21. Apply small amount of Loctite® “Instajoint 574” or equivalent on entire surface
of flat ring (89), smooth out on entire surface, press flat ring (89) on reducer
cover (5).
NOTICE
• Do not use force when installing muffler assembly (88). Hand tighten only.
22. Install the muffler assembly (88) in adapter support (95).
23. Install limit stop valve assemblies (340).
24. Lubricate and install load chain, limit stops and load hook. Refer to procedures
in ‘Load Chain Replacement’ on page 7.
18 ton Triple and 25 ton Quad Fall
Refer to Dwg. MHP3014.
1. Lubricate and install ‘O’ ring (6) on hoist body (36).
2. Install oil seal (20) in hoist body (36) with lip of seal towards sprocket.
3. Install bearing (8) on sprocket (30) shaft external gear teeth end.
4. Install two oil seals (37) in bore of sprocket (30). Seal lips must face away from
each other.
5. Install bearing (38) in sprocket bore and secure with retainer ring (9).
6. Tap sprocket (30) into hoist body (36).
7. Install bearing (8) on sprocket and in bore of hoist body.
8. Install chain stripper (31) and tap pins (43) in until flush.
9. Lubricate and install ‘O’ rings (104) on hoist body.
10. Install ‘O’ ring (105) and bearing (149) on sprocket (50).
11. Install bearing (38) on pinion shaft (218).
12. Install ‘O’ rings (40) and spacer (97) on pinion shaft (218) and secure with
retainer ring (10).
13. Tap assembled pinion shaft into sprocket (50). Install retainer ring (9).
14. Install assembled sprocket in chain guide housing (58).
15. Install ‘O’ ring (105) and bearing (149) on sprocket and in bore of chain guide
housing.
16. Assemble chain guide housing to hoist body with adapter positioned between.
Clamp with capscrews (41) and lockwashers (44). Refer to “TORQUE CHART”
on page 19 for torque requirements.
17. Align and install reducer assembly on hoist body. Secure with capscrews (4) and
washers (44). Torque to 4,7 Nm and refer to“TORQUE CHART” on page 19 for
torque requirements. Use an alternating pattern.
18. Install limit stop valve assemblies (340).
19. Fill with recommended oil. Refer to “LUBRICATION” section in Product
Information manual. Install plug (1) in reducer housing (22).
20. Lubricate and install load chain, limit stops and load hook. Refer to procedures
in ’Load Chain Replacement’ on page 7.
n
Disc Brake Assembly
1.5 ton Single, 3 ton Double Fall and 6 ton Quad Fall
Refer to Dwgs. MHP2650 and MHP2822.
1. Lubricate and install ‘O’ ring (6) on brake housing (61).
2. Press piston assembly in brake housing (61). Internal ‘O’ ring (64) must enter
brake housing first. Avoid damaging ‘O’ rings.
3. Install plates in brake housing (61) in the following order: Friction plate without
clips (66) then drive plate (67) then friction plate with clips (72) then drive plate
(67). Repeat this plate sequence finishing with a friction plate with clips (72).
Align drive plate splines with slots in splined hub (65).
4. Install splined hub (65).
5. Lubricate and install ‘O’ rings (64) and (6) on piston (63) and reaction plate (68).
6. Align holes and install gasket (7) with grease on brake housing (61).
7. Ensure retainer ring (10) is installed on spline of drive gear (80).
8. Install springs (69) in motor housing (76).
9. Temporarily install the motor on the brake housing. Partially lift out and turn the
motor to align splines in the splined hub (65) and on drive gear (80). For a correct
assembly the brake housing must be completely inside motor housing. Remove
the motor and install brake springs (69). Reinstall the motor and check position
is correct.
10. Install plug (1) and washer (151) in brake housing and secure with capscrews
(62). Install capscrews (62) with Loctite® 243 or equivalent.
4 ton and 6 ton Single, 8 ton and 12 ton Double, 18 ton Triple and 25 ton Quad
Fall
Refer to Dwg. MHP2999 and MHP3038.
1. Lubricate and install ‘O’ ring (6) on brake housing (61).
2. Press piston assembly in brake housing (61). Internal ‘O’ ring (64) must enter
brake housing first. Avoid damaging ‘O’ rings.
3. Install plates in brake housing (61) in the following order: Friction plate without
clips (66) then drive plate (67) then friction plate with clips (72) then drive plate
(67). Repeat this plate sequence finishing with a friction plate with clips (72).
Align drive plate slots with slots in splined hub (65).
4. Install splined hub (65).
5. Lubricate and install ‘O’ rings (64) and (6) on piston (63) and reaction plate (68)
into brake housing (61).
6. Align holes and install gasket (7) on brake housing (61).
7. Ensure retainer ring (10) is installed on spline of drive gear (80).
8. Install springs (69) in motor housing (76).
9. Carefully install assembled brake in motor housing (61) and secure with capscrews
(62). Install capscrews (62) with Loctite® 243 or equivalent. Splined hub must
locate on motor drive gear (80) and remain engaged in drive plates. Refer to
“TORQUE CHART” on page 19 for torque requirements. For a correct assembly
the brake housing must be completely inside the motor housing.
10. Install plug (1) and washer (151) in brake housing.
11. Mount motor and brake assembly on end cover (73).
n
Motor Emergency Stop and Overload Assembly
Refer to Dwgs. MHP3037 and MHP3038.
1. Lubricate and install seal (189) and ‘O’ ring (201) on base plate (199).
2. Lubricate and install ‘O’ ring (197) on plunger (198).
3. Install diaphragm (196) on plunger and secure with nut (194) and washer (195).
4. Install plunger assembly on base plate and ensure plunger slides easily in the
bore of the base plate.
5. Install spring (213) on motor cover (83).
6. Install seal (210) on cap (202).
7. Install seal (203) on cap (211).
8. Install cap (202), washer (206), spacer tube (209), washer (208), cap (211),
diaphragm (212), and washer (206) into valve seat (205) and secure with
capscrew (62). Apply Loctite® 243 or equivalent to capscrew (62) threads. Do not
over tighten, apply torque for snug fit.
9. Lubricate and install ‘O’ rings (204) on valve seat (205).
10. Lubricate and install ‘O’ ring (191) on regulating screw (192).
11. Screw regulating screw (192) into emergency stop end cover (183).
12. Lubricate spring (193) with grease and install into regulating screw (192).
13. Install setscrew (102) with Loctite® 243 or equivalent onto emergency stop end
cover.
14. Install seal (189) on axle (188).
15. Install axle (188) into valve seat (186).
16. Install the second seal (189) on axle (188).
17. Lubricate and install ‘O’ rings (187) on valve seat (186).
18. Install valve assembly into emergency stop end cover.
19. Lubricate ball (47) with grease and install into emergency stop end cover.
20. Install gasket (91) with grease on motor cover.
21. Install emergency stop end cover assembly on motor cover and secure with
capscrews (103). Refer to “TORQUE CHART” on page 19 for torque requirements.
22. Lubricate and install ‘O’ rings (70) on emergency stop end cover.
23. Install setscrew (180).
24. Install plug (182).
n
Motor Assembly
3.5 HP Motor
Refer to Dwg. MHP2652.
1. Clean the grease from bearings (78).
2. Clean interior and exterior diameter of bearings with Loctite® 7063 or equivalent.
3. Put a continuous thin film of Loctite® 603 or equivalent on interior diameter of
bearing (78). Refer to Dwg. MHP2644 on page 15,
A.
Use a continuous thin film
of Loctite® 603 or equivalent to bond one bearing on each gear. Apply where
arrows indicate;
B.
Do not bond bearings on this side of gears;
C.
Use a continuous
thin film of Loctite® 603 or equivalent;
D.
Note: Wait 10 minutes with the housing
in this position, to ensure proper bond;
E.
Install brake hub and rotate to ensure
a proper bond; for correct application locations.
4. Put a continuous thin film of Loctite® 603 or equivalent on bearing diameter on
drive gear (80) and install bearing (78).
5. Install a second bearing (78), not bonded, on drive gear (80).
6. Put a continuous thin film of Loctite® 603 or equivalent on interior diameter of
bearing (78).
7. Put a continuous thin film of Loctite® 603 or equivalent on bearing diameter on
idle gear (79) and install bearing (78).
8. Install a second bearing (78), not bonded, on idle gear (79).
9. Put a continuous thin film of Loctite® 603 or equivalent on bore for bearings in
the motor housing (76).
10. Install drive gear (80) and idle gear (79) into motor housing, ensure the drive
gear and idle gear are completely inside motor housing and leave the motor
housing in a position as shown on Dwg. MHP2644 on page 15 for 10 minutes.
11. Install splined hub (65) and turn the gears with a tool. Check bearings do not
rotate on bonded diameters and gears rotate freely.
12. Install pins (82) on motor cover (83).
13. Install exhaust washer (81) with a point of Loctite® 601 or equivalent on motor
cover.
14. Install motor cover (83) on motor housing and secure with capscrews (90). Refer
to “TORQUE CHART” on page 19 for torque requirements. Install capscrews (90)
with Loctite® 243 or equivalent.
15. Check valve (86) and (87) ‘O’ rings are not damaged.
16. Install springs (84), valves (86) and (87) in motor cover (83).
14
Form MHD56279 Edition 4
