collar 34321 12 Anchor Bracket 43034 144 Ball 11 req d Y16 10 113 Chain Stop 43051 1 45 Bucket 43019 14 Sheave and Bearing 43046 146 Pin 43702 2 Form 10590149 Edition 2 11 Parts List FStno Description Partno S n Description Partno 147 Pin Y178 122 173 Screw 4 req d Y61 85 C 148 Safety Latch includes bolt nut and spring 35023 174 Connector 3 req d Y54 2 149 Hook 175 Handle 43122 Steel Hook for standard 1 ton models 34337 176 Roll Pin 2 req d y178 58 Bronze Hook for 1500 Ib spark resistant 177 Lever up 45616 2 models 34651 178 Lever down 45616 1 LOWER HOOK ASSEMFLY for 1 ton 179 Guard Assembly includes warning plate 44312 models includes items 143 thru 145 and 43000 44197 and four rivets 45119 47 thru 149 with steel hook LOWER HOOK ASSEMBLY for 1500 Ib HANDLE ASSEMBLY includes items 43102 spark resistant models includes items 143 168 thru 179 thru 145 and 147 thru 149 with bronze hook 43110 PENDENT CONTROL ASSEMBLY includes items 156 thru 179 43106 6 UPPER HOOK ASSEMBLY for standard 1 80 S Hook 2 req d 37659 ton models includes items 143 144 and 81 Handle 2 req d 33268 47 thru 150 with steel hook 43002 82 Control
12. pendent control Pulling the chain further or depressing the pendent further will result in a faster speed Load Chain Removal Drive out roll pin 106 and remove clevis from chain Ifa chain basket is being used with hoist remove chain stop from end of chain 2 Ton models with double reeved chain remove retaining ring 110 and pin 111 from anchor bracket 112 Pull down on one end of control arm 68 to release brake and pull chain from housing Load Chain Installation Anew chain should never be used on a worn pocketwheel Replace chain and pocketwheel as a pair Place hoist in vise and clamp on upper hook mount Remove housing cap 95 brake spring 94 and brake shoes 92 Turn brake wheel 93 by hand to rotate pocketwheel while carefully feeding chain thru chain guide and around pocketwheel 64 Pull sufficient chain thru housing to allow end link to be attached to anchor lug on housing amp CAUTION Chain must be positioned around pocketwheel so weld on the standing links face outward from pocketwheel see illustration Endlink of chain must also be positioned properly to permit attaching to anchor lug on housing without twisting of chain Do not attempt to feed chain over pocketwheel by air power as chain will be pulled thru housing at a very fast rate Attach other end of chain to lower hook or anchor bracket on 2 Ton models POCKET WHEEL CHAIN GUIDE
13. 00 airline FILTER REGULATOR LUBRICATOR F R L is recommended to maintain the above air supply specifications Recommended Lubricants After disassembly is complete all parts except sealed or shielded bearings should be washed with solvent To relubricate parts or for routine lubrication use the following recommended lubricants Where Used ARO Parti Description Air Motor 29665 1 qt Spindle Gears and Bearings 33153 5 Ib EP NLGI 11Grease O Rings Lip Seals 36460 4 oz Stringy Lubricant Gearing Oil Chamber 40164 1 qt EP Gear Oil Insert an equal number of SPACERS on each inside of the trolley SIDE PLATES until beam flange 1 2 measurement is reached SIDE PLATES must be vertical Insert SHAFTS 43009 through hoist or adapter if used and trolley SIDE PLATES Position trolley and hoist assembly on beam Put an equal number of SPACERS on each end of SHAFTS 43009 with lock washer being last Tighten nuts on SHAFTS 43009 SHAFTS should extend all the way through the NUTS Move trolley over entire length of beam If it appears the trolley SIDE PLATES can be moved closer together and freedom of movement will be maintained remove an equal number of SPACERS from inside the SIDE PLATES and assemble these SPACERS to the outside of the SIDE PLATES Tighten NUTS to 25 30 ft Ibs Connect sufficient length of air hose to reach the maximum travel distance of trolley WIDTH OF BEAM F
14. 66 193 Washer 84 req d 43014 160 Piston Rod 42955 194 Nameplate not shown 44081 1 161 Spring 33981 195 Skid Bracket 4 req d not shown 44618 1 162 O Ring Y325 13 196 Rivet 8 req d Y193 33 163 Adapter 41067 TROLLEY ASSEMBLY 164 O Ring Y325 116 or spark resistant models includes 165 Elbow Y54 23 items 186 thru 196 166 Adapter 2 req d 33989 or 1 ton models 7763 BC 167 Hose Assembly includes hoses and strain or 2 ton models 7764 BC cable 43103 6 or standard models includes items 186 168 Screw 2 req d 37511 hru 194 169 O Ring 2 req d Y325 111 or 1 ton models I Beam 170 Spring 2 req d 32858 or 1 ton models H Beam 7795 FT 171 Valve 2 req d 34757 or 2 ton models I Beam 7796 172 Ring 2 req d Y325 6 or 2 ton models H Beam 7796 FT 5 SERVICE KIT includes items marked 41619 1 Y SERVICE KIT includes items marked v 41759 12 Form 10590149 Edition 2 Model Identification Model No Upper Mounting Type Control Type Load Chain Lbs Kg Capacity 7790 A9 Hook Ass y 43002 Pull Chain Link 7790 11 None Pull Chain Link 2 200 7790 A13 Hook Ass y 43002 Pendent Link 1000 Kg 7790 A15 None Pendent Link 7792 A9 Hook Ass y 43049 Pull Chain Link 7792 A11 None Pull Chain Link 4 400 7792 A13 Hook Ass y 43049 Pendent Link 2 000 Kg 7792 A15 None Pendent Link Spark Resistant Models Model No Upper Mounting Type Cont
15. LANGE PLUS 1 22 SIDE PLATES MUST BE VERTICAL TIGHTEN NUTS 46049 25 30 FT LBS TORQUE EQUAL OF SPACERS 4 EQUAL OF SPACERS Lo Form 10590149 Edition 2 Adjusting Brake Properly attach rated load of hoist to load chain hook Slowly raise load to 6 height above floor by slowly pulling pull chain handle or depressing pendent control Release pull chain handle or pendent control Ifload starts to lower tighten brake adjustment by turning counter clockwise until load stops lowering Do not over tighten brake If brake it too tight the lifting and lowering of load will be eratic not smooth BRAKE ADJUST N REW LOCATION Setting Maximum Up and Down Speeds Never attempt to adjust speed regulator valves on spark resistant hoists They are preset by ARO Attach rated load of hoist to load chain hook Turn speed regulator valves clockwise until they stop This is lowest setting Lift load by pulling pull chain or depressing pendent control completely As load is being lifted turn up speed regulator valve counter clockwise to set the hoist at the desired maximum speed Lower load by pulling pull chain or depressing pendent control completely As load is lowered turn DN speed regulator valve counter clockwise to set the hoist at the desired maximum lowering spee
16. O Ring 2 req d 04614574 Nameplate not shown 41596 17 Lift Valve 43080 Drive Screw 4 req d not shown Y60 44 5318 O Ring 2 req d Y325 25 v 52 Seal 42967 19 Adapter 2 req d 40017 553 O Ring Y325 46 20 O Ring 2 req d not required with pendent 554 O Ring Y325 155 control models Y325 116 55 Ring Gear 42963 21 Valve Cap 2 req d not required with 556 O Ring Y 325 211 pendent control models 34026 57 Washer Y 117 875 22 Cap Screw 6 req d Y154 54 58 Nut 42964 23 Washer 6 req d Y14 10 59 Control Rod 46121 24 Set Screw 2 req d 60 Brake Block 34029 or standard models 41598 61 Roll Pin Y178 60 spark resistant models 41627 1 62 Hanger 2 req d 43033 25 34022 v 63 Chain Guide 42989 26 Roll Pin 178 56 v 64 Pocket Wheel 42961 ARO 27 Ring 2 req d Y325 111 65 Plate 42990 28 2 req d 43107 566 Washer 6 req d Y117 10 29 Descent Valve 43081 v 67 Screw 6 req d Y154 52 30 Oilite Casting 33190 68 Control Arm 43133 5 91 Gasket 43008 69 Roll Pin Y178 55 532 O Ring Y325 9 70 Retaining Ring 42975 33 Washer 2 req d 31389 71 Bearing 41864 34 Screw 2 req d 30747 72 Shaft 43072 1 35 O Ring 2 req d Y325 12 73 Bearing 40048 Form 10590149 Edition 2 Parts List
17. balls 144 One Ton Models Collar 116 thrust bearing 120 and bearing races 119 Two Ton Models Upper Hook Assembly Position hook on bracket 150 Apply a liberal amount of grease to groove of collar 143 and assemble eleven balls 144 to collar Slide collar and balls over shank of hook and secure with roll pin 147 One Ton Models Apply a liberal amount of grease to thrust bearing 120 and assemble thrust races 119 and bearing 120 to shank of hook Secure with roll pins 154 and 155 Two Ton Models Assemble bracket 150 shafts 151 washers 152 and nuts 153 4 CAUTION Do not over tighten nuts 153 tighten 25 to 30 ft Ibs torque Lower Hook Disassembly 1 Ton Models Remove snap ring 139 Slide snap ring 139 and sleeve 140 up on chain and remove pin 146 Separate connector 142 from bucket 145 and remove pin 141 Drive out roll pin 147 and remove hook from bucket 145 2 Ton Models Remove bolts 134 washers 133 and shrouds 130 Remove bolts 124 129 washers 125 and spacers 126 Remove shaft 128 spacers 127 and sheave 114 Drive out roll pins 118 and 117 Remove collar 116 thrust bearing 120 bearing races 119 and hook 123 Form 10590149 Edition 2 Lower Hook Assembly 1 Ton Models Slide snap ring 139 and sleeve 140 on end of load chain Position end of load chain in connector 142
18. brake wheel Assembly Brake and Gearing Assembly Lubricate and assemble six o rings 86 into counterbores of fixed ring gear 84 Assemble seal 88 to end plate 89 lip of seal facing out Assemble wave washer 87 and end plate 89 to fixed ring gear 84 and secure with four washers 102 and shoulder screws 101 Assemble gears 77 bearing races 76 and shafts 78 to gear carrier 75 Assemble spacer 79 to gear carrier aligning spacer with notched ends of shafts 78 Lubricate bearings 73 and 80 with NLGI 1 EP grease 33153 and assemble to gear carrier 75 Lubricate bearing 71 with NLGI 1 EP grease 33153 and assemble to shaft 72 Assemble shaft 72 to gear carrier 75 and secure with retaining ring 70 IMPORTANT punch marks on gears 77 indicating aligned teeth must be held in alignment with punch marks on gear carrier 75 when shaft 72 to assembled to gear carrier PUNCH MARKS ON GEARS AND PUNCH MARK CARRIER MUST BE IN ALIGNMENT Lubricate bearing 81 with NLGI 1 EP grease 33153 and assemble to shaft 72 Assemble retaining ring 82 and 83 to shaft 72 Assuming o ring 53 and ring gear 55 are assembled to housing see housing assembly assemble gearing into ring gear 55 Lubricate and assemble o ring 54 over fixed ring gear 84 and slide up to end plate Assemble fixed ring gear and end plate to gearing and h
19. d The pull chain or pendent control is used as the variable control of lift and lowering speeds up to the maximum speed set by the speed regulator valves REGULATOR VALVES Chain Stop Do not operate hoist unless chain stop is properly attached to hoist load chain Do not use chain stop to limit the distance the load is to be lifted The function of the chain stop is to keep the lower hook components from striking the control arm should an over run condition ever occur Installation instructions should be completed before attempting to operate the hoist Before Securing Load to Lift Chain Perform routine inspection and lubrication procedures Securing Load to Lift Chain DONOT WRAP LOAD CHAIN AROUND LOAD Approved slings or other approved devices should be used to provide adequate single point securing of load to Form 10590149 Edition 2 hoist load chain hook Be sure safety latch on hook is closed Besure load chain is not twisted or kinked Hoist should be centered over the load Always secure load chain hook to center of load Never lift a load from the side or end Allow only a sufficient amount of slack in load chain to permit attaching hook to load Lifting and Lowering Load 1 Pull pull chain models or depress pendent control models controls slowly to eliminate abrupt jerky operation 2 Take up slack in chain slowly 3 Speed of load lifting can be controlled by the pull chain or
20. ear oil 40164 Housing Disassembly Remove head motor and gearing sections Remove screws 67 washers 66 and plate 65 Place brass or wood block in pocketwheel cavity to prevent shaft 50 from turning Remove nut 58 washer 57 o ring 56 and ring gear 55 Remove retaining ring 46 from motor end of housing Remove shaft 50 with bearing 47 Remove pocketwheel 64 and chain guide 63 Remove seal 52 for replacement only Housing Assembly Assemble bearing 47 and retaining ring 46 to brake end of housing Assemble chain guide 63 and pocketwheel 64 to housing NOTE part number stamped on face of pocketwheel must face motor end of housing Assemble retaining ring 48 and bearing 47 to shaft 50 Insert shaft 50 into housing and thru pocketwheel 64 and bearing 47 Assemble retaining ring 46 to housing Assemble plate 65 washers 66 and screws 67 to housing Assemble new seal 52 into housing with lip of seal facing out Lubricate and assemble o ring 53 into groove in housing Assemble ring gear 55 o ring 56 washer 57 and nut 58 Assemble motor gearing and head sections to hoist Form 10590149 Edition 2 Upper Hook Disassembly Remove nuts 153 washers 152 and bracket 150 Drive out roll pin 147 One Ton Models Roll pins 155 and 154 Two Ton Models Remove collar 143 and
21. in head Assemble valve body 15 into head see Timing of Head this page Assemble o rings 27 to regulator valves 28 Assemble regulator valves 28 to head and secure with set screws 24 NOTE groove in regulator valve must be aligned to accept set screw See setting hoist speed page 2 Assemble muffler filler 13 screen 12 and exhaust deflector 11 to head and secure with washers 10 and screws 9 Clean and assemble screen 8 to head Assemble o rings 5 and 7 to swivel body 6 and assemble body to head Assemble swivel 3 to swivel body and secure with retaining ring 4 Clean and assemble screen 2 and inlet adapter 1 to swivel Fill oil reservoir in head with spindle oil 29665 Pendent Control Disassembly Remove pendent hoses from fittings 156 and 165 Remove adapter 166 from head releasing strain cable Remove screws 168 springs 170 and valves 171 Pendent Control Assembly Lubricate o rings 172 and assemble to valves 171 Assemble valves 171 and springs 170 to handle Lubricate o rings 169 and assemble to screws 168 Assemble screws 168 to handle securing valve components Pendent Cylinder Disassembly Unthread cylinder 157 from adapter 163 Pendent Cylinder Assembly Assemble piston rod 160 to piston 159 Lubricate and assemble o ring 158 to piston 159 Lubricate and assemble o rings 162 and 164
22. ined to this hoist Operation Suspending Hoist Adjusting Brake Always select an overhead support capable of supporting combined weight of hoist trolley and hoist s load capacity Hook Suspended Models Upper hook should be firmly seated in center of hook saddle and that safety latch is closed 43059 secondary support cable is recommended 43066 RESTRAIN ING CABLE 5 16 DIA X 3 FT LONG AIRCRAFT CABLE Dwg Trolley Suspended Models Be sure TROLLEY WHEELS are compatible with beam being used Width between outside of TROLLEY WHEELS should be the width of beam flange 1 2 If 43111 90 ADAPTER is used mount to hoist before attempting to install trolley Width is varied by using SPACERS between the hoist body and the trolley SIDE PLATES Always follow proper operating instructions given in this manual Allow only people who have received training in proper hoist operation to operate hoists Follow all operating and routine inspection procedures prescribed in this manual Operator of hoist shall operate hoist in a position that will not be hazardous to his health Do not attempt to operate hoist if it is not operating properly Before operating hoist all routine inspection and lubrication procedures should be completed AIR PRESSURE 90 PSIG 6 bar AIR FILTRATION 50 micron LUBRICATED AIR SUPPLY HOSE SIZE 1 2 13 mm I D An ARO model 128241 8
23. ntrol rod 59 attached to gear 25 To accomplish this Remove two screws 96 and housing cap 95 Drive out roll pin 61 and remove brake block 60 Drive out roll pin 69 from control arm 68 Remove six screws 22 and washers 23 Remove head section and control rod from housing as one unit To disassemble head components without removing head section from hoist Remove two screws 96 and housing cap 95 Drive out roll pin 69 from control arm 68 Drive out roll pin 26 from gear 25 and drive control rod 59 back thru gear 25 and remove gear Remove adapters 19 valves 17 and 29 and valve body 15 Remove set screws 24 and regulator valves 28 4 CAUTION do not attempt to adjust or remove regulator valves 28 from spark resistant hoist models these valves are pre set at fatctory Remove adapter 1 and screen 2 Remove retaining ring 4 swivel 3 swivel body 6 and screen 8 Remove two screws 9 washers 10 exhaust deflector 11 screen 12 and muffler filler 13 STEP 1 POSITION HOIST SO YOU ARE FACING END WITH AIR INLET WITH VALVE PARTS AND GEAR 25 REMOVED PLACE VALVE BODY IN VALVE OPENING INSERT FINGER IN EACH END OF VALVE OPENING AND ALIGN END OF VALVE BODY WITH ENDS OF BUSHING NOTE VALVE BODY MUST BE INSTALLED WITH IDENTIFICATION MARK AS SHOWN ENDS OF VALVE BODY FLUSH WITH BUSHING oes
24. ousing Use reasonable caution so as not to damage seal 88 in end plate Secure end plate and components to housing with washers 104 and screws 103 Assemble brake wheel 93 to shaft 72 and secure with washer 100 nut 99 and cotter pin 74 Remove cotter pin 74 nut 99 and washer 100 Remove brake wheel 93 Remove roll pin 61 and brake block 60 Remove four screws 103 and washers 104 Place blade type screwdrivers or similar tool at opposite sides behind edge of end plate 89 and pry out on end plate to remove from housing Remove gearing assembly Remove retaining rings 70 and 82 Push on threaded end of shaft 72 and remove out opposite end of gear carrier 75 Remove bearing 80 spacer 79 and shafts 78 releasing gears 77 and bearing races 76 Remove retaining ring 83 and bearing 81 Remove four shoulder screws 101 and washers 102 and fixed ring gear 84 Remove seal 88 for replacement only Assemble control rod 59 thru housing hangers 62 and control arm 68 Secure control arm 68 to rod with roll pin 69 Assemble brake block 60 and roll pin 61 to control arm 59 Assemble screw 90 balls 91 brake shoes 92 and brake spring 94 Assemble housing cap 95 and secure with two screws 96 See brake adjustment page 2 Fill gearing oil chamber with 6 to 7 ounces to lower plug hole level EP g
25. rol Type Load Chain Lbs Kg Capacity 7790 A21 Hook Ass y 43097 Pull Chain Link 1 500 7790 A22 None Pull Chain Link 680 Kg 7792 A21 Hook Ass y 43096 Pull Chain Link 2 400 7792 A22 None Pull Chain Link 1 089 Kg 7792 A23 Hook Ass y 43096 Pull Chain Link 3 000 7792 A24 None Pull Chain Link 1 361 Kg FOR TROLLEY MOUNTING TROLLEY MUST BE ORDERED SEPARATELY STAINLESS STEEL LINK CHAIN AND BRONZE HOOKS Form 10590149 Edition 2 13 Notes 14 Form 10590149 Edition 2 Notes Form 10590149 Edition 2 15 Ingersoll Rand www irtools com O 2005 Ingersoll Rand Company
26. tle Valve Head and Gears Check valve body valves and O rings on valves Check gear teeth and bearings Air Motor Check end faces of rotor for roughness and blade slots for wear or burrs A new blade should slide in and out of slots without binding Check blades for wear warpage or other damage Check cylinder bore diameter for rough circular grooves from scoring A badly scored cylinder cannot be restored by honing since it will only enlarge bore diameter widening seal point between rotor and cylinder hindering free exhaust of air and result in loss of speed and power Check end plates for wear or scoring Check bearings Follow all operating and routine inspection procedures prescribed in this manual Disconnect air supply from hoist before performing maintenance or service procedures Never apply excessive pressure by a holding device which may cause distortion of a port Apply pressure evenly to parts which have a press fit Apply even pressure to the bearing race that will be press fitted to the mating part Use correct tools and fixtures when servicing this tool Don t damage O rings when servicing tool Use only genuine ARO replacement parts for this tool When ordering specify part number description tool model number and serial number Form 10590149 Edition 2 Maintenance Dissassembly Head Disassembly To remove head section from housing without disassembling head components remove head with co
27. to adapter 163 Motor Disassembly Remove head section see Head Disassembly Remove motor from housing Remove retaining ring 36 motor assembly will come apart Motor Assembly Lubricate bearings 37 with NLGI 1 EP grease 33153 and assemble bearings to end plate 38 and 43 shielded side of bearing facing out Assemble end plate 43 to spindle 45 and slide up to shoulder of spindle Assemble key 44 to key slot in spindle 45 Assemble rotor 41 over spindle aligning key way and ey 44 Assemble cylinder 39 over rotor 41 and insert blades 42 into blade slots of rotor straight side of blade out Assemble end plate 38 to spindle and align hole in end plate with roll pin 40 Secure assembled parts to spindle with retaining ring 36 Assemble motor to housing Lubricate and assemble o rings 35 into counterbore of end plate 38 Assemble new gasket 31 and head to housing Brake and Gearing Disassembly Remove two screws 96 and housing cap 95 Carefully slide brake spring 94 part way off brake shoes 92 and using brake spring spreader 33541 remove brake spring 94 4 CAUTION remove brake spring 94 with due regard for safety as spring is assembled with considerable tension Remove brake shoes 92 and steel balls 91 Align hole in brake wheel 93 with hole in end plate 89 and insert a punch or pin thru holes to secure
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