2. Install the assembled chain wheel (76), small bearing end first, into the brake
end of the housing (1). Tap the chain wheel lightly on its trailing end to make
certain the plain end bearing (77) is fully seated.
3. Install a brake housing bolt seal (90A) into each of the four bolt holes in the brake
housing (90) so that the tapered end of each Seal faces the shoulder side of the
brake housing.
4. Align the bolt holes in the flange of the ring gear (88) with the bolt holes in the
brake housing, and press the ring gear, flange side first, onto the shoulder of the
brake housing.
CAUTION
•
It is very important that the planet gears (82) and ring gear be aligned when
the gear frame assembly is inserted into the ring gear.
5. Align the gearing as follows:
a. Stand the ring gear and brake housing upright.
b. Align the arrows and scribe lines on the faces of the planet gears in a straight
line as shown in Dwg. MHP3299.
c. While maintaining this alignment, insert the gear frame assembly, bearing
end first, into the ring gear seating the gear frame bearing (86) in the brake
housing.
Planet Gear
Ring Gear
Planet Gear
Frame
(Dwg. MHP3299)
6. Apply a thin film of grease on the ring gear gasket (89) and place the gasket on
the face of the ring gear.
7. While holding the entire assembly so that the planet gears (82) are aligned with
the cutout areas in the housing (1), install the assembly in the housing so that
the splined hub of the gear frame engages the splined hub on the chain wheel.
8. Place the motor retaining washer (63) dished (concave) side first, against the
front end plate and engage the dowel hole in the washer with the guide rod.
9. While aligning the guide rod with the dowel hole in the bottom of the housing
bore, slide the assembled motor into the housing so that the motor shaft (64)
passes through the chain wheel and meshes with the planet gears.
10. Withdraw the guide rod from the motor and install the cylinder dowel (71) so
tapered end enters first.
11. Insert the Mufflers (49) into the recess in the valve chest plate (46).
12. Place the housing gasket (9) onto the motor end of the housing and install the
valve chest plate with the valve chest plate screws (48) at 9.5 - 10.8 Nm (7-8 ft-
lbs) torque.
13. Slide the brake driver (92) on the splined end of the motor shaft and install the
brake driver retainer (93).
14. Manually, rotate the brake driver several revolutions to make certain the planet
gears are properly aligned and properly meshed with the motor shaft and the
motor rotates freely.
15. Insert the brake tube (57) in the hole in the boss at the upper right-hand corner
of the brake housing and install a brake tube seal (58) on each end of the brake
tube.
16. Place a brake plate (94) followed by a brake disc (95), brake plate, brake disc and
two brake plates over the brake driver, aligning the notches in the brake plates
with the bolt holes in the brake housing and main housing.
NOTICE
•
Brake discs and brake plates must be free from oil and grease. This may
cause the brake to slip.
17. Insert the brake tube housing seal (59) into the hole in the boss of the brake
spring and piston housing (96). Install the assembled brake spring and piston
housing, making certain that the brake tube enters the hole in the base on the
housing. Align the bolt holes in the brake spring and piston housing with those
in the brake housing and install the four shoulder bolts (105) and lockwashers
(106). Torque to 23 - 27 Nm (17 - 20 ft-lbs).
18. Stand the Hoist upright on the brake end. Place the valve chest gasket (43) on
the valve chest plate, making certain that the small flapper is properly positioned
in the recess between the two ports.
CAUTION
•
If the valve chest gasket is flipped over, the flapper will not be in the recess
between the two ports, and the brake will not release.
19. Center the two round rubber discs in corresponding recesses in the valve chest
plate.
20. Place the assembled valve chest (14) on the valve chest gasket, and install the
valve chest screws (44 and 45) at 9.5 - 10.8 Nm (7-8 ft-lbs) torque.
21. Position the chain guide (10) underneath the chain wheel, and install the chain
guide screws (11) at 2.9 - 3.6 Nm (26 - 32 in. lb) torque.
22. Place the throttle shaft spring (56) over one hub of the throttle lever (53) so that
the bent leg of the spring is toward the inside of the throttle lever.
23. Hold the throttle lever in the housing recess beneath the chain wheel so that
the throttle shaft spring is toward the valve chest end of the Hoist and the legs
of the spring engage a rib on the bottom of the chain guide. Place a throttle lever
thrust washer (55) at each end of the throttle lever bore, and insert the throttle
shaft (50) round end first, through the valve chest plate, housing and throttle
lever. Install the throttle lever retaining pin (54). throttle shaft (50) has two cross
holes. On MLK hoists ensure throttle lever retaining pin (54) locates in the hole
nearest the stepped end of the throttle shaft (50).
24. Place the limit actuator (51) on the square end of the throttle shaft, and install
the limit actuator retaining pin (52).
25. Install the two pendant links (223) between the limit actuator and the valve
shafts.
26. Apply a thin film of O-ring lubricant to the two swivel inlet seals (40) and install
them in the grooves of the inlet nipple (39).
27. Being careful to prevent cutting the seals, push the inlet nipple into the inlet
body (38).
28. Apply a thin film of O-ring lubricant to the swivel inlet seal (41) and install the
seal on the nipple.
29. Thread the inlet assembly into the top of the valve chest and tighten it at 5.6 -
6.8 Nm (50 - 60 in. lb) torque.
30. Thread the inlet strainer (42) into the inlet body and tighten it.
n
Load Chain Anchoring
1. Chain Anchor Bolt (107) should be torqued to 9.5 - 10.8 Nm (7 - 8 ft-lbs)
n
Pendant Installation
WARNING
•
Disconnect the hoist from the air supply before installing this pendant
control kit.
When installing pendant assembly on an MLK Hoist, a crimping tool or compatible
grooving tool must be used to install the clamping sleeve (216) on the either end of
the strain relief cable (215).
The strain relief cable (215) must be long enough to allow the pendant hose to hang
nearly straight yet short enough to absorb the pendant weight and forces.
When the control hoses are cut to length, the hose at the rear of the handle should
extend 6 in. (150 mm) beyond the top clamping thimble. With an
MLK-A545A valve chest, the two hoses at the front of the handle should extend 2 in.
(51 mm) beyond the top clamping thimble (217).
Install one hose tie (218) above the pendant handle (200) and one hose tie below
the clamping thimble (217). Install the remaining hose ties every 2-1/2 feet (0.76 m)
between the hose ties at the handle and thimble.
When installing the warning plate (219), ensure the plate can be read from the lever
side of the pendant handle.
n
Load Test
Prior to initial use, all new, extensively repaired, or altered hoists shall be load tested
by or under the direction of a qualified person, and a written report furnished
confirming the rating of the hoist. Dynamically load test hoist to 100% of its rated
capacity in accordance with ASME B30.16 standards. Testing to more than 100% may
be necessary to comply with standards and regulations set forth in areas outside of
the USA.
10
Form 47099007 Edition 3
